Production of formed material by solid-state formation with a high-pressure liquid stream

A process for permanently transforming a substantially continuous web of substantially planar, deformable material comprising a film into a web of debossed and perforated material without substantially altering the physical properties or the thermo-mechanical history of said substantially planar web, using a forming structure having a three-dimensionally patterned forming surface and an opposed surface, said forming surface comprising depressions which have sidewalls and end in holes, said forming structure being open from said holes in said forming surface to said opposed surface, said web of material having an indefinite length, a first surface and a second surface, said material having a transformation temperature range, said process comprising the steps of:

• (a) providing said web of material on said forming surface with said first surface of said web of material proximate said three-dimensionally patterned forming surface of said forming structure, said forming surface moving in a direction of said length of said web of material and carrying said web of material in said direction;
• (b) applying a substantially unconstrained liquid stream which is substantially stationary in the direction of travel of said moving web substantially uniformly to said second surface of said web of deformable material in those areas to be transformed, said substantially unconstrained liquid stream having sufficient force and mass flux to cause perforations to be created in said web of material in the areas coinciding with said depressions in said forming surface immediately upon contact therebetween;
• (c) flowing at least a portion of said substantially stationary liquid stream through said perforations in said web of material, through said holes in said forming surface, and through said forming structure so long as said moving web remains subject to said substantially stationary liquid stream;
• and
• (d) controlling the temperature of said web of material such that said material remains below said transformation temperature range throughout said process, thereby maintaining said web of substantially planar material in a substantially solid state throughout said process;
• said liquid stream having sufficient force and mass flux to cause said web of material to be extended into said depression and to cause said first surface of said web of material to be urged toward said sidewalls of said depressions, such that perforated protuberances are formed in said web of material.

An apparatus for permanently transforming a substantially continuous web of substantially planar material comprising a film having an indefinite length into a formed material having a substantial third dimensional structure perpendicular to the plane of said material without substantially altering the physical properties or the thermo-mechanical history of said substantially planar web, said material having a transformation temperature range, said apparatus comprising:

• a forming structure having a three-dimensionally patterned forming surface;
• (b) means for moving said forming surface in a direction of said length of said web of material;
• (c) means for applying a substantially unconstrained liquid stream to said forming surface with sufficient force and mass flux to cause said web of material to be formed substantially in the image of said three-dimensionally patterned forming surface;
• and
• (d) means for controlling the temperature of said web of material such that the temperature of said material remains below said transformation temperature range.

An apparatus for permanently transforming a substantially continuous web of substantially planar material comprising a film having an indefinite length into a debossed and perforated material, said material having a transformation temperature range, said apparatus comprising:

• (a) a forming structure having a patterned forming surface and an opposed surface, said forming surface comprising depressions which have sidewalls and end in holes, said forming structure being open from said holes in said forming surface to said opposed surface;
• (b) means for moving said forming surface in a direction of said length of said web of material;
• (c) means for applying a liquid stream to said forming surface with sufficient force and mass flux to cause said web of material to be formed substantially in the image of said forming surface and to cause perforated protuberances to be formed in said web of material;
• and
• (d) means for controlling the temperature of said web of material such that the temperature of said material remains below said transformation temperature range.