EP0059506A2 — Macroscopically expanded three-dimensional plasti…

Claim 1

Independent Claim 146 words

A macroscopically expanded three-dimensional plastic web (30,40) having at least one substantially non-glossy visible surface (31,41), characterised in' that' said substantially non-glossy visible surface (31,41) exhibits a regularly spaced, microscopic pattern of surface aberrations (33,43) which are not discernible to the normal naked eye when the perpendicular distance between the viewer's eye and the plane of said web is at least 30 cm, each of said surface aberrations being free of planar areas which are large enough to inscribe a 0.1 mm diameter circle, each of said surface aberrations being so spaced relative to all adjacent surface aberrations that the maximum diameter of any circle which can be inscribed on any planar surface intermediate said surface aberration and said adjacent surface aberrations is less than 0.1 mm, whereby light incident upon said non-glossy surface is diffusely reflected into a multiplicity of directions by said surface aberrations.

Claim 2

Dependent Claim 146 words

A macroscopically expanded three-dimensional plastic web (30,40) having at least one substantially non-glossy visible surface (31,41), characterised in' that' said substantially non-glossy visible surface (31,41) exhibits a regularly spaced, microscopic pattern of surface aberrations (33,43) which are not discernible to the normal naked eye when the perpendicular distance between the viewer's eye and the plane of said web is at least 30 cm, each of said surface aberrations being free of planar areas which are large enough to inscribe a 0.1 mm diameter circle, each of said surface aberrations being so spaced relative to all adjacent surface aberrations that the maximum diameter of any circle which can be inscribed on any planar surface intermediate said surface aberration and said adjacent surface aberrations is less than 0.1 mm, whereby light incident upon said non-glossy surface is diffusely reflected into a multiplicity of directions by said surface aberrations.

Claim 3

Dependent Claim 28 words

A web according to Claim 1, wherein at least a portion of said surface aberrations comprise protuberances (33) projecting generally outwardly from the surface (31) of said web.

Claim 4

Dependent Claim 28 words

A web according to Claim 1, wherein at least a portion of said surface aberrations comprise depressions (43) projecting generally inwardly from the surface (41) of said web.

Claim 5

Dependent Claim 27 words

A web according to Claim 3, wherein said surface abberations are disposed in a pattern corresponding to that of the knuckles of a woven mesh support structure.

Claim 6

Dependent Claim 39 words

A web according to Claim 4, wherein the pattern of said woven mesh support structure is a square weave of 0.025-0.05 mm diameter filaments having a mesh count in the range 63-157 filaments per lineal cm in each direction.

Claim 7

Dependent Claim 27 words

A web according to any one of Claims 1-5, wherein said surface aberrations have a minimum amplitude of at least 0.01 mm, preferably at least 0.015 mm.

Claim 8

Dependent Claim 46 words

A web according to Claim 6, wherein the amplitude of each of said surface aberrations, as measured perpendicular to the surface in which said surface aberration originates, is within ± 20%, preferably ± 10% of the average value of the amplitude for all adjacent surface aberrations.

Claim 9

Dependent Claim 37 words

A web according to any one of Claims 1-7 wherein the maximum dimension of any of said surface aberrations is less than 0.15 mm, as measured in a plane substantially perpendicular to the amplitude of said aberrations.

Claim 10

Independent Claim 265 words

A method of forming a macroscopically expanded three-dimensional plastic web having at least one substantially non-glossy visible surface, said method being characterised in that it comprises: (a) bringing a substantially planar plastic web in contacting relation with, or extruding a melt of plastic resin to form a web on the periphery of, a forming structure exhibiting a three-dimensional regulated continuum of capillary networks originating in and extending continuously from the web contacting surface to the non-web contacting surface thereof, the portions of said forming structure coinciding with the visible surface of said web further exhibiting a regularly spaced, microscopic pattern of surface aberrations which, when imparted to said plstic web, are not discernible to the normal naked eye when the perpendicular distance between the viewer's eye and the plane of said web is at least 30 cm, each of 'said surface aberrations on said forming structure being free of planar areas which are large enough that when imparted to said web the resultant surface aberration in said web will be free of any planar areas which are large enough to inscribe a 0.1 mm diameter circle, each of said surface aberrations on said forming structure being so spaced relative to all adjacent surface - aberrations on said forming structure that when imparted to said plastic web the maximum diameter of any circle which can be inscribed on any planar surface intermediate said surface aberration on said web and said adjacent surface aberrations on said web is less than 0.1 mm; and (b) causing said plastic web to conform to the image of said forming structure.

Claim 11

Independent Claim 265 words

A method of forming a macroscopically expanded three-dimensional plastic web having at least one substantially non-glossy visible surface, said method being characterised in that it comprises: (a) bringing a substantially planar plastic web in contacting relation with, or extruding a melt of plastic resin to form a web on the periphery of, a forming structure exhibiting a three-dimensional regulated continuum of capillary networks originating in and extending continuously from the web contacting surface to the non-web contacting surface thereof, the portions of said forming structure coinciding with the visible surface of said web further exhibiting a regularly spaced, microscopic pattern of surface aberrations which, when imparted to said plstic web, are not discernible to the normal naked eye when the perpendicular distance between the viewer's eye and the plane of said web is at least 30 cm, each of 'said surface aberrations on said forming structure being free of planar areas which are large enough that when imparted to said web the resultant surface aberration in said web will be free of any planar areas which are large enough to inscribe a 0.1 mm diameter circle, each of said surface aberrations on said forming structure being so spaced relative to all adjacent surface - aberrations on said forming structure that when imparted to said plastic web the maximum diameter of any circle which can be inscribed on any planar surface intermediate said surface aberration on said web and said adjacent surface aberrations on said web is less than 0.1 mm; and (b) causing said plastic web to conform to the image of said forming structure.

Claim 12

Dependent Claim 83 words

A method according to Claim 9 wherein the forming structure is perforate including the steps of (a) heating a portion of said web in contact with said forming structure above its softening temperature; (b) applying a sufficiently great fluid differential pressure to said heated plastic web to cause said web to conform to the image of said perforate forming structure; and (c) cooling the macroscopically expanded three-dimensional plastic web thus formed below its softening temperature before removing said web from said forming structure.

Claim 13

Dependent Claim 38 words

ll. A method according to Claim 10, wherein said fluid differential pressure applied to said heated plastic web is pneumatic and is sufficient to cause said web to be perforated in the image of said perforate forming structure.

Claim 14

Independent Claim 262 words

A method of forming a macroscopically expanded three-dimensional plastic web having at least one substantially non-glossy visible surface, said method being characterised in that a surface of a substantially planar plastic web, or a surface of a melt of plastic resin extruded so as to form a planar web is contacted by two separate forming structures, one forming structure exhibiting a regularly-spaced microscopic pattern of surface aberrations which, when imparted to said plastic web, are not discernible to the normal naked eye when the perpendicular distance between the viewer's eye and the plane of said web is at least 30 cm, each of said surface aberrations being free of planar areas which are large enough that when imparted to said web the resultant surface aberration in said web will be free of any planar areas which are large enough to inscribe a 0.1 mm diameter circle, each of said surface aberrations on said first forming structure being so spaced relative to all adjacent surface aberrations-on said first forming structure that when imparted to said plastic web the maximum diameter of any circle which can be inscribed on any planar surface intermediate said surface aberration on said web and said adjacent surface aberrations on said web is less than 0.1 mm; the other forming structure exhibiting a three-dimensional regulated continuum'of capillary networks originating in and extending continuously from the web contacting surface thereof; and said web being caused to conform to the three-dimensional image of said other forming structure and having the image of said one forming structure imparted to its visible surface.

Claim 15

Independent Claim 262 words

A method of forming a macroscopically expanded three-dimensional plastic web having at least one substantially non-glossy visible surface, said method being characterised in that a surface of a substantially planar plastic web, or a surface of a melt of plastic resin extruded so as to form a planar web is contacted by two separate forming structures, one forming structure exhibiting a regularly-spaced microscopic pattern of surface aberrations which, when imparted to said plastic web, are not discernible to the normal naked eye when the perpendicular distance between the viewer's eye and the plane of said web is at least 30 cm, each of said surface aberrations being free of planar areas which are large enough that when imparted to said web the resultant surface aberration in said web will be free of any planar areas which are large enough to inscribe a 0.1 mm diameter circle, each of said surface aberrations on said first forming structure being so spaced relative to all adjacent surface aberrations-on said first forming structure that when imparted to said plastic web the maximum diameter of any circle which can be inscribed on any planar surface intermediate said surface aberration on said web and said adjacent surface aberrations on said web is less than 0.1 mm; the other forming structure exhibiting a three-dimensional regulated continuum'of capillary networks originating in and extending continuously from the web contacting surface thereof; and said web being caused to conform to the three-dimensional image of said other forming structure and having the image of said one forming structure imparted to its visible surface.

Claim 16

Dependent Claim 92 words

A method of forming a web according to Claim 12 wherein said web is brought first into contact with, so as to cause the visible surface thereof to conform to, the forming structure defining said regularly spaced microscopic pattern of surface aberrations and subsequently into contact with, so as to cause the surface opposite said visible surface to conform to, a second perforate forming structure exhibiting a three-dimensional regulated continuum of capillary networks, said conformation occurring without removing the image of said first forming structure from the visible surface of the web.

Claim 17

Dependent Claim 95 words

A method of forming a web according to Claim 12 wherein said web is brought first into contact with, so as to cause a surface thereof to conform to, the forming structure defining said regularly spaced microscopic pattern of surface aberrations and is then removed from said,forming structure before being brought into contact with, so as to cause the same surface thereof to conform to, a second forming structure exhibiting a three-dimensional regulated continuum of capillary networks, said conformation occurring without removing the image of said first forming structure from said surface of the web.

Claim 18

Dependent Claim 84 words

A method of forming a web according to Claim 12 wherein said web is brought first into contact with, so as to cause the non visible surface thereof to conform to, a first forming structure exhibiting a three-dimensional regulated continuum of capillary networks and wherein, whilst said web is supported by said first structure, said web is brought into contact with, so as to cause the visible surface thereof to conform to, a second forming structure exhibiting a regularly spaced microscopic pattern`of surface aberrations.

Claim 19

Dependent Claim 38 words

A method according to Claim 15 wherein said first forming structure is tubular in form and.said web is caused to conform thereto without removing the image of said second forming structure from the visible surface of said web.

Claim 20

Dependent Claim 35 words

A method according to Claim 13 wherein both surfaces of said web are caused to conform to their respective forming structures by applying mechanical compression to said web while in contact with said forming structures.

Claim 21

Dependent Claim 42 words

A method according to Claim 13 wherein one or both surfaces of said web are caused to conform to their respective forming structures by heating said web to a temperature above its softening temperature and applying a fluid pressure to differential thereto.

Claim 22

Independent Claim 47 words

The method of any one of Claims 13-18 wherein said forming structure defining said microscopic pattern of surface aberrations comprises a square woven mesh of filaments of diameter 0.025-0.05 mm and a mesh count between 63 filaments per cm and 157 filaments per cm in each direction.

Claim 23

Independent Claim 39 words

A method according to any one of Claims 13-19 wherein one or both of said forming structures is heated prior to bringing said web in contacting relation therewith to facilitate better conformance of the surface of said web thereto.

Claim 24

Independent Claim 37 words

A method according to any one of Claims 13-20 wherein surface aberrations imparted to the visible surface of said web by the forming structure defining said microscopic pattern exhibit a minimum amplitude of at least 0.01 mm.

Macroscopically expanded three-dimensional plastic web exhibiting non-glossy visible surface and cloth-like tactile impression and process for its manufacture

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