EP0057484A2
Expired / Lapsed
EP
⏱️ 0.0 years remaining
Apparatus for uniformly debossing and aperturing a resilient plastic web
Assignee: Procter and Gamble Co
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Filing: 1982-01-26
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Granted: —
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Expires: 2002-01-26
Abstract
Abstract Method and apparatus for constructing a three-dimensional film forming structure for imparting a uniformly apertured three-dimensional pattern to a heated plastic material subjected to a fluid pressure differential while in contact with said forming structure. In a preferred embodiment, said forming structure is created by forming a substantially continuous pattern of apertures in a multiplicity of planar sheets, at least a portion of said sheets having aperture patterns which are concentrically aligned but dissimilar in size to one another. The sheets having said concentrically aligned aperture patterns are thereafter superposed upon one another so as to form a stack exhibiting a three-dimensional continuum of capillary networks. A sufficient number of laminae are employed to ensure that said networks are of greater overall length than the maximum depth to which the plastic film being processed thereon is drawn when subjected to said fluid pressure differential. Said capillary networks exhibit a cross sectional area which reaches a minimum intermediate the uppermost and lowermost surfaces of the stack and thereafter increases in the direction of the lowermost surface of the stack to increase fluid permeability. The superposed sheets are bonded to one another at contact points while in the stacked configuration to form an integral laminate structure. The laminate forming structure is preferably caused to assume a tubular shape and its opposing free edges are secured to one another without disrupting the three-dimensional continuum of capillary networks along its periphery, thereby facilitating continuous plastic web processing against its outermost surface. The tubular laminate forming structure is preferably supported on a cylindrical drum by a multiplicity of radially oriented support members having lands which contact the innermost surface of the tubular member, but which are of ' insufficient cross-section to obstruct fluid flow through the capillary networks. Plastic material to be debossed and uniformly apertured may be extruded directly onto the surface of the forming structure while in a molten state or continuously fed in the form of film from a roll into contacting relation with the tubular laminate structure. The plastic material is subjected to a fluid pressure differential on said forming structure while at a temperature above its softening point. The overall thickness and configuration of the permeable laminate structure permits uniform application of fluid pressure, usually vacuum, to the lowermost surface of the plastic film, while preventing contact between the film and the support members. As a result, the heated film is uniformly debossed and apertured in conformance with the surface of the forming structure. The uniformly debossed and apertured film is cooled below its softening temperature and thereafter removed from the forming structure.
Inventors
- 👤 William Irvin Mullane, Jr.
Bibliographic Details
Application Number
—
Jurisdiction
EP
Data Source
google_patents
Last Synchronized
2026-11-09 01:20
CPC Classifications
B; B29; B29C; B29C59/00; B29C59/02; B29C59/06; B26; B26F; B26F1/00; B26F1/26; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1002; Y10T156/1043; Y10T156/1044; Y10T156/1052; Y10T156/1056; Y10T428/00; Y10T428/24; Y10T428/24273; Y10T428/24281; Y10T428/24289; Y10T428/24322; Y10T428/24479; Y10T428/24521; Y10T428/24628; Y10T428/24661
Claims Analysis
Total Claims: 26
Claim 1
Independent Claim
214 words
A forming cylinder (555) for imparting an uninterrupted, uniformly apertured, fine scale three-dimensional pattern to a heated plastic film subjected to a fluid pressure differential while in contact with its surface, said cylinder comprising a tubular shaped structure (122', 122", 340, 440, 622', 740) exhibiting a three-dimensional continuum of capillary networks (141-45) about its periphery, each of said capillary networks placing the outermost and innermost surfaces (464, 465) of said tubular structure in exclusive fluid communication with one another, said tubular structure being supported at its innermost surface (465) by a multiplicity of support members (123), each of said support members having a land (124) which contacts the innermost surface of said tubular structure, said support members (123) being secured in fixed relation to one another, characterised in that each of said capillary networks has an overall length greater than the maximum depth to which said film is drawn when subjected to said fluid pressure differential, each of said capillary networks also having a cross-sectional area which increases from its minimum in the direction of.the innermost surface of said tubular structure, the width of the lands (124) of said support members (123) being insufficient to completely obstruct said capillary networks at their points of contact with the innermost surface (465) of said tubular structure.
Claim 2
Dependent Claim
214 words
A forming cylinder (555) for imparting an uninterrupted, uniformly apertured, fine scale three-dimensional pattern to a heated plastic film subjected to a fluid pressure differential while in contact with its surface, said cylinder comprising a tubular shaped structure (122', 122", 340, 440, 622', 740) exhibiting a three-dimensional continuum of capillary networks (141-45) about its periphery, each of said capillary networks placing the outermost and innermost surfaces (464, 465) of said tubular structure in exclusive fluid communication with one another, said tubular structure being supported at its innermost surface (465) by a multiplicity of support members (123), each of said support members having a land (124) which contacts the innermost surface of said tubular structure, said support members (123) being secured in fixed relation to one another, characterised in that each of said capillary networks has an overall length greater than the maximum depth to which said film is drawn when subjected to said fluid pressure differential, each of said capillary networks also having a cross-sectional area which increases from its minimum in the direction of.the innermost surface of said tubular structure, the width of the lands (124) of said support members (123) being insufficient to completely obstruct said capillary networks at their points of contact with the innermost surface (465) of said tubular structure.
Claim 3
Dependent Claim
31 words
A forming cylinder according to Claim 1, wherein said tubular structure (122', 122", 340, 440, 622', 740) exhibits substantial continuity of said three-dimensional continuum of capillary networks about its entire periphery.
Claim 4
Dependent Claim
22 words
A forming cylinder according to either one of Claims 1 and 2, wherein said capillary networks (140--145) exhibit a substantially circular cross-section.
Claim 5
Dependent Claim
20 words
A forming cylinder according to either one of Claims 1 and 2, wherein said capillary networks exhibit an irregular cross-section.
Claim 6
Dependent Claim
41 words
A forming cylinder according to Claim 4, wherein said capillary networks placing said outermost and said innermost surfaces (464, 465) of said tubular shaped structure in exclusive fluid communication with one another are subdivided intermediate said outermost and said innermost surfaces.
Claim 7
Dependent Claim
112 words
A forming cylinder according to any one of Claims 1 to 5, characterised in that the cylinder comprises a tubular shaped laminate structure (340, 440, 740) formed from a multiplicity of laminar sheets (150-154) bonded to one another at their points of contact,each of said sheets having a substantially continuous pattern of apertures (141-145) therein, said apertures in each of said sheets being concentrically aligned with the corresponding apertures in the balance of said sheets, said apertures in at least one of said laminar sheets being dissimilar in size from the corresponding apertures in another of said sheets, said corresponding apertures in said sheets thereby forming the three-dimensional continuum of capillary networks.
Claim 8
Dependent Claim
35 words
A forming cylinder according to Claim 6, wherein said apertures in said substantially continuous patterns of concentrically aligned apertures are formed by a multiplicity of intersecting fiber-like elements interconnected to one another at their ends.
Claim 9
Independent Claim
367 words
A method for constructing a forming cylinder for imparting an uninterrupted, uniformly apertured three-dimensional pattern to a heated plastic film subjected to a fluid pressure differential while in contact with its surface, characterised in that it comprises the steps of: a) forming substantially continuous patterns of apertures (141-145) in a multiplicity of planar sheets (150-154), at least a portion of said sheets having aperture patterns in which the apertures at least to a degree coincide from one sheet to another, at least a portion of said coinciding apertures being dissimilar in size from one lamina to another; b) superposing said sheets having said patterns of coinciding, dissimilarly sized apertures upon one another to form a three-dimensional stack (340, 440) having a greater overall thickness than the maximum depth to which said film is drawn when subjected to said fluid pressure differential, said stack further exhibiting a three-dimensional continuum of capillary networks, each of said capillary networks placing the uppermost and lowermost surfaces (464, 465) of said stack (340, 440) in exclusive fluid communication with one another, each of said capillary networks having a cross-sectional area which increases from its minimum in the direction of the lowermost surface of said stack; c) bonding said superposed stack.of sheets to one another at contact points to form an integral laminate structure; d) causing the uppermost surface (464) of said laminate structure to assume a radius of curvature greater than that of said lowermost surface (465) of said laminate structure without causing delamination thereof, thereby causing said laminate structure to assume a substantially tubular shape; e) securing the opposing free edges of said tubular shaped laminate structure to one another while maintaining substantial. continuity of said three-dimensional continuum of capillary networks about the entire periphery of the tubular member thus formed; and f) supporting the innermost surface (465) of said tubular laminate (340, 440) structure on a multiplicity of support members (123), each of said support members having a land (124) which contacts the innermost surface (465) of said tubular laminate structure (340, 440), the width of said lands being insufficient to completely obstruct said capillary networks at their points of contact with the innermost surface of said tubular laminate structure.
Claim 10
Independent Claim
367 words
A method for constructing a forming cylinder for imparting an uninterrupted, uniformly apertured three-dimensional pattern to a heated plastic film subjected to a fluid pressure differential while in contact with its surface, characterised in that it comprises the steps of: a) forming substantially continuous patterns of apertures (141-145) in a multiplicity of planar sheets (150-154), at least a portion of said sheets having aperture patterns in which the apertures at least to a degree coincide from one sheet to another, at least a portion of said coinciding apertures being dissimilar in size from one lamina to another; b) superposing said sheets having said patterns of coinciding, dissimilarly sized apertures upon one another to form a three-dimensional stack (340, 440) having a greater overall thickness than the maximum depth to which said film is drawn when subjected to said fluid pressure differential, said stack further exhibiting a three-dimensional continuum of capillary networks, each of said capillary networks placing the uppermost and lowermost surfaces (464, 465) of said stack (340, 440) in exclusive fluid communication with one another, each of said capillary networks having a cross-sectional area which increases from its minimum in the direction of the lowermost surface of said stack; c) bonding said superposed stack.of sheets to one another at contact points to form an integral laminate structure; d) causing the uppermost surface (464) of said laminate structure to assume a radius of curvature greater than that of said lowermost surface (465) of said laminate structure without causing delamination thereof, thereby causing said laminate structure to assume a substantially tubular shape; e) securing the opposing free edges of said tubular shaped laminate structure to one another while maintaining substantial. continuity of said three-dimensional continuum of capillary networks about the entire periphery of the tubular member thus formed; and f) supporting the innermost surface (465) of said tubular laminate (340, 440) structure on a multiplicity of support members (123), each of said support members having a land (124) which contacts the innermost surface (465) of said tubular laminate structure (340, 440), the width of said lands being insufficient to completely obstruct said capillary networks at their points of contact with the innermost surface of said tubular laminate structure.
Claim 11
Dependent Claim
28 words
). A method according to Claim 8, wherein the center lines of 3 aid coinciding apertures (141-145) formed in said planar sheets are concentrically aligned with one another.
Claim 12
Independent Claim
25 words
A method according to either one of Claims 8 and 9, wherein said coinciding apertures (141-145) formed in said planar sheets are of similar shape.
Claim 13
Independent Claim
29 words
A method according to any one of Claims 8-10, wherein said apertures (141-145) in said substantially continuous patterns of apertures in said planar sheets are substantially circular in shape.
Claim 14
Independent Claim
39 words
A method according to any one of Claims 8-10, wherein said apertures in said substantially continuous patterns of apertures in said planar sheets are formed by a multiplicity of intersecting fiber-like elements interconnected to one another at their ends.
Claim 15
Dependent Claim
55 words
A method according to Claim 12, wherein said coinciding apertures in at least one of said sheets located intermediate said uppermost and said lowermost surfaces of said stack include an additional interconnected fiber-like element which sub-divides the capillary network formed by said stack of planar sheets intermediate the uppermost and lowermost surfaces of said stack.
Claim 16
Independent Claim
29 words
A method according to any one of Claims 8 to 13, wherein said planar sheets are comprised of metal and said patterns of apertures are formed therein by photoetching.
Claim 17
Independent Claim
80 words
A method according to any one of Claims 8 to 14, wherein said planar sheets are superposed, on one another prior to bonding with their opposing free edges vertically misaligned with one another so that said opposing free edges of said laminate structure mate with one another when said laminate structure is caused to assume a substantially tubular shape to provide substantial continuity of said three-dimensional continuum of capillary networks about the entire periphery of the tubular member thus formed.
Claim 18
Dependent Claim
44 words
A method according to Claim 15, wherein said planar sheets are so vertically misaligned when superposed on one another that the opposing free edges thereof mate with one another in stairstep fashion when said laminate structure is caused to assume a substantially tubular shape.
Claim 19
Dependent Claim
43 words
A method according to Claim 15, wherein said sheets are so vertically misaligned when superposed on one another that the opposing free edges thereof mate with one another in interleaved fashion when said laminate structure is caused to assume a substantially tubular shape.
Claim 20
Independent Claim
197 words
A method of continuously forming a thermoplastic film exhibiting a fine scale, three-dimensional, uniformly apertured pattern, said method comprising the steps of: a) continuously bringing a ribbon of said film into contacting relation with, or extruding a melt of thermoplastic resin onto the periphery of, a tubular shaped perforate forming structure which is uniformly supported and uniformly pervious to fluid about its entire periphery, said forming structure exhibiting a three-dimensional microstructure comprising a regulated continuum of capillary networks originating in and extending continuously from the film-contacting surface to the non-film-contacting surface thereof, said capillary networks having a cross-sectional area which increases from its minimum in the direction of the non-resin contacting surface of said forming structure, said capillary networks also having an overall length greater than the maximum depth to which said film is drawn when subjected to said fluid pressure differential; b) applying a sufficiently great pneumatic differential pressure to said film or said heated thermoplastic resin to cause said film or said resin to uniformly conform to the image of said perforate forming structure; and c) cooling the three-dimensional apertured film thus formed below its thermoplastic temperature before removing said film from said forming structure.
Claim 21
Independent Claim
197 words
A method of continuously forming a thermoplastic film exhibiting a fine scale, three-dimensional, uniformly apertured pattern, said method comprising the steps of: a) continuously bringing a ribbon of said film into contacting relation with, or extruding a melt of thermoplastic resin onto the periphery of, a tubular shaped perforate forming structure which is uniformly supported and uniformly pervious to fluid about its entire periphery, said forming structure exhibiting a three-dimensional microstructure comprising a regulated continuum of capillary networks originating in and extending continuously from the film-contacting surface to the non-film-contacting surface thereof, said capillary networks having a cross-sectional area which increases from its minimum in the direction of the non-resin contacting surface of said forming structure, said capillary networks also having an overall length greater than the maximum depth to which said film is drawn when subjected to said fluid pressure differential; b) applying a sufficiently great pneumatic differential pressure to said film or said heated thermoplastic resin to cause said film or said resin to uniformly conform to the image of said perforate forming structure; and c) cooling the three-dimensional apertured film thus formed below its thermoplastic temperature before removing said film from said forming structure.
Claim 22
Dependent Claim
39 words
A method according to Claim 18, wherein the pneumatic differential pressure applied to said film or said heated thermoplastic resin comprises, at least in part, suction applied to the non-resin-contacting surface of said tubular shaped perforate laminate forming structure.
Claim 23
Independent Claim
46 words
A method according to either one of Claims 18 and 19, wherein said tubular shaped perforate forming structure is preheated prior to bringing said film or said resin in contacting relation therewith to facilitate better conformance of said resin or said film to said forming surface.
Claim 24
Dependent Claim
82 words
A method of uniformly debossing and perforating a running ribbon of planar thermoplastic film according to Claim 20, said method comprising the steps of: a) establishing and maintaining control of said film by establishing and maintaining constant tension therein; b) isolating a portion of said film from said constant tension while it is in contacting relation with the tubular shaped perforate forming structure; and c) cooling the debossed and perforated film below its thermoplastic temperature before subjecting said film to downstream tension.
Claim 25
Dependent Claim
205 words
A plastic web exhibiting a continuous fine scale, three-dimensional, uniformly apertured pattern (950', 950", 850') along its entire surface, said web being formed by: a) continuously bringing the plastic material comprising said web in contacting relation with a tubular shaped perforate forming structure which is uniformly supported and uniformly pervious to fluid about its entire periphery, said forming structure exhibiting a three-dimensional microstructure comprising a regulated continuum of capillary networks originating in and extending continuously from the web-contacting surface to the non-web-contacting surface thereof, said capillary networks having a corss-sectional area which increases from its minimum in the direction of the non-web-contacting surface of said forming structure, said capillary networks also having an overall length greater than the maximum depth to which said plastic web is drawn when subjected to said fluid pressure differential; b) applying a sufficiently great pneumatic differential pressure uniformly across the surface of said plastic material while said material is above its softening temperature to cause said material to be uniformly debossed and perforated in the image of said perforate forming structure; c) cooling said debossed and perforated plastic material below its thermoplastic temperature to form said web; and d) removing said uniformly debossed and perforated web from said forming structure.
Claim 26
Dependent Claim
205 words
A plastic web exhibiting a continuous fine scale, three-dimensional, uniformly apertured pattern (950', 950", 850') along its entire surface, said web being formed by: a) continuously bringing the plastic material comprising said web in contacting relation with a tubular shaped perforate forming structure which is uniformly supported and uniformly pervious to fluid about its entire periphery, said forming structure exhibiting a three-dimensional microstructure comprising a regulated continuum of capillary networks originating in and extending continuously from the web-contacting surface to the non-web-contacting surface thereof, said capillary networks having a corss-sectional area which increases from its minimum in the direction of the non-web-contacting surface of said forming structure, said capillary networks also having an overall length greater than the maximum depth to which said plastic web is drawn when subjected to said fluid pressure differential; b) applying a sufficiently great pneumatic differential pressure uniformly across the surface of said plastic material while said material is above its softening temperature to cause said material to be uniformly debossed and perforated in the image of said perforate forming structure; c) cooling said debossed and perforated plastic material below its thermoplastic temperature to form said web; and d) removing said uniformly debossed and perforated web from said forming structure.
References Cited (Backward Citations)
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