Multi-phase process for debossing and perforating a polymeric web to coincide with the image of one or more three-dimensional forming structures and apparatus for carrying out the method

Claim 2

A continuous, multi-phase process for debossing and perforating a substantially continuous web of substantially planar polymeric film to form a macroscopically expanded, three-dimensional, apertured polymeric web, said process comprising the steps of: (a) continuously supporting said web of film on a forming structure exhibiting a multiplicity of fine-scale apertures which place the opposed surfaces of said forming structure in fluid communication with one another, said forming structure moving in a direction parallel to the direction of travel of said web of film and carrying said web of film in said direction; (b) substantially continuously applying a first fluid pressure differential across the thickness of said web of film along said direction of movement of said forming structure exhibiting said fine-scale apertures, said fluid pressure differential being sufficiently great to cause said web of film to rupture in those areas coinciding with said fine-scale apertures in said forming structure; (c) continuously supporting said finely apertured web of film on a forming structure exhibiting a macroscopic, three-dimensional, cross-section defined by a multiplicity of macroscopic cross-section apertures which place the opposed surfaces of said forming structure in fluid communication with one another, said forming structure moving in a direction parallel to the direction of travel of said web of film and carrying said web of film in said direction; and (d) substantially continuously applying a second fluid pressure differential across the thickness of said web of film along said direction of movement of said forming structure, said second fluid pressure differential being sufficiently great to cause said web of film to be urged into substantial conformance with the macroscopic, three-dimensional cross-section of said forming structure while substantially maintaining the integrity of said fine-scale apertures formed by said fluid pressure differential.

Claim 3

A process according to Claim 1 wherein said second fluid pressure differential is sufficiently great to rupture said web in those areas coinciding with said macroscopic cross-section apertures in said forming structure.

Claim 4

A process according to either one of Claims 1 and 2, wherein said fine-scale aperturing of said web and said macroscopic conformance of said web are performed on separate forming structures.

Claim 5

A process according to Claim 3 wherein said fine-scale aperturing of said web is carried out across the surface of said web on a first forming structure, said finely apertured web being thereafter fed from said first forming structure onto a second forming structure, where it is urged into conformance with the three-dimensional, macroscopic cross-section of said second forming structure.

Claim 6

A process according to Claim 4 wherein said web is fed onto said second forming structure so that the surface of the web which contacted said first forming structure does not contact said second forming structure.

Claim 7

A process according to Claim 5, wherein said web is transferred from said first forming structure to said second forming structure by passing it through a nip formed between said first and second forming structures.

Claim 8

-7. A process according to Claim 6, wherein said fine scale apertures imparted to said web and said macroscopic, three-dimensional cross-section imparted to said web are maintained in register with one another by avoiding stretching of said web as it is transferred from said first forming structure to said second forming structure.

Claim 9

A process according to any one of Claims 1-7 wherein said fine scale aperturing of said web is carried out by directing a high pressure liquid jet at said web.

Claim 10

A process according to any one of Claims 1-8 wherein said web is urged into substantial compliance with said forming structure exhibiting a macroscopic, three-dimensional cross-section by directing a high pressure liquid jet at said web.

Claim 11

A process according to any one of Claims 1-9 wherein said web is urged into substantial compliance with said forming structure exhibiting a macroscopic, three-dimensional cross-section by subjecting the non-web contacting surface of said forming structure to vacuum.

Claim 12

A process according to any one of Claims 1-10 wherein said web of substantially planar polymeric film is initially formed by extrusion of a resin melt.

Claim 13

A process according to any one of Claims 1-11 wherein only a predetermined portion of said web is caused to rupture in those areas coinciding with said fine scale apertures.

Claim 14

A process according to any one of Claims 1-12 wherein only a predetermined portion of said web is caused to substantially conform to said macroscopic, three-dimensional cross-section of said forming structure.

Claim 15

A process according to either one of Claims 12 and 13, wherein an apertured mask element is interposed between said fluid pressure differential and said web to limit the portions of said web to be subjected to said fluid pressure differential to those areas coinciding with said apertures in said mask element.

Claim 16

A continuous, multi-phase process for debossing and perforating a substantially continuous web of substantially planar polymeric film to form a macroscopically expanded, three-dimensional, apertured polymeric web, said process comprising the steps of: (a) elevating the temperature of said web to a molten state; (b) continuously supporting said web of film on a forming structure exhibiting a multiplicity of fine-scale apertures which place the opposed surfaces of said forming structure in fluid communication and a macroscopic, three-dimensional cross-section defined by a multiplicity of macroscopic cross-section apertures which also place the opposed surfaces of said forming structure in fluid communication with one another, said forming structure moving in a direction parallel to the direction of travel of said web of film and carrying said web of film in said direction; (c) substantially continuously applying a first fluid pressure differential comprising vacuum to the non-web contacting surface of said forming structure, thereby causing said web of film to be urged into substantial conformance with the macroscopic, three-dimensional cross-section of said forming structure and to rupture in those areas coinciding with said macroscopic cross-section apertures in said forming structure; (d) cooling said web to its solid-state temperature; and (e) substantially continuously applying a second fluid pressure differential comprising a high pressure liquid jet across the thickness of said web of film along said direction of movement of said forming structure, the force applied by said liquid jet being sufficiently great to cause said web of film to rupture in those areas coinciding with said fine-scale apertures in said forming structure while substantially maintaining the integrity of the macroscopic, three-dimensional configuration formed by said first fluid pressure differential.

Claim 17

A continuous, multi-phase process for debossing and perforating a substantially continuous web of substantially planar polymeric film to form a macroscopically expanded, three-dimensional, apertured polymeric web, said process comprising the steps of: (a) elevating the temperature of said web to a molten state; (b) continuously supporting said web of film on a forming structure exhibiting a multiplicity of fine-scale apertures which place the opposed surfaces of said forming structure in fluid communication and a macroscopic, three-dimensional cross-section defined by a multiplicity of macroscopic cross-section apertures which also place the opposed surfaces of said forming structure in fluid communication with one another, said forming structure moving in a direction parallel to the direction of travel of said web of film and carrying said web of film in said direction; (c) substantially continuously applying a first fluid pressure differential comprising vacuum to the non-web contacting surface of said forming structure, thereby causing said web of film to be urged into substantial conformance with the macroscopic, three-dimensional cross-section of said forming structure and to rupture in those areas coinciding with said macroscopic cross-section apertures in said forming structure; (d) cooling said web to its solid-state temperature; and (e) substantially continuously applying a second fluid pressure differential comprising a high pressure liquid jet across the thickness of said web of film along said direction of movement of said forming structure, the force applied by said liquid jet being sufficiently great to cause said web of film to rupture in those areas coinciding with said fine-scale apertures in said forming structure while substantially maintaining the integrity of the macroscopic, three-dimensional configuration formed by said first fluid pressure differential.

Claim 18

A continuous, multi-phase process for debossing and perforating a substantially continuous web of substantially planar polymeric film to form a macroscopically expanded, three-dimensional, apertured polymeric web, said process comprising the steps of: (a) elevating the temperature of said web above its solid-state temperature; (b) continuously supporting said web of film on a forming structure exhibiting a macroscopic, three-dimensional cross-section defined by a multiplicity of macroscopic cross-section debossments having endwalls exhibiting a multiplicity of fine-scale apertures which place the opposed surfaces of said forming structure in fluid communication with one another, said forming structure moving in a direction parallel to the direction of travel of said web of film and carrying said web of film in said direction; (c) substantially continuously applying a first fluid pressure differential comprising vacuum applied to the non-web contacting surface of said forming structure across the thickness of said web of film along said direction of movement of said forming structure, said fluid pressure differential being sufficiently great to cause said web of film to be urged into substantial conformance with the macroscopic, three-dimensional cross-section of said forming structure; (d) cooling said web below its molten temperature; and (e) substantially continuously applying a second fluid pressure differential comprising a high pressure liquid jet across the thickness of said web of film along said direction of movement of said forming structure, the force applied by said high pressure liquid jet being sufficiently great to cause said web of film to rupture in those areas coinciding with said fine-scale apertures in the endwalls of said debossments in said forming structure while substantially maintaining the integrity of the macroscopic, three-dimensional configuration formed by said first fluid pressure differential.

Claim 19

A continuous, multi-phase process for debossing and perforating a substantially continuous web of substantially planar polymeric film to form a macroscopically expanded, three-dimensional, apertured polymeric web, said process comprising the steps of: (a) elevating the temperature of said web above its solid-state temperature; (b) continuously supporting said web of film on a forming structure exhibiting a macroscopic, three-dimensional cross-section defined by a multiplicity of macroscopic cross-section debossments having endwalls exhibiting a multiplicity of fine-scale apertures which place the opposed surfaces of said forming structure in fluid communication with one another, said forming structure moving in a direction parallel to the direction of travel of said web of film and carrying said web of film in said direction; (c) substantially continuously applying a first fluid pressure differential comprising vacuum applied to the non-web contacting surface of said forming structure across the thickness of said web of film along said direction of movement of said forming structure, said fluid pressure differential being sufficiently great to cause said web of film to be urged into substantial conformance with the macroscopic, three-dimensional cross-section of said forming structure; (d) cooling said web below its molten temperature; and (e) substantially continuously applying a second fluid pressure differential comprising a high pressure liquid jet across the thickness of said web of film along said direction of movement of said forming structure, the force applied by said high pressure liquid jet being sufficiently great to cause said web of film to rupture in those areas coinciding with said fine-scale apertures in the endwalls of said debossments in said forming structure while substantially maintaining the integrity of the macroscopic, three-dimensional configuration formed by said first fluid pressure differential.

Claim 20

The process of Claim 15 or Claim 16, wherein said cooling of said web is carried out by applying a low pressure cooling liquid spray thereto while said web is still subject to the vacuum comprising said first fluid pressure differential.

Claim 21

A continuous, multi-phase apparatus for debossing and perforating a substantially continuous web of substantially planar polymeric film to form a macroscopically expanded, three-dimensional, apertured polymeric web, said apparatus comprising: (a) a first forming structure for continuously - supporting said web of film, said first forming structure exhibiting a multiplicity of fine-scale apertures which place the opposed surfaces of said forming structure in fluid communication with one another; (b) means for moving said first forming structure in a direction parallel to the direction of travel of said web of film; (c) high pressure liquid jet means for substantially continuously applying a first fluid pressure differential across the thickness of said web of film along said direction of movement of said first forming structure, said fluid pressure differential being sufficiently great to cause said web of film to rupture in those areas coinciding with said fine-scale apertures in said first forming structure; (d) a second forming structure for continuously supporting said fine-scale apertured web of film, said second forming structure exhibiting a macroscopic, three-dimensional, cross-section defined by a multiplicity of macroscopic cross-section apertures which place the opposed surfaces of said second forming structure in fluid communication with one another; (e) means for moving said second forming structure in a direction parallel to the direction of travel of said web of film; and (f) high pressure liquid jet means for substantially continuously applying a second fluid pressure differential across the thickness of said web of film along said direction of movement of said second forming structure, said second fluid pressure differential being sufficiently great to cause said web of film to be urged into - substantial conformance with the macroscopic, three-dimensional cross-section of said second forming structure and to rupture said web in those areas coinciding with said macroscopic cross-section apertures in said second forming structure while substantially maintaining the integrity of said fine-scale apertures formed by said first fluid pressure differential in the areas of said web which are outside said macroscopic cross-section apertures.

Claim 22

A continuous, multi-phase apparatus for debossing and perforating a substantially continuous web of substantially planar polymeric film to form a macroscopically expanded, three-dimensional, apertured polymeric web, said apparatus comprising: (a) a first forming structure for continuously - supporting said web of film, said first forming structure exhibiting a multiplicity of fine-scale apertures which place the opposed surfaces of said forming structure in fluid communication with one another; (b) means for moving said first forming structure in a direction parallel to the direction of travel of said web of film; (c) high pressure liquid jet means for substantially continuously applying a first fluid pressure differential across the thickness of said web of film along said direction of movement of said first forming structure, said fluid pressure differential being sufficiently great to cause said web of film to rupture in those areas coinciding with said fine-scale apertures in said first forming structure; (d) a second forming structure for continuously supporting said fine-scale apertured web of film, said second forming structure exhibiting a macroscopic, three-dimensional, cross-section defined by a multiplicity of macroscopic cross-section apertures which place the opposed surfaces of said second forming structure in fluid communication with one another; (e) means for moving said second forming structure in a direction parallel to the direction of travel of said web of film; and (f) high pressure liquid jet means for substantially continuously applying a second fluid pressure differential across the thickness of said web of film along said direction of movement of said second forming structure, said second fluid pressure differential being sufficiently great to cause said web of film to be urged into - substantial conformance with the macroscopic, three-dimensional cross-section of said second forming structure and to rupture said web in those areas coinciding with said macroscopic cross-section apertures in said second forming structure while substantially maintaining the integrity of said fine-scale apertures formed by said first fluid pressure differential in the areas of said web which are outside said macroscopic cross-section apertures.

Claim 23

The apparatus of Claim 18, including means for feeding said web onto said second forming structure so that the surface of the web which contacted said first forming structure does not contact said second forming structure.

Claim 24

The apparatus of Claim 19, wherein said means for feeding said web from said first forming structure to said second forming structure comprises a nip formed between said first and second forming structures.

Claim 25

The apparatus of Claim 18 wherein a vacuum chamber is positioned adjacent the non-web contacting surface of at least one of said forming structures, said vacuum chamber being aligned with said high pressure liquid jet associated with said forming structure to collect the liquid which penetrates said web.

Claim 26

The apparatus of Claim 18, including extruder means for initially forming said substantially planar polymeric film from a resin melt.

Claim 27

The apparatus of Claim 18, including an apertured mask element interposed between said second fluid pressure differential and said web to limit the portions of said web to be subjected to said second fluid pressure differential to those areas coinciding with said apertures in said mask element.

Claim 28

A continuous, multi-phase apparatus for debossing and perforating a substantially continuous web of substantially planar polymeric film to form a macroscopically expanded, three-dimensional, apertured polymeric web, said apparatus comprising: (a) means for elevating the temperature of said web above its solid-state temperature; (b) a forming structure for continuously supporting said web of film, said forming structure exhibiting a multiplicity of fine-scale apertures which place the opposed surfaces of said forming structure in fluid communication with one another and a macroscopic, three-dimensional cross-section defined by a multiplicity of macroscopic cross-section apertures which also place the opposed surfaces of said forming structure in fluid communication with one another; (c) means for moving said forming structure in a direction parallel to the direction of travel of said web of film; (d) vacuum means for substantially continuously applying a first fluid pressure differential across the thickness of said web of film along said direction of movement of said forming structure, the force applied by said fluid pressure differential being sufficiently great to cause said web of film to be urged into substantial conformance with the macroscopic, three-dimensional cross-section of said forming structure and to rupture said web in those areas coinciding with said macroscopic cross-section apertures in said forming structure; (e) means for cooling said web below its molten temperature; and (f) high pressure liquid jet means for substantially continuously applying a second fluid pressure differential across the thickness of said web of film along said direction of movement of said forming structure, said second fluid pressure differential being sufficiently great to rupture said web in those areas coinciding with said fine-scale apertures in said forming structure while substantially maintaining the integrity of the macroscopic, three-dimensional configuration formed by said first fluid pressure differential.

Claim 29

A continuous, multi-phase apparatus for debossing and perforating a substantially continuous web of substantially planar polymeric film to form a macroscopically expanded, three-dimensional, apertured polymeric web, said apparatus comprising: (a) means for elevating the temperature of said web above its solid-state temperature; (b) a forming structure for continuously supporting said web of film, said forming structure exhibiting a multiplicity of fine-scale apertures which place the opposed surfaces of said forming structure in fluid communication with one another and a macroscopic, three-dimensional cross-section defined by a multiplicity of macroscopic cross-section apertures which also place the opposed surfaces of said forming structure in fluid communication with one another; (c) means for moving said forming structure in a direction parallel to the direction of travel of said web of film; (d) vacuum means for substantially continuously applying a first fluid pressure differential across the thickness of said web of film along said direction of movement of said forming structure, the force applied by said fluid pressure differential being sufficiently great to cause said web of film to be urged into substantial conformance with the macroscopic, three-dimensional cross-section of said forming structure and to rupture said web in those areas coinciding with said macroscopic cross-section apertures in said forming structure; (e) means for cooling said web below its molten temperature; and (f) high pressure liquid jet means for substantially continuously applying a second fluid pressure differential across the thickness of said web of film along said direction of movement of said forming structure, said second fluid pressure differential being sufficiently great to rupture said web in those areas coinciding with said fine-scale apertures in said forming structure while substantially maintaining the integrity of the macroscopic, three-dimensional configuration formed by said first fluid pressure differential.

Claim 30

A continuous, multi-phase apparatus for debossing and perforating a substantially continuous web of substantially planar polymeric film to form a macroscopically expanded, three-dimensional, apertured polymeric web, said apparatus comprising: (a) a forming structure for continuously supporting said web of film, said forming structure exhibiting a macroscopic, three-dimensional cross-section defined by a multiplicity of macroscopic cross-section debossments having endwalls exhibiting a multiplicity of fine-scale apertures which place the opposed surfaces of said forming structure in fluid communication with one another; (b) means for moving said forming structure in a direction parallel to the direction of travel of said web of film; (c) means for elevating the temperature of said - web above its solid-state temperature; (d) means for substantially continuously applying a first fluid pressure differential comprising vacuum to the non-web contacting surface of said forming structure across the thickness of said web of film along said direction of movement of said forming structure, said fluid pressure differential being sufficiently great to cause said web of film to be urged into substantial conformance with the macroscopic, three-dimensional cross-section of said forming structure; (e) means for cooling said macroscopically expanded web below its molten temperature prior to subjecting it to said second fluid pressure differential; and (f) means for substantially continuously applying a second fluid pressure differential comprising a high pressure liquid jet across the thickness of said web of film along said direction of movement of said forming structure, the force applied by said high pressure liquid jet being sufficiently great to cause said web of film to rupture in those areas coinciding with said fine-scale apertures in the endwalls of said debossments in said forming structure while substantially maintaining the integrity of the macroscopic, three-dimensional configuration formed by said first fluid pressure differential.

Claim 31

A continuous, multi-phase apparatus for debossing and perforating a substantially continuous web of substantially planar polymeric film to form a macroscopically expanded, three-dimensional, apertured polymeric web, said apparatus comprising: (a) a forming structure for continuously supporting said web of film, said forming structure exhibiting a macroscopic, three-dimensional cross-section defined by a multiplicity of macroscopic cross-section debossments having endwalls exhibiting a multiplicity of fine-scale apertures which place the opposed surfaces of said forming structure in fluid communication with one another; (b) means for moving said forming structure in a direction parallel to the direction of travel of said web of film; (c) means for elevating the temperature of said - web above its solid-state temperature; (d) means for substantially continuously applying a first fluid pressure differential comprising vacuum to the non-web contacting surface of said forming structure across the thickness of said web of film along said direction of movement of said forming structure, said fluid pressure differential being sufficiently great to cause said web of film to be urged into substantial conformance with the macroscopic, three-dimensional cross-section of said forming structure; (e) means for cooling said macroscopically expanded web below its molten temperature prior to subjecting it to said second fluid pressure differential; and (f) means for substantially continuously applying a second fluid pressure differential comprising a high pressure liquid jet across the thickness of said web of film along said direction of movement of said forming structure, the force applied by said high pressure liquid jet being sufficiently great to cause said web of film to rupture in those areas coinciding with said fine-scale apertures in the endwalls of said debossments in said forming structure while substantially maintaining the integrity of the macroscopic, three-dimensional configuration formed by said first fluid pressure differential.