Systems And Methods For Providing Micro-Aberrations On Film

A method for forming a vacuum formed, apertured film with micro-aberrations, the method comprising:

• receiving a molten polymer web at an engagement point between a screen with a positive aberration and a roller comprising a surface with a negative depression pre-formed therein, wherein the roller comprises a diameter of no more than about 5.5 inches;
• expanding a micro-aberration on a land of the molten polymer web at the engagement point by inserting the positive aberration on the screen into the negative aberration on the surface of the roller with the molten polymer web therebetween, wherein the positive aberration on the screen is inserted into the negative depression on the surface of the roller at a pressure of about 1.5 to about 3.5 pounds per linear inch (PLI).

The method of 11, wherein the surface of the roller further remains unaltered when the positive aberration is inserted into the negative depression pre-formed on the surface of the roller.

A method for forming a vacuum formed, apertured film with micro-aberrations, the method comprising:

• receiving a molten polymer web at an engagement point between a screen with a positive aberration and a roller comprising a surface with a negative depression therein, wherein the roller comprises a diameter of no more than about 5.5 inches;
• expanding a micro-aberration on a land of the molten polymer web at the engagement point by inserting the positive aberration on the screen into the negative aberration on the surface of the roller with the molten polymer web therebetween, wherein the positive aberration on the screen is inserted into the negative depression on the surface of the roller at a pressure of about 1.5 to about 3.5 pounds per linear inch (PLI), and wherein the micro-aberration comprises a fine scale mesh of at least about 5,500 aberrations per square centimeter with an average aberration height of about 30 μm or greater.