MULTI-PHASE PROCESS FOR DEBOSSING AND PERFORATING A POLYMERIC WEB TO COINCIDE WITH THE IMAGE OF ONE OR MORE THREE-DIMENSIONAL FORMING STRUCTURES

摘要

MULTI-PHASE PROCESS FOR DEBOSSING AND PERFORATING APOLYMERIC WEB TO COINCIDE WITH THE IMAGE OFONE OR MORE THREE-DIMENSIONAL FORMING STRUCTURESABSTRACTA continuous, multi-phase process for debossingand perforating a substantially continuous web ofsubstantially planar polymeric film to coincide with the imageof one or more forming structures, each having a patternedforming surface with a multiplicity of holes and an opposedsurface. Each forming structure is open from the holes inthe forming surface to its opposed surface. The web of filmhas an indefinite length, a first surface, a second surfaceand a thickness. The thickness comprises the distancebetween the first surface and the second surface. Theprocess comprises at least two sequential forming phases, oneof which involves three-dimensional conformance of the web tothe macroscopic profile of the forming structure and anotherof which involves aperturing of the web to coincide withfine-scale apertures in either the same or a separate formingstructure. The order in which the phases are carried outwill depend upon the properties desired in the resultantmacroscopically expanded, three-dimensional, aperturedpolymeric web. Because the process is carried out insequential phases, previously incompatible characteristicswhich could not be provided by prior art single-phaseforming processes can now be achieved.