Method of imparting a three-dimensional fiber-like appearance and tactile impression to a running ribbon of thermoplastic film

Claim 1

A method of continuously debossing a running ribbon of substantially planar thermoplastic film to produce a resilient three-dimensional web having first and second surfaces and containing a multiplicity of capillary networks, said first surface having a multiplicity of apertures in which said capillary networks originate, each of said apertures being defined by a multiplicity of intersecting fiber-like elements, each of said fiber-like elements exhibiting a substantially uniform U-shaped cross-section along its length, said method comprising the steps of : (a) continuously bringing said film in contacting relation with a tubular-shaped perforate laminate 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, each of said capillary networks in said forming structure being defined by a multiplicity of intersecting fiber-like elements interconnected to one another, each of said fiber-like elements further exhibiting a substantially uniform cross-section along its length, said cross-section comprising a base portion and a sidewall portion joined to each edge of said base portion, said intersecting sidewall portions of said interconnected fiber-like elements being interconnected to one another intermediate said film-contacting and said non-film contacting surfaces of said forming structure; (b) heating a portion of said film in contact with said forming surface above its thermoplastic temperature; (c) applying a sufficiently great pressure to said heated thermoplastic film to cause those portions of said film which do not coincide with the base portions of said fiber-like elements in said forming structure to substantially conform with each of the intersecting sidewall portions of each of said interconnected fiber-like elements in said forming structure without causing rupture of said film at the points of intersection between said sidewall portions, thereby forming said capillary networks and imparting a three-dimensional fiber-like appearance and tactile impression to said film; and (d) cooling the debossed film below its thermoplastic temperature to form said resilient web before removing said web from said forming structure.

Claim 2

A method of continuously debossing a running ribbon of substantially planar thermoplastic film to produce a resilient three-dimensional web having first and second surfaces and containing a multiplicity of capillary networks, said first surface having a multiplicity of apertures in which said capillary networks originate, each of said apertures being defined by a multiplicity of intersecting fiber-like elements, each of said fiber-like elements exhibiting a substantially uniform U-shaped cross-section along its length, said method comprising the steps of : (a) continuously bringing said film in contacting relation with a tubular-shaped perforate laminate 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, each of said capillary networks in said forming structure being defined by a multiplicity of intersecting fiber-like elements interconnected to one another, each of said fiber-like elements further exhibiting a substantially uniform cross-section along its length, said cross-section comprising a base portion and a sidewall portion joined to each edge of said base portion, said intersecting sidewall portions of said interconnected fiber-like elements being interconnected to one another intermediate said film-contacting and said non-film contacting surfaces of said forming structure; (b) heating a portion of said film in contact with said forming surface above its thermoplastic temperature; (c) applying a sufficiently great pressure to said heated thermoplastic film to cause those portions of said film which do not coincide with the base portions of said fiber-like elements in said forming structure to substantially conform with each of the intersecting sidewall portions of each of said interconnected fiber-like elements in said forming structure without causing rupture of said film at the points of intersection between said sidewall portions, thereby forming said capillary networks and imparting a three-dimensional fiber-like appearance and tactile impression to said film; and (d) cooling the debossed film below its thermoplastic temperature to form said resilient web before removing said web from said forming structure.

Claim 3

A method of continuously debossing a running ribbon of substantially planar thermoplastic film to produce a resilient three-dimensional web having first and second surfaces and containing a multiplicity of capillary networks of non-uniform cross-section along their length, said first surface having a multiplicity of apertures in which said capillary networks originate, each of said apertures being defined by a multiplicity of intersecting fiber-like elements, each of said fiber-like elements exhibiting a substantially uniform U-shaped cross-section along its length, said method comprising the steps of: (a) continuously bringing said film in contacting relation with a tubular-shaped perforate laminate forming structure exhibiting a three-dimensional microstructure comprising a regulated continuum of capillary networks of non-uniform cross-section along their length originating in and extending continuously from the film contacting surface to the non-film contacting surface thereof, each of said non-uniform cross-section capillary networks in said forming structure being defined by a multiplicity of intersecting fiber-like elements interconnected to one another, each of said fiber-like elements further exhibiting a substantially uniform cross-section along its length, said cross-section comprising a base portion and a sidewall portion joined to each edge of said base portion, said intersecting sidewall portions of said interconnected fiber-like elements being interconnected to one another intermediate said film-contacting and said non-film contacting surfaces of said forming structure; (b) heating a portion of said film in contact with said forming surface above its thermoplastic temperature; (c) applying a sufficiently great pressure to said heated thermoplastic film to cause those portions of said film which do not coincide with the base portions of said fiber-like elements in said forming structure to substantially conform with each of the intersecting sidewall portions of each of said interconnected fiber-like elements in said forming structure without causing rupture of said film at the points of intersection between said sidewall portions, thereby forming said non-uniform cross-section capillary networks and imparting a three-dimensional fiber-like appearance and tactile impression to said film; and (d) cooling the debossed film below its thermoplastic temperature to form said resilient web before removing said web from said forming structure.

Claim 4

A method of continuously debossing a running ribbon of substantially planar thermoplastic film to produce a resilient three-dimensional web having first and second surfaces and containing a multiplicity of capillary networks of non-uniform cross-section along their length, said first surface having a multiplicity of apertures in which said capillary networks originate, each of said apertures being defined by a multiplicity of intersecting fiber-like elements, each of said fiber-like elements exhibiting a substantially uniform U-shaped cross-section along its length, said method comprising the steps of: (a) continuously bringing said film in contacting relation with a tubular-shaped perforate laminate forming structure exhibiting a three-dimensional microstructure comprising a regulated continuum of capillary networks of non-uniform cross-section along their length originating in and extending continuously from the film contacting surface to the non-film contacting surface thereof, each of said non-uniform cross-section capillary networks in said forming structure being defined by a multiplicity of intersecting fiber-like elements interconnected to one another, each of said fiber-like elements further exhibiting a substantially uniform cross-section along its length, said cross-section comprising a base portion and a sidewall portion joined to each edge of said base portion, said intersecting sidewall portions of said interconnected fiber-like elements being interconnected to one another intermediate said film-contacting and said non-film contacting surfaces of said forming structure; (b) heating a portion of said film in contact with said forming surface above its thermoplastic temperature; (c) applying a sufficiently great pressure to said heated thermoplastic film to cause those portions of said film which do not coincide with the base portions of said fiber-like elements in said forming structure to substantially conform with each of the intersecting sidewall portions of each of said interconnected fiber-like elements in said forming structure without causing rupture of said film at the points of intersection between said sidewall portions, thereby forming said non-uniform cross-section capillary networks and imparting a three-dimensional fiber-like appearance and tactile impression to said film; and (d) cooling the debossed film below its thermoplastic temperature to form said resilient web before removing said web from said forming structure.

Claim 7

A method of continuously debossing and perforating a running ribbon of planar thermoplastic film to produce a resilient three-dimensional web having first and second surfaces and containing a multiplicity of capillary networks, said first surface having a multiplicity of apertures in which said capillary networks originate, each of said apertures being defined by a multiplicity of intersecting fiber-like elements, each of said fiber-like elements exhibiting a substantially uniform U-shaped cross-section along its length, 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 a tubular shaped perforate laminate 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, each of said capillary networks in said forming structure being defined by a multiplicity of intersecting fiber-like elements interconnected to one another, each of said fiber-like elements further exhibiting a substantially uniform cross-section along its length, said cross-section comprising a base portion and a sidewall portion joined to each edge of said base portion, said intersecting sidewall portions of said interconnected fiber-like elements being interconnected to one another intermediate said film-contacting and said non-film contacting surfaces of said forming structure; (c) heating the tension isolated portion of said film above its thermoplastic temperature; (d) applying a sufficiently great pressure to said heated, tension isolated portion of said thermoplastic film to cause those portions of said film which do not coincide with the base portions of said fiber-like elements in said forming structure to substantially conform with each of the intersecting sidewall portions of each of said interconnected fiber-like elements in said forming structure without causing rupture of said film at the points of intersection between said sidewall portions, thereby forming said capillary networks and imparting a three-dimensional fiber-like appearance and tactile impression to said film; and (e) cooling the debossed and perforated film below its thermoplastic temperature to form said resilient web before subjecting said web to downstream tension.

Claim 8

A method of continuously debossing and perforating a running ribbon of planar thermoplastic film to produce a resilient three-dimensional web having first and second surfaces and containing a multiplicity of capillary networks, said first surface having a multiplicity of apertures in which said capillary networks originate, each of said apertures being defined by a multiplicity of intersecting fiber-like elements, each of said fiber-like elements exhibiting a substantially uniform U-shaped cross-section along its length, 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 a tubular shaped perforate laminate 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, each of said capillary networks in said forming structure being defined by a multiplicity of intersecting fiber-like elements interconnected to one another, each of said fiber-like elements further exhibiting a substantially uniform cross-section along its length, said cross-section comprising a base portion and a sidewall portion joined to each edge of said base portion, said intersecting sidewall portions of said interconnected fiber-like elements being interconnected to one another intermediate said film-contacting and said non-film contacting surfaces of said forming structure; (c) heating the tension isolated portion of said film above its thermoplastic temperature; (d) applying a sufficiently great pressure to said heated, tension isolated portion of said thermoplastic film to cause those portions of said film which do not coincide with the base portions of said fiber-like elements in said forming structure to substantially conform with each of the intersecting sidewall portions of each of said interconnected fiber-like elements in said forming structure without causing rupture of said film at the points of intersection between said sidewall portions, thereby forming said capillary networks and imparting a three-dimensional fiber-like appearance and tactile impression to said film; and (e) cooling the debossed and perforated film below its thermoplastic temperature to form said resilient web before subjecting said web to downstream tension.

Claim 9

A method of continuously debossing and perforating a running ribbon of planar thermoplastic film to produce a resilient three-dimensional web having first and second surfaces and containing a multiplicity of capillary networks of non-uniform cross-section along their length, said first surface having a multiplicity of apertures in which said capillary networks originate, each of said apertures being defined by a multiplicity of intersecting fiber-like elements, each of said fiber-like elements exhibiting a substantially uniform U-shaped cross-section along its length, 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 a tubular shaped perforate laminate forming structure exhibiting a three-dimensional microstructure comprising a regulated continuum of capillary networks of non-uniform cross-section along their length originating in and extending continuously from the film contacting surface to the non-film contacting surface thereof, each of said non-uniform cross-section capillary networks in said forming structure being defined by a multiplicity of intersecting fiber-like elements interconnected to one another, each of said fiber-like elements further exhibiting a substantially uniform cross-section along its length, said cross-section comprising a base portion and a sidewall portion joined to each edge of said base portion, said intersecting sidewall portions of said interconnected fiber-like elements being interconnected to one another intermediate said film-contacting and said non-film contacting surfaces of said forming structure; (c) heating the tension isolated portion of said film above its thermoplastic temperature; (d) applying a sufficiently great pressure to said heated, tension isolated portion of said thermoplastic film to cause those portions of said film which do not coincide with the base portions of said fiber-like elements in said forming structure to substantially conform with each of the intersecting sidewall portions of each of said interconnected fiber-like elements in said forming structure without causing rupture of said film at the points of intersection between said sidewall portions, thereby forming said capillary networks and imparting a three-dimensional fiber-like appearance and tactile impression to said film; and (e) cooling the debossed and perforated film below its thermoplastic temperature to form said resilient web before subjecting said web to downstream tension.

Claim 10

A method of continuously debossing and perforating a running ribbon of planar thermoplastic film to produce a resilient three-dimensional web having first and second surfaces and containing a multiplicity of capillary networks of non-uniform cross-section along their length, said first surface having a multiplicity of apertures in which said capillary networks originate, each of said apertures being defined by a multiplicity of intersecting fiber-like elements, each of said fiber-like elements exhibiting a substantially uniform U-shaped cross-section along its length, 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 a tubular shaped perforate laminate forming structure exhibiting a three-dimensional microstructure comprising a regulated continuum of capillary networks of non-uniform cross-section along their length originating in and extending continuously from the film contacting surface to the non-film contacting surface thereof, each of said non-uniform cross-section capillary networks in said forming structure being defined by a multiplicity of intersecting fiber-like elements interconnected to one another, each of said fiber-like elements further exhibiting a substantially uniform cross-section along its length, said cross-section comprising a base portion and a sidewall portion joined to each edge of said base portion, said intersecting sidewall portions of said interconnected fiber-like elements being interconnected to one another intermediate said film-contacting and said non-film contacting surfaces of said forming structure; (c) heating the tension isolated portion of said film above its thermoplastic temperature; (d) applying a sufficiently great pressure to said heated, tension isolated portion of said thermoplastic film to cause those portions of said film which do not coincide with the base portions of said fiber-like elements in said forming structure to substantially conform with each of the intersecting sidewall portions of each of said interconnected fiber-like elements in said forming structure without causing rupture of said film at the points of intersection between said sidewall portions, thereby forming said capillary networks and imparting a three-dimensional fiber-like appearance and tactile impression to said film; and (e) cooling the debossed and perforated film below its thermoplastic temperature to form said resilient web before subjecting said web to downstream tension.

Claim 12

A method of continuously forming a resilient three-dimensional thermoplastic web having first and second surfaces and containing a multiplicity of capillary networks, said first surface having a multiplicity of apertures in which said capillary networks originate, each of said apertures being defined by a multiplicity of intersecting fiber-like elements, each of said fiber-like elements exhibiting a substantially non-uniform U-shaped cross-section along its length, said method comprising the steps of: (a) continuously extruding a melt of thermoplastic resin onto the periphery of a tubular-shaped perforate laminate forming structure exhibiting a three-dimensional microstructure comprising a regulated continuum of capillary networks originating in and extending continuously from the resin contacting surface to the non-resin contacting surface thereof, each of said capillary networks in said forming structure being defined by a multiplicity of intersecting fiber-like elements interconnected to one another, each of said fiber-like elements further exhibiting a substantially uniform cross-section along its length, said cross-section comprising a base portion and a sidewall portion joined to each edge of said base portion, said intersecting sidewall portions of said interconnected fiber-like elements being interconnected to one another intermediate said film-contacting and said non-film contacting surfaces of said forming structure; (b) applying a sufficiently great pressure to said heated thermoplastic resin to cause those portions of said resin which do not coincide with the base portions of said fiber-like elements in said forming structure to substantially conform with each of the intersecting sidewall portions of each of said interconnected fiber-like elements in said forming structure without causing rupture of said film at the points of intersection between said sidewall portions, thereby forming said capillary networks and imparting a fiber-like appearance and tactile impression to said film; and (c) cooling the three-dimensional film thus formed below its thermoplastic temperature to form said resilient web before removing said web from said forming structure.

Claim 13

A method of continuously forming a resilient three-dimensional thermoplastic web having first and second surfaces and containing a multiplicity of capillary networks, said first surface having a multiplicity of apertures in which said capillary networks originate, each of said apertures being defined by a multiplicity of intersecting fiber-like elements, each of said fiber-like elements exhibiting a substantially non-uniform U-shaped cross-section along its length, said method comprising the steps of: (a) continuously extruding a melt of thermoplastic resin onto the periphery of a tubular-shaped perforate laminate forming structure exhibiting a three-dimensional microstructure comprising a regulated continuum of capillary networks originating in and extending continuously from the resin contacting surface to the non-resin contacting surface thereof, each of said capillary networks in said forming structure being defined by a multiplicity of intersecting fiber-like elements interconnected to one another, each of said fiber-like elements further exhibiting a substantially uniform cross-section along its length, said cross-section comprising a base portion and a sidewall portion joined to each edge of said base portion, said intersecting sidewall portions of said interconnected fiber-like elements being interconnected to one another intermediate said film-contacting and said non-film contacting surfaces of said forming structure; (b) applying a sufficiently great pressure to said heated thermoplastic resin to cause those portions of said resin which do not coincide with the base portions of said fiber-like elements in said forming structure to substantially conform with each of the intersecting sidewall portions of each of said interconnected fiber-like elements in said forming structure without causing rupture of said film at the points of intersection between said sidewall portions, thereby forming said capillary networks and imparting a fiber-like appearance and tactile impression to said film; and (c) cooling the three-dimensional film thus formed below its thermoplastic temperature to form said resilient web before removing said web from said forming structure.

Claim 14

A method of continuously forming a resilient three-dimensional thermoplastic web having first and second surfaces and containing a multiplicity of capillary networks of non-uniform cross-section along their length, said first surface having a multiplicity of apertures in which said capillary networks originate, each of said apertures being defined by a multiplicity of intersecting fiber-like elements, each of said fiber-like elements exhibiting a substantially non-uniform U-shaped cross-section along its length, said method comprising the steps of: (a) continuously extruding a melt of thermoplastic resin onto the periphery of a tubular-shaped perforate laminate forming structure exhibiting a three-dimensional microstructure comprising a regulated continuum of capillary networks of non-uniform cross-section along their length originating in and extending continuously from the resin contacting surface to the non-resin contacting surface thereof, each of said non-uniform cross-section capillary networks in said forming structure being defined by a multiplicity of intersecting fiber-like elements interconnected to one another, each of said fiber-like elements further exhibiting a substantially uniform cross-section along its length, said cross-section comprising a base portion and a sidewall portion joined to each edge of said base portion, said intersecting sidewall portions of said interconnected fiber-like elements being interconnected to one another intermediate said film-contacting and said non-film contacting surfaces of said forming structure; (b) applying a sufficiently great pressure to said heated thermoplastic resin to cause those portions of said resin which do not coincide with the base portions of said fiber-like elements in said forming structure to substantially conform with each of the intersecting sidewall portions of each of said interconnected fiber-like elements in said forming structure without causing rupture of said film at the points of intersection between said sidewall portions, thereby forming said capillary networks and imparting a fiber-like appearance and tactile impression to said film; and (c) cooling the three-dimensional film to thus formed below its thermoplastic temperature to form said resilient web before removing said web from said forming structure.

Claim 15

A method of continuously forming a resilient three-dimensional thermoplastic web having first and second surfaces and containing a multiplicity of capillary networks of non-uniform cross-section along their length, said first surface having a multiplicity of apertures in which said capillary networks originate, each of said apertures being defined by a multiplicity of intersecting fiber-like elements, each of said fiber-like elements exhibiting a substantially non-uniform U-shaped cross-section along its length, said method comprising the steps of: (a) continuously extruding a melt of thermoplastic resin onto the periphery of a tubular-shaped perforate laminate forming structure exhibiting a three-dimensional microstructure comprising a regulated continuum of capillary networks of non-uniform cross-section along their length originating in and extending continuously from the resin contacting surface to the non-resin contacting surface thereof, each of said non-uniform cross-section capillary networks in said forming structure being defined by a multiplicity of intersecting fiber-like elements interconnected to one another, each of said fiber-like elements further exhibiting a substantially uniform cross-section along its length, said cross-section comprising a base portion and a sidewall portion joined to each edge of said base portion, said intersecting sidewall portions of said interconnected fiber-like elements being interconnected to one another intermediate said film-contacting and said non-film contacting surfaces of said forming structure; (b) applying a sufficiently great pressure to said heated thermoplastic resin to cause those portions of said resin which do not coincide with the base portions of said fiber-like elements in said forming structure to substantially conform with each of the intersecting sidewall portions of each of said interconnected fiber-like elements in said forming structure without causing rupture of said film at the points of intersection between said sidewall portions, thereby forming said capillary networks and imparting a fiber-like appearance and tactile impression to said film; and (c) cooling the three-dimensional film to thus formed below its thermoplastic temperature to form said resilient web before removing said web from said forming structure.