US 4,609,518 AGranted

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

AssigneeThe Procter & Gamble Company

InventorsJohn J. Curro, James C. Baird, Donald L. Gerth, George M. Vernon, E. Kelly Linman

Life of this patent

Estimating the term…

Loading patent…

Abstract

A continuous, multi-phase process for debossing and perforating a substantially continuous web of substantially planar polymeric film to coincide with the image of one or more forming structures, each having a patterned forming surface with a multiplicity of holes and an opposed surface. Each forming structure is open from the holes in the forming surface to its opposed surface. The web of film has an indefinite length, a first surface, a second surface and a thickness. The thickness comprises the distance between the first surface and the second surface. The process comprises at least two sequential forming phases, one of which involves three-dimensional conformance of the web to the macroscopic profile of the forming structure and another of which involves aperturing of the web to coincide with fine-scale apertures in either the same or a separate forming structure. The order in which the phases are carried out will depend upon the properties desired in the resultant macroscopically expanded, three-dimensional, apertured polymeric web. Because the process is carried out in sequential phases, previously incompatible characteristics which could not be provided by prior art single-phase forming processes can now be achieved.

Claims47

Dependent claims

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 surface 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 first fluid pressure differential.

2 more elements

(a) continuously supporting said web of film on a 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, 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 comprising a high pressure liquid jet across the thickness of said web of film along said direction of movement of said forming structure exhibiting said fine-scale apertures, the force applied by said fluid jet 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;
(c) transferring said finely apertured web of film to a 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, said second 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 comprising a second high pressure liquid jet 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 in those areas coinciding with said macroscopic cross-section apertures in said second forming sructure 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.

2 more elements

(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 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;
(b) 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 conformace 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;
(c) 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.

(a) 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;
(b) 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;
(c) 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.

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) 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) 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.

4 more elements

(a) 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;
(b) means for moving said forming structure in a direction parallel to the direction of travel of said web of film;
(c) 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;
and
(d) 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.

2 more elements

A continuous, mulit-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 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;
and
(d) 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.

2 more elements

Dependencies are inferred from the claim text.

Facts

Application: 06/740,145Filed 31 May 1985
Granted: 2 Sep 1986
Term ends: Not estimatedThe source records don’t support an estimate.

Classification11 codes

A61F 13/512
Topsheet, i.e. the permeable cover or layer facing the skin: characterised by its apertures, e.g. perforations
A61F 13/15577
Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor;…:…
A61F 13/15731
Mechanical treatment, e.g. notching, twisting, compressing, shaping: treating webs, e.g. for giving them a fibrelike appearance, e.g. by embossing
A61F 13/51104
Topsheet, i.e. the permeable cover or layer facing the skin: the top sheet having a three-dimensional cross-section, e.g. corrugations,…