Method of forming textile-like apertured plastic films

Claim 1

A method for forming an apertured film comprising a stretchable thermoplastic polymeric material having a plurality of micro-holes therein, said micro-holes being defined by a network of fibrils formed from said thermoplastic polymeric material, said method comprising: a) providing a starting film comprising said stretchable thermoplastic polymeric material and having an upper surface and a lower surface; b) providing a backing member comprising localized support regions for supporting said starting film, recessed zones into which the film may be deformed by the application thereto of fluid forces; and means for allowing said applied fluid to be transported away from said backing member; c) supporting said starting film on said backing member with portions of the lower surface of said film being in contact with the support regions of said backing member and with the upper surface of said film facing away from said backing member; d) providing a manifold adjacent to the starting film on said backing member, said manifold having a plurality of holes therein having areas ranging from about 7.07×10 -6 square inches to about 78.5×10 -6 square inches; e) directing a fluid through said manifold holes in the form of columnar streams against the upper surface of said starting film in a zone of contact and at a pressure sufficient to urge the unsupported portions of said starting film between said supported portions downwardly at least partially into said recessed zones and to cause the formation of said micro-holes and fibrils; f) moving said film from said contact zone; and g) removing said now-apertured film from said backing member.

Claim 2

A method for forming an apertured film comprising a stretchable thermoplastic polymeric material having a plurality of micro-holes therein, said micro-holes being defined by a network of fibrils formed from said thermoplastic polymeric material, said method comprising: a) providing a starting film comprising said stretchable thermoplastic polymeric material and having an upper surface and a lower surface; b) providing a backing member comprising localized support regions for supporting said starting film, recessed zones into which the film may be deformed by the application thereto of fluid forces; and means for allowing said applied fluid to be transported away from said backing member; c) supporting said starting film on said backing member with portions of the lower surface of said film being in contact with the support regions of said backing member and with the upper surface of said film facing away from said backing member; d) providing a manifold adjacent to the starting film on said backing member, said manifold having a plurality of holes therein having areas ranging from about 7.07×10 -6 square inches to about 78.5×10 -6 square inches; e) directing a fluid through said manifold holes in the form of columnar streams against the upper surface of said starting film in a zone of contact and at a pressure sufficient to urge the unsupported portions of said starting film between said supported portions downwardly at least partially into said recessed zones and to cause the formation of said micro-holes and fibrils; f) moving said film from said contact zone; and g) removing said now-apertured film from said backing member.