CA1133321A - Method and apparatus for embossing and perforating a running ribbon of thermoplastic film on a metallic pattern roll - Google Patents
Method and apparatus for embossing and perforating a running ribbon of thermoplastic film on a metallic pattern rollInfo
- Publication number
- CA1133321A CA1133321A CA341,246A CA341246A CA1133321A CA 1133321 A CA1133321 A CA 1133321A CA 341246 A CA341246 A CA 341246A CA 1133321 A CA1133321 A CA 1133321A
- Authority
- CA
- Canada
- Prior art keywords
- roll
- film
- embossing
- pressure
- perforating
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/15577—Apparatus or processes for manufacturing
- A61F13/15707—Mechanical treatment, e.g. notching, twisting, compressing, shaping
- A61F13/15731—Treating webs, e.g. for giving them a fibrelike appearance, e.g. by embossing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
- B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
- B26F1/26—Perforating by non-mechanical means, e.g. by fluid jet
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
- B29C35/04—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using liquids, gas or steam
- B29C35/06—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using liquids, gas or steam for articles of indefinite length
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/18—Thermoforming apparatus
- B29C51/20—Thermoforming apparatus having movable moulds or mould parts
- B29C51/22—Thermoforming apparatus having movable moulds or mould parts rotatable about an axis
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
- B29C35/04—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using liquids, gas or steam
- B29C35/045—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using liquids, gas or steam using gas or flames
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only
- B29C51/082—Deep drawing or matched-mould forming, i.e. using mechanical means only by shaping between complementary mould parts
Landscapes
- Engineering & Computer Science (AREA)
- Health & Medical Sciences (AREA)
- Mechanical Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Biomedical Technology (AREA)
- Heart & Thoracic Surgery (AREA)
- Oral & Maxillofacial Surgery (AREA)
- Thermal Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Epidemiology (AREA)
- Forests & Forestry (AREA)
- Physics & Mathematics (AREA)
- Vascular Medicine (AREA)
- Animal Behavior & Ethology (AREA)
- General Health & Medical Sciences (AREA)
- Public Health (AREA)
- Veterinary Medicine (AREA)
- Shaping Of Tube Ends By Bending Or Straightening (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Absorbent Articles And Supports Therefor (AREA)
Abstract
METHOD AND APPARATUS FOR EMBOSSING AND PERFORATING A RUNNING
RIBBON OF THERMOPLASTIC FILM ON A METALLIC PATTERN ROLL
Abstract The invention disclosed is an apparatus and method to make a thermoplastic film embossed with tapered bosses having perforations in the tips of each boss through use of a metallic pattern roll and a heated perforating roll. The apparatus and method allow a film having tapered bosses with decreased cross-sectional areas leading to a perforation to be formed without use of expensive vacuum forming methods.
The invention discloses a film 10 being heated by a heating means 14 to a deformable state and being embossed on an embossing surface 16 of embossing roll 13 under pressure from the silicone rubber surface 33 of first pressure roll 15. The film on the apex of the cone 26 on embossing surface 16 is removed to perforate the cone by perforating roll 17, which is a resilient hollow metal tube heated from a radiant heater mounted on the inside of the hollow metal tube. The perforated film is then embossed a second time by the action of a second embossing roll 18 and then rewound onto a rewind roll.
RIBBON OF THERMOPLASTIC FILM ON A METALLIC PATTERN ROLL
Abstract The invention disclosed is an apparatus and method to make a thermoplastic film embossed with tapered bosses having perforations in the tips of each boss through use of a metallic pattern roll and a heated perforating roll. The apparatus and method allow a film having tapered bosses with decreased cross-sectional areas leading to a perforation to be formed without use of expensive vacuum forming methods.
The invention discloses a film 10 being heated by a heating means 14 to a deformable state and being embossed on an embossing surface 16 of embossing roll 13 under pressure from the silicone rubber surface 33 of first pressure roll 15. The film on the apex of the cone 26 on embossing surface 16 is removed to perforate the cone by perforating roll 17, which is a resilient hollow metal tube heated from a radiant heater mounted on the inside of the hollow metal tube. The perforated film is then embossed a second time by the action of a second embossing roll 18 and then rewound onto a rewind roll.
Description
- 1~;3332~
{
MET~IOD AND APPA~ATUS FQR EMBOSSING AND PERFORATI~G A RU~rlIl~G
RIB~ON OF T~IER~10PL~STI'C FILM ON A ~ETALLIC PATT~R~ ROLL
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'Description Technical'Field The apparatus and method of this invention rela~es to embossing thermoplastic ilm with cone-shaped bosses and perorating the apex of each cone. The embossed and perforated thermoplastic film can be used as a barrier layer which allows liquid to pass through in one direction and prevents its passage back in the other direction, but allows vapor to pass in either di,rection.
In making the-embossed and perforated film, it is essential that the perforations occur at the apex of each'cone and that the'embossed cone shape be maintained in the film. It is the tapered shape o~ each cone that imparts the preferential ~apillary action which allows liquid to pass through the perforated apex of the cone in one direction but prev~nts liquid from passing through the perforated cone in ~he other direction. The shape has a decreasing cross section rrom the base of the boss towards the apex having the perforation.
Background of the' Inv'ention The background art teaches several apparatus and methods for perforating or embossing a thermoplastic sheet. For example, U.S. Patent No. 3,214,795 issued to Hannauer on November 2, 1965 and U.S. Patent ~o. 3,243,488 issued to Hannauer on March 29, 1966 teach an apparatus and method to perforate a thermoplastic sheet by passing it between a pattern roll and a heated roll. ~lannauer discloses an apparatus wherein the ~mbossing roll and the pressure roll are heated. Complete contact is maintained between the nip of the pressure roll and the embossing roll through use of a rigid pressure r.oll mounted on a pivoc and a piston device which varies pressure applied to the embossing roll by the pressure roll.
~;t332~
U.S, Patent No. 3,560,601 issued to Johnson on February 2, 1971 teaches a method to emboss and perforate a fabric backed thermoplastic film. Johnson teaches a two step method wherein the material is first embossed by passing between the nip of a studded embossing roll and a pressure roll which embosses but does not perforate the material. In the second step, the material is perforated by blowing hot gases throug'n the wealcened film sections created by embossing to create a perforatPd material.
U.S. Patent ~o, 3,707,102 issued to Huppenthal on December 26, 1972 teaches a film perforating apparatus wherein the film is passed over the perforating roll having a series of hot pins which perforate the film. The perforating roll has a generally cool external surface having apertures which contain heated pins. The contact with the heated pins creates the perforations in the film.
U.S. Patent ~o. 3,950,480 issued to Adams on April 13, lg76 teaches a method to emboss a plastic film where a sheet ~f thermoplastic material is indirectl~r heated as it is passed between two hea~ers and is subsequently passed between the nip of an embossing roll and a pressure roll. As the heated film is passed between the nip of the embossing roll and pressure roll, it is embossed.
Canadian Patent 664,640 issued to Wangner on June 11, 1963 teaches a method to emboss a vinyl film on a fabric back wherein the vinyl layer of the film is impressed into a heated moving wire belt.
Defensive Publication 544,271 published by Zeisberg on December 24, 1968 teaches a method to create an apertured nonwoven structure from a film fibril sheet~ Zeisberg teaches the method of passing a film fibril sheet through a nip ~etween an embossing surface having male bosses and a ~1333"1 resilient moving surface, at least one of which is heated.
The male bosses on the embossing surface are elongated metal wires. Contact of the thermoplastic film with the male bosses in a heated environment causes the thermoplastic fibers to melt and be extruded away from the male bosses to create a film having elongated perforations with grommet-like structures around each perforation. The film material is then stretched thereby causing the elongated slits to become circular.
None of the above disclosed patents teach a method to create an embossed and perforated thermoplastic sheet having embossed cones wherein the perforations are critically located in the apex of each cone of each boss. Furthermore, these references do not teach a method to perforate and emboss a film using a metallic pattern roll rolling against a resilient flexible heating roll.
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'D'i's'c'los'ure of th'e''Inv'en't'i'on . . _ The method and apparatus disclosed herein teach a method to ~.ake a thermoplastic film having raised bosses with perforated tips. The resulting product can be used in conjunction with an absorbent means to create an absorbent device having the embossed and perforated thermoplastic film placed adjacent and next to the absorbent device with the e~bossed tapered cones facing into the absorbent material.
2S The perforated film will present to the liquid to be absorbed capillaries having decreasing cross-section which will, through capillary action, draw liquid into the absorbent material.
The ~ethod and apparatus disclosed herein teach a new method of perforating and em~ossing thermoplastic film wit~out the use of a vacuum mechanism. Avoidance of use of a vacu saves considerable amounts of energy.
The object of the invention is to provide a method and apparatus to manufacture thermoplastic films having a plurality of tapered, cone-shaped bosses having perforated apexes wherein the tapered boss would easily pass liquid in one direction, but not pass liquid in the other direction.
It is a further object of the invention to disclose a method and apparatus to manufacture thermoplastic sheets having a plurality of tapered bosses with perforated apexes which will exhibit capillary action encouraging the flow of liquid in one direction through the thermoplastic film and discouraging the liquid flow through the thermoplastic film in the other direction and yet allow vapor to pass through the bosses.
It is a further object of the invention to teach a method to produce an embossed thermoplastic film having perforated cone tips having the steps of supplying a heated, deformable plastic film to a male patterned embossing surface having a multiplicity of raised knobs having apices which define a raised surface and conforming the thermoplastic film in intimate contact with the raised knobs to produce an embossed ,~ film having a multiplicity of raised bosses. The bosses are then perforated by pressing the tips of the raised bosses between the apices of the knobs of the embossing roll and a heated perforating roll while maintaining the film in contact with the embossing surface~ The film is then cooled to a less deformable state while still in registration and contact with the raised knobs. The embossed film is then removed from the male patterned embossing surface.
The method disclosed herein also teaches the step of conforming the perforated film to male knobs on the embossing surface a first time before perforation and a second time after the tips of the bosses in the film have been perforated.
The method of the current invention teaches that the thermoplastic ; film will be conformed to the male embossing roll by passing it between the nip of the embossing roll and a first pressure - roll prior to perforation. After perforation, while still in intimate contact with the embossing roll, the film passes through the nip betwecn the second pressure roll and the embossing roll to be embossed the second time.
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, T~c method of the cnrr~nt invention teachcs per~o~ating the l~csses ill t:llc ~ilm by colltact wit-h a heated per~orating s;~l~acc o a r~;i]ient l~ollow mc~tal roll wllcrein the hollow roll is lleatecl by a radiant heater placed within the resi]ient 5 metal roll.
The apparatus o~ the ins~ant invention that produces an cmbossed thermoplast.ic film and perforates the tips of the bosses has means to supply a continuous the~noplastic film and a means to heat the thermoplastic film to a deformable state. ~ male patterned em~ossing roll having a multiplicity of raised Icnobs defining a cylindrical peripheral surface and a means to conform the thermoplastic film to the raised knobs on the embossing roll produce an embossed film having a multiplicity of raised bosses. A relatively resilient, heated perforating roll held captive against the male patterned embossing roll forms a nip with the cylindrical peripheral surface of the embossing roll to perforate the tips of the `~ bosses. Subsequently, there is a means to cool the embossed film to a less deformable state.
The apparatus of the present invention includes' a first and second mean.s to conform the'perforated thermoplastic film to the raised bosses of the male patterned e~nbossing roll before the bosses in the film have been perforated and after perforation to retain the'embossing.
In the'apparatus of the current in~7ention, the first and second means to conform the film to the'sur~ace of the embossing roll are a first and sccond pressure roll.
In the apparatus of the current invention, the heated perfora~ing surface comprises a resilient, hollow perforating roll forming a nip with the embossing roll w7herein a thermop]astic ilm is passed therebetween. The hollow roll is forced against the embossing roll so as to m~intain contact with the ~ilm across the'l~7idtl~ of the embossing roll to perforate the ~ips of tl~e bosses.
1~33321 Desc iption 'of the_Dr'awings A preferred embodiment of the disclosed inven~ion can be seen in the following drawing:
Figure 1 shows a side elevational view of the preferred embodiment of the apparatus of the invention;
Figure 2 shows an enlarged elevational view of the male embossing pattern on the embossing roll;
Figure 3 shows a side elevational view of the male embossing pattern taken along'line 3-3 of Figure 2;
Figure 4 shows a side elevational view of the heater means used in the current invention.
Figure 5 is a photograph of a plan view of the product of the invention magnified 36 times;
Figure 6 is a cross sectional view taken through section lines 6-6 in Figure 5; and Figure 7 is a cross-sectional view taken through'section lines 7-7 in Figure 6.
While the following disclosure of the preferred embodiments of the current invention illustrates the best mode presently known to the'inventor of the method and apparatus of his invention, the inventor does not limit the scope of his invention to the embodiment expressly disclosed, but defines the scope of his invention according to the claims following this specification.
Detailed Description 'of_the'Inve_ ion An example of apparatus to make the embossed and perforated film of this invention can be seen in Figure 1. All elements.
of the apparatus are attached to a main frame of conventional 11333;~1 design which i~ omitted rom the dra~ings to more clearly show the invention. As seen, a fi]m 10 is taken from a storage means 11, here an unwind roll, and unwound over idler ro~l 12 onto an embossing roll 13. The film 10 is heated by a heating means 14 prior to contact with embossing roll 13 and is subsequently placed in intimate contact with rotating embossing roll 13. A first pressure roll 15 adjacent embossing roll 13 is in contact with film 10 and applies pressure to film 10 to put film 10 in intimate contact with the embossing surface 16 of embossing roll 13 and to conform to the raised knobs on the male patterned embossing surface 16 of embossing roll 13. The film 10 is pulled forward by the rotation of embossing roll 13 ~hile in intimate contact with embossing surface 16~ While the film is still in contacting relation with the embossing surface 16, a perforating roll 17 contacts the film on the raised portions formed in the film conforming to the outer surface 16 of the embossing roll 13 to perforate the apices of the bosses in the film.
The film 10 remains in contacting relation with the embossing surface 16 as it rotates with the embossing roll and a second pressure roll 18 contacts the film 10 adjacent embossing roll 13 and causes the perforated filn to con~orm to the surface of the raised knobs of the male patterned embossing surface 16 of embossing roll 13. The film 10 is taken off from embossing roll 13 over idler roll 19 and goes into storage.
The ilm made by the method and apparatus of the present invention is made from polyethylene film manufactured by VisQueen Division, Ethyl Corporation, Baton Rouge, Louisiana.
In the apparatus shown in Figure 1, the film has a thickness of 0.001 inches (0.025 mm) and has a width of 12 inches (305 mm). Although the embodiment of the invention described here utilizes polyethylene, the method and apparatus of the current invention also can be used with other thermoplastic films.
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The storage means 11 for the film is an unwind roll and thefilm is unwound by surface tensioning with an unwind tension of approximately 0.1 to 0.7 pounds (0.44 - 3.1 N) of tension over the full film width.
Heating means 14 comprises air heating nozzles. The nozzle comprises a lower plenum 20 and an upper plenum 21 ~see Figure 4) fabricated from thin stainless steel sheet metal.
The lower plenum 20 is tapered and forms a slot 22 having a width of approximately 0.1 inches (2.5 mm) and a length of 12 inches (305 mm). The heating means 14 is mounted such that the width dimension of this slot 22 preferably overlies the entire width of the film 10. Upper plenum 21 has openings for electric heaters 23 which heat air to be blown through the slot 22. The electric heaters have a rating of I5 6 kilowatts at 240 volts to heat air to a maximum of 1200F
(650C). The air heaters are manufactured by GTE Sylvania Emmissive Products, Exeter, New Hampshire. Air temperature is controlled through thermocouples 24 in lower plenum 20 and voltage control loops (not shown) to the air heaters 23. The heaters discharge about 115 SCFH of air per lineal inch of slot length (1.28 standard m3 per hour per lineal cm of slot length) at a temperature typically controlled at `~
360F (182C). Slot 22 of the nozzle is positioned -approximately 0.5 inches to 1 inch (13 - 25 mm) above the thermoplastic film as seen in Figure 1.
After being heatec, the film is placed in intimate contact with the embossing surface 16 of embossing roll 13. Embossing roll 13 rotates in a clockwise direction about rotatable axle 25 pulling film 10 with it. Embossing roll 13 is powered by conventional means not shown.
Embossing surface 16 is a male patterned embossing surface having a plurality of embossing knobs comprising closely packed truncated cones 26. As seen in Figure 2, cones 26 are in close packed array with the center of rotation of each truncated cone forming an equilateral triangle with the 33~1 g other centers of rotation of the close packed cones having a dimension A equal to 0.040 inches (1.02 mm) and an angle B
between sides equal to ~0. Figure 3 shows a cross-sectional view of the embossing surface 16 through section line 3-3 in Figure 2. As seen in Figure 3, truncated cones 26 have a base diameter C equal to 0.040 inches (1~02 mm) and a top diameter D equal to 0.010 inches (0.25 mm), an angle of incline of opposite sides of the cones E equal to 90 and each cone has a height from the base to the flat trlmcated surface F equal to 0.015 inches (0.38 mm). Embossing roll 1 13 has approximately 217,420 bosses on its embossing surface.
The flat apices 26a of the truncated cones 26 form an outside peripheral circumferential surface in embossing roll 13 wi~h an outside diameter of 8.030 (203.96 mm) inches and a roll dia~eter across the cone bases of 8.000 (203.20) inches. s~hile the diame~er shows truncated cones as the raised knobs in the embossing surface, one skilled in the art could also utilize other shapes for the raised embossing knobs.
Embossing roll 13 is a hollow steel cylinder having a hollow interior space 27 and water passages 28 through axle 25 for the passage of water through embossing roll 13 facili-tating cooling the surface of the roll. The steel roll is made of No. 4142 steel hardened to Rockwell Scale C58. In a preferred embodiment, embossing roll 13 has an outside diameter of 8.030 inches (203.96 ~m), and inside diameter of 5.12 inches (130 m~), a total roll width of l3.0 inches (330 mm) and an embossing surface 16 width of 12.0 inches (304 mm). A steel roll with an outer embossing surface of close packed cones can be purchased from Inta-Roto, Inc., Richmond, Virginia. The embossing surface having a series of close packed cones,must be shaped on its outer cylindrical surface to create an embossing pattern of truncated cones of the dimensions specified above.
Embossing roll 13 is driven through a chain transmission by a 0.5 horsepower (0.37 kw) variable speed DC motor. The surface speed of embossing roll 13 is 31 feet per minute 11333'~
(15.7 cm/sc). Pressure rolls 15 and 18, and perforating ', roll 17 are ro~ated through friction arising from contact with embossing roll 13. The embossing roll 13 may be sprayed with silicone oil prior to contact with the film to facilitate release of the film from the roll after perforation.
First pressure roll 15 is a silicone rubber coated steel cylinder rotating about axis 29 which is fitted in bearings 30. For clarity, only one side o the apparatus is shown and only one of a pair of mechanisms mounted on any roller is shown. Bearings 30 are slidably mounted in channels 31 and can be moved in channels 31 by pressure cylinders 32.
Pressure cylinders 32 can be used to adjust the position of bearings 30 and thus adjust the pressure applied to the film 10 at the'nip of pressure roll 15 and embossing roll 13.
Pressure roll 15 is made'of cold rolled steeI and has an elastomeric coating 33 consisting of silicone rubber having a hardness of 50 Durometer on the A scale. First pressure roll 15 has a silicone rubber coat 33 with an outside diameter of 8.0 inches (203 mm) applied to a steel cylinder having an outside diameter of 7.5 inches (190 mm), and an inside diameter of 5.5 inches (140 mm) and a roll width of 15.00 inches (381 mm). Silicone rubber coat 33 has a width on the cylinder of 13 inches (330 mm). --The'first pressure roll 15 functions to force heat softened film 10 ag~inst embossing surface 16 where it acquires an , embossed shape matching embossing surface 16. Embossing surface 16 causes the film to have a series of bosses shaped as truncated cones across the entire width of the film to be used as an end product.
After the film is embossed onto the embossing surface of embossing roll 13 and has acquired the shape of the truncated cones 26 of embossing surface 16, the film is then contacted with the outer circumferential surface 17a of perforating .
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roll 17 to perforate each boss on the film on the truncated surface 26a of each cone. The perforating roll 17 is a hollow steel roll ground to a smooth surface on the outside and inside. The roll is made ~rom ~o. 4130 steel tubing / 5 hardened to a hardness of Rockwell Scale C-35. The perforating roll 17 has an outside diameter of 4.0 inches (102 mm), a wall thickness of 0.16 inches (4.06 mm) and the length of 10.00 inches (254 mm). The inside circumferential wall of the perforating roll 17 is blackened to allow for increased heat absorption.
Inside the perforating roll 17 extending throughout the length of the perforating roll 17 is a heater 34. ~eater 34 is a quartz infrared lamp which heats the roll to a temperature of 300~-500~F (149-260C,).
Perforating roll 16 freely rotates without an axle and is pressed against embossing roll 13 and held captive by twb solid rolls 35 and 36. Roll 35 is mounted on axles 37, roll 36 is mounted on axles 38 and axles 37 and 38 are mounted on frames 39. Frames 39 are'pivotally mounted to the main frame via pivot 40 so as to move'about pivot 40 to apply pressure to the'perforating roll 17. On the opposite end of frane 39 from pivot 40 are mounted two pressure cylinders 41 which are also mounted on the'main frame.' Pressure cylinders 41 are adjustable to vary the pressure which is exerted against perforating roll 17 by solid rollers 35 and 36 and thus vary the` pressure'exerted by perforating roll 17 against the film on embossing roll 13. Perforating roll 17 rotates freely and is not supported by an axle or similar apparatus. Perforating roll 17 is kept in lateral alignment with embossing roll 13 by two cam followers (not shown) which contact the axial edges of the rotating perforating roll 17.
The perforating roll is a resilient, flexible roll with a wall thickness calculated to provide deflection necessary to il33321 : ` ' maintain full leng~h contact with ilm 10 on the embossing surface 16 of embossing roll 13. The perforating roll must contact the embossing roll over its entire width in order to perforate the film over the entire width of interest. It has been found that when a load of 90 pounds per lineal inch (158 N per lineal cm) is applied to the perforating roll 17, through rolls 35 and 36 by cylinders 41, it will maintain contact with embossing roll 13 across the entire width of the embossing roll 13 and result in a total deflection of the perforating roll 17 of approximately 0.00,7 inches (0.18 mm).
Contact of the heated outer circumferential surface of the perforating roll 17 with the film embossed upon the truncated surfaces 26a of the truncated cones 26 on embossing surface 16 create holes or perforations in the film on the truncated surface 26a of the cones of the embossing surface at the area of the nip between the embossing roll 13 and perforating roll 17.
~ fter the film has been perforated by perforating roll 17, the'film maintains registration and contact with'the male patterned embossing surface 16 of the embossing roll 13 as it rotates. The film is contacted by a second pressure roll 18. The second pressure roll 18 forces the film back over --, the truncated cones 26 of the embossing surface 16 to conform the film to the embossing surface 16 to ensure tha~ any residual memory in the thermoplastic film has not caused the film to lose its embossed shape during perforation.
The s'econd pressure roll 18 is a hollow aluminum roll having hubs 42 welded on the ends of the roll and moun~ed on shaft 43. Roll 18 has a silicone rubber coating 44 around the outside circumferential surface of the roll 18. Shaft 43 ~; is supported by bearings attached to pivoting members 45.
Members 45 are pivotally mounted to the ~ain frame via pivots 46 on one end of each mcmber 45 and by pressure cylinders 47 attached to members 45 at pivots 48 on the other end. Cylinders 47 are attached to the main frame.
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Pressure cylinders 47 are adjustable to move pivoting member 45 and roll 18 against film 10 which is still in registration and contact with embossing surface 16 of embossing roll 13.
By adjusting pressure cylinders 47, pressure roll 18 can be pressed against film 10 to cause the film to conform to the ~; embossing surface 16 of embossing roll 13.
Second pressure roll lS is made of aluminum alloy having a cylindrical silicone rubber coating 44 of a hardness of 50 Durometer on the A scale. The aluminum roll has an outside diameter of 4.5 inches (114 mm~, an inside diameter of 3.5 inches (89 mm), the silicone rubber coat has an outside diameter of approximately 5 inches (127 mm) and the width of both the roll and its rubber coating is 10 inches (254 mm).
During operations, pressure roll 18 CQntaCtS film 10 directly and is driven by friction of contact with film 10 on embossing roll 13.
After a second embossing of the film caused by pressure applied to film 10 by pressure roll 18, the film is wound off on embossing roll 13 and over idler roller 19 to a rewind stand in its embossed condition.
. .
In the method of this invention, the film 10 is rolled from storage means 11 and passes under the slot 22 of heating means 14. Heating means contacts the thermoplastic film 10 with hot air to preheat the film between 200-300F
(93-149C). Film 10 is then applied to the embossing surface 16 of embossing roll 13 through the application of - pressure by pressure roll 15. Hydraulic cylinders 32 apply approximately 4600 pounds (20460 ~) of force through pressure roll 15 to film 10 on embossing surface 16 of embossing roll 13. Contact length of the nip be~een the pressure roll 15 and em~ossing roll 13 is 13 inches (330 mm) and the resulting specific loading is 350 pounds per lineal inch (613 M per lineal cm).
1 1 ~ 3 32~
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The pressure from pressure roll 15 places the film in intimate contact with and conforms it to the raised knobs of the male patterned embossing surface 16 of embossing roll 13. The circulating water in embossing roll 13 maintains the temperature at the outer circumferential surface of the embossed surface 16 between 100 and 175~F (38-79C). I~ere the film is in intimate contact with embossing surface 16, the film will stay at essentially the temperature of the outer embossing surface 16 substantially throughout the distance that it rotates in contact with the embossing surface 16.
The temperature of film 10 momentarily rises to a higher temperature durîng contac~ with the perforating roll 17, As the film is rotated near the perforating roll, it will be heated by radiant heat from perforating roller 17 and the temperature of the film will rise above the surface temperature of the embossing roll during exposure to infrared radiation rom perforating roll 17.
After the film has been conformed to embossing surface 16 from the pressure applied by pressure roll 15, the film then rotates with embossing roll 13 through the nip of contact with perforating roll 17. Perforating roll 17 is heated by internal heater 34s which is a quartz lamp, which heats the contact surface of the perforating roll 17 to a temperature between 300-500F (149-260C) and preferably to a temperature of 475F (246C). Perforatîng roll 17 is pressed against film 10 on embossing roll 13 through the action of air cylinders 41 pivoting frame 17 and applying pressure to the perforating roll through rolls 35 and 36. Total force applied to press perforating roll 17 against embossing roll 13 is about 900 pounds (4000 ?a) and the contact length between the two rolls is 10 inches (254 mm), yielding a specific loading applied by the perforating roll of 90 pounds per lineal inch (158 `~I per lineal cm). Pressure exerted by the perforating roll on the film on embossing 113332~
surface lG e,~ ru(les the ilm material out of the con~act area o i-he peroratirlg roll 17 and ~hc flat surfaces 26a of the ~rurlca~e(l cones 26 on embossing surEace 16. The material ex~lude~3 from the hole area forms a grommet-like reinforcing ri~ aroun~l ~he perforatibn~
In areas close to, bu~ not in contact with the perforating roll, the film 10 is heated due to radiation from the surface of the perforating roll 17. Because some thermoplastic films have memory, the heat may cause the embossed material to begin to reform into a flat shape and lose its embossing.
Because of this memory, it is advantageous to subject the film to a second pressurizing force which causes the film tb reconform to the embossing surfacP 16.
After leaving the nip of the embossing roll 13 and the ; 15 perforating roll 17, a film 10 rotates with the embossing roll to a nip with a second pressure roll 18 and embossing rol] 13.
At the nip between the second pressure roll 18 and embossing roll 13, pressure is exerted on roll 18 by pressure cylinders ~' 47 and pivoting frame 45 to cause the film 10 to be embossed into intimate'contact with the male patterned embossing, ,~ surface 16. Silicone rubber surface 44 of pressure roll 18 forces the film to reac~uire the shape of the truncated cones ~6 on embossing surface 16. Pressure cylinders 47 exert a total force of around 3200 pounds (14230 ~) on pressure roll 18 over the contact length between roll 13 and pressure roll 18 of about 10 inches (254 mm). This results in a specific loading ~pplied by the second pressure roller 18 to film 10 of appro~i~ately 320 pounds per lineal inch ~560 N per lineal cm). The second embossing step causes film 10 to conform to the embossing surface 16 of embossing roll 13 and retake the orm of truncated cones 26.
After leaving the nip of second pressure roll 18 and embossing roll 13, film 10 passes over idler roller 19 and . _ , . . .. . . .. ..... . .. .. _ .. __ ~_ __ ~333 is wound into ~ roll on the rcwind stand (not shown). Once leaving the surface o embossing roll 13, ~he film re~urn.s to ambient tempcrature.
The resulting product from this method is a film embossed with a closely packed array of truncated cones wherein the tip of each truncated cones is perforated. T.he resulting product has cones having a pitch of approximately 0.040 inches (1.02 mm); the included angle of the sides of each cone is approximatelY 90; each cone havin~ a ~erforation in i~9 - 10 apex with a diameter of approximately 0.010 to 0.012 inches (0.25 - 0.30 mm); the aperture in each.cone being. . --slightly eliptical; and the resulting truncated cones on the embossed film havîng a cone height slightly less than cone 26 on the embossing surface 16 of embossing roll 13.
As ~an be seen by one skilled in the art, the geometry of the bosses in the embossed film can be varied by varying the geometry on perforating surface 16 of embossing roll 13.
The embossed and perforated film resulting from the application of the above disclosed method results in therrnoplastic film having a plurality of tapered bosses having perforations in the tips of each boss. The film -.
can be used in combination with absorbent means to create an absorbent device wherein the film is located adjacent to the absorbent means with the tapered perforated bosses facing into the absorbent means. The bosses present a structure having decreasing cross section to liquid which transports the liquid into the abosrbent means, through the - perforations, by capillary action. The shape of the pore prevents movement of liquid through the perforated bosses from 3Q the absorbent means to outside the thermoplastic filrn. The perforated bosses freely allow the passage of vapor thoughout the perforated film.
xample - A perforated, embossed film is made by the method of this invention on apparatus si.milar to that disclosed in Figure 1.
1~333~
, VisQucen polyet,hylene film, 12 inches (305 n~) wide and 0.001 inclles (0.025 mm~ thick, is unwound from unwind roll 11 ,-over an idler roll 12 and onto an embossing roll 13. The embossing roll will pull the film from the unwind roll at a film tension of approximately 0.4 pounds (1.78 N) over the full film width. The film is heated by heating means 14, air heaters, which are located approximately ~.7 inches (17.8 n~l) above the film to heat the film by directing a jet of hot air against the film in a direc~ion approximately perpendicular to the film direction. The air heaters direct 115 SCFH per inch width of-film (1.28 meter3 hour/lineal cm of slot length at a nozzle temperature of 359 F (182 C).
The thermoplastic film is pulled through the apparatus by the rotation of the embossing roll 13,which has a surface speed of 31 feet per minute (15.75 centimeter per second). , The embossing surface 16 of the embossing roll is heated by contact with the'perforating roll 17 and the warm'film and has a surface temperature in the center of 130 F (54.4 C).
The film is er.~bossed over the male patterned embossing surface 16 of embossing roll 13 through the pressure applied to the film by first pressure roll 15. Pressure is applied by cylinder 32 to the first pressure roll 15 to yield a specific loading on the first pressure roll 15 of 352 pounds per lineal inch (616 N/cm) to force the film over the embossing surface 16. The central portion of the first pressure roll is heated to 144 F (62.2 C) by residual heat on the embossing roll as a result from contact with a perforating roll and as a result of contact with heated air being emitted by heating means 14 which is located adjacent the 30 pressure roll.
As the film rotates around embossing surface 16 of the embossing roll 13, it is perforated by contact with,perfol-ating roll 17. The temperature of the outer circumferential surface of the perforating roll is 476 F-(247 C)''which, on contacting -35 the film overlaid on the embossing surface, melts the film . _ _ _ . . , . . . _ ..... ... ~ . . . , . _ _ _ ~ 18 -an~ extrudes it frolll the surface ~o perforate the film.
Thc perfora~ing roll is sprayed wi~h small amounts of silicone oil to prevent the thermoplastic ilm rom sticking to the surface of the perforating roll. Prcssure cylinder 41 exerts prcssure on frame 39 through the solid rolls 35 and 36 to apply pressure to the perforating roll 17 yielding a specific-loading of the perforating roll against the film overlaid on the embossing roll of 91.3 pounds per lineal inch (160 N/cm).
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The polyethylene film rotates around with and in intimat~
contact with male patterned embossing surface 16 on embossing roll 13 where it is embossed for a second time as a result of pressure applied by a second pressure roll 18 to conform the film to the male patterned embossing surface 16. Pressure cylinder 47 exerts pressure on the second embossing roll through members 45 to yield a specific loading on the second pressure roll 18 of 326 pounds per lineal inch (570 N/cm).
The second embossing steps conforms the film to the surface of the male patterned embossing surface to yield an embossed and perforated film.
The final resulting product of a film resulting from the _ application of this method through the use of the above disclosed apparatus yields an e~bossed and perforated film as seen in Figures 5 - 7, consisting of a close packed triangular array of truncated cones 48 with perforated truncated top surfaces 49. The triangular array of close packed cones have a base diameter C equal to 0.04 inches (1.02 mm) having an included top angle E of 90 and having perforation on the apex of each cone which is slightly -30 eliptical, with a major axis of approximately 0.012 inches (0.305 mm) in the direction of web movement and ~ minor axis o approximately 0.011 inches (0.279 mm) in a perpendicular direction. The cone height is slightly less than the cone height of the embossing sur~ace 16 ~0.015 inches (0.038 m~)3.
The melting and cxtruding of thermoplastic film at the top of 26a o each truncated cone yields a grotmnet-like structure 50 around cach pcroration.
1~33321 The mctllocl and apparat~us described above as can be seen by one skillcd in ~:he art, are merely e~emplary and:may be varied within the scopc of the invention.
What is claimed is:
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MET~IOD AND APPA~ATUS FQR EMBOSSING AND PERFORATI~G A RU~rlIl~G
RIB~ON OF T~IER~10PL~STI'C FILM ON A ~ETALLIC PATT~R~ ROLL
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'Description Technical'Field The apparatus and method of this invention rela~es to embossing thermoplastic ilm with cone-shaped bosses and perorating the apex of each cone. The embossed and perforated thermoplastic film can be used as a barrier layer which allows liquid to pass through in one direction and prevents its passage back in the other direction, but allows vapor to pass in either di,rection.
In making the-embossed and perforated film, it is essential that the perforations occur at the apex of each'cone and that the'embossed cone shape be maintained in the film. It is the tapered shape o~ each cone that imparts the preferential ~apillary action which allows liquid to pass through the perforated apex of the cone in one direction but prev~nts liquid from passing through the perforated cone in ~he other direction. The shape has a decreasing cross section rrom the base of the boss towards the apex having the perforation.
Background of the' Inv'ention The background art teaches several apparatus and methods for perforating or embossing a thermoplastic sheet. For example, U.S. Patent No. 3,214,795 issued to Hannauer on November 2, 1965 and U.S. Patent ~o. 3,243,488 issued to Hannauer on March 29, 1966 teach an apparatus and method to perforate a thermoplastic sheet by passing it between a pattern roll and a heated roll. ~lannauer discloses an apparatus wherein the ~mbossing roll and the pressure roll are heated. Complete contact is maintained between the nip of the pressure roll and the embossing roll through use of a rigid pressure r.oll mounted on a pivoc and a piston device which varies pressure applied to the embossing roll by the pressure roll.
~;t332~
U.S, Patent No. 3,560,601 issued to Johnson on February 2, 1971 teaches a method to emboss and perforate a fabric backed thermoplastic film. Johnson teaches a two step method wherein the material is first embossed by passing between the nip of a studded embossing roll and a pressure roll which embosses but does not perforate the material. In the second step, the material is perforated by blowing hot gases throug'n the wealcened film sections created by embossing to create a perforatPd material.
U.S. Patent ~o, 3,707,102 issued to Huppenthal on December 26, 1972 teaches a film perforating apparatus wherein the film is passed over the perforating roll having a series of hot pins which perforate the film. The perforating roll has a generally cool external surface having apertures which contain heated pins. The contact with the heated pins creates the perforations in the film.
U.S. Patent ~o. 3,950,480 issued to Adams on April 13, lg76 teaches a method to emboss a plastic film where a sheet ~f thermoplastic material is indirectl~r heated as it is passed between two hea~ers and is subsequently passed between the nip of an embossing roll and a pressure roll. As the heated film is passed between the nip of the embossing roll and pressure roll, it is embossed.
Canadian Patent 664,640 issued to Wangner on June 11, 1963 teaches a method to emboss a vinyl film on a fabric back wherein the vinyl layer of the film is impressed into a heated moving wire belt.
Defensive Publication 544,271 published by Zeisberg on December 24, 1968 teaches a method to create an apertured nonwoven structure from a film fibril sheet~ Zeisberg teaches the method of passing a film fibril sheet through a nip ~etween an embossing surface having male bosses and a ~1333"1 resilient moving surface, at least one of which is heated.
The male bosses on the embossing surface are elongated metal wires. Contact of the thermoplastic film with the male bosses in a heated environment causes the thermoplastic fibers to melt and be extruded away from the male bosses to create a film having elongated perforations with grommet-like structures around each perforation. The film material is then stretched thereby causing the elongated slits to become circular.
None of the above disclosed patents teach a method to create an embossed and perforated thermoplastic sheet having embossed cones wherein the perforations are critically located in the apex of each cone of each boss. Furthermore, these references do not teach a method to perforate and emboss a film using a metallic pattern roll rolling against a resilient flexible heating roll.
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'D'i's'c'los'ure of th'e''Inv'en't'i'on . . _ The method and apparatus disclosed herein teach a method to ~.ake a thermoplastic film having raised bosses with perforated tips. The resulting product can be used in conjunction with an absorbent means to create an absorbent device having the embossed and perforated thermoplastic film placed adjacent and next to the absorbent device with the e~bossed tapered cones facing into the absorbent material.
2S The perforated film will present to the liquid to be absorbed capillaries having decreasing cross-section which will, through capillary action, draw liquid into the absorbent material.
The ~ethod and apparatus disclosed herein teach a new method of perforating and em~ossing thermoplastic film wit~out the use of a vacuum mechanism. Avoidance of use of a vacu saves considerable amounts of energy.
The object of the invention is to provide a method and apparatus to manufacture thermoplastic films having a plurality of tapered, cone-shaped bosses having perforated apexes wherein the tapered boss would easily pass liquid in one direction, but not pass liquid in the other direction.
It is a further object of the invention to disclose a method and apparatus to manufacture thermoplastic sheets having a plurality of tapered bosses with perforated apexes which will exhibit capillary action encouraging the flow of liquid in one direction through the thermoplastic film and discouraging the liquid flow through the thermoplastic film in the other direction and yet allow vapor to pass through the bosses.
It is a further object of the invention to teach a method to produce an embossed thermoplastic film having perforated cone tips having the steps of supplying a heated, deformable plastic film to a male patterned embossing surface having a multiplicity of raised knobs having apices which define a raised surface and conforming the thermoplastic film in intimate contact with the raised knobs to produce an embossed ,~ film having a multiplicity of raised bosses. The bosses are then perforated by pressing the tips of the raised bosses between the apices of the knobs of the embossing roll and a heated perforating roll while maintaining the film in contact with the embossing surface~ The film is then cooled to a less deformable state while still in registration and contact with the raised knobs. The embossed film is then removed from the male patterned embossing surface.
The method disclosed herein also teaches the step of conforming the perforated film to male knobs on the embossing surface a first time before perforation and a second time after the tips of the bosses in the film have been perforated.
The method of the current invention teaches that the thermoplastic ; film will be conformed to the male embossing roll by passing it between the nip of the embossing roll and a first pressure - roll prior to perforation. After perforation, while still in intimate contact with the embossing roll, the film passes through the nip betwecn the second pressure roll and the embossing roll to be embossed the second time.
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, T~c method of the cnrr~nt invention teachcs per~o~ating the l~csses ill t:llc ~ilm by colltact wit-h a heated per~orating s;~l~acc o a r~;i]ient l~ollow mc~tal roll wllcrein the hollow roll is lleatecl by a radiant heater placed within the resi]ient 5 metal roll.
The apparatus o~ the ins~ant invention that produces an cmbossed thermoplast.ic film and perforates the tips of the bosses has means to supply a continuous the~noplastic film and a means to heat the thermoplastic film to a deformable state. ~ male patterned em~ossing roll having a multiplicity of raised Icnobs defining a cylindrical peripheral surface and a means to conform the thermoplastic film to the raised knobs on the embossing roll produce an embossed film having a multiplicity of raised bosses. A relatively resilient, heated perforating roll held captive against the male patterned embossing roll forms a nip with the cylindrical peripheral surface of the embossing roll to perforate the tips of the `~ bosses. Subsequently, there is a means to cool the embossed film to a less deformable state.
The apparatus of the present invention includes' a first and second mean.s to conform the'perforated thermoplastic film to the raised bosses of the male patterned e~nbossing roll before the bosses in the film have been perforated and after perforation to retain the'embossing.
In the'apparatus of the current in~7ention, the first and second means to conform the film to the'sur~ace of the embossing roll are a first and sccond pressure roll.
In the apparatus of the current invention, the heated perfora~ing surface comprises a resilient, hollow perforating roll forming a nip with the embossing roll w7herein a thermop]astic ilm is passed therebetween. The hollow roll is forced against the embossing roll so as to m~intain contact with the ~ilm across the'l~7idtl~ of the embossing roll to perforate the ~ips of tl~e bosses.
1~33321 Desc iption 'of the_Dr'awings A preferred embodiment of the disclosed inven~ion can be seen in the following drawing:
Figure 1 shows a side elevational view of the preferred embodiment of the apparatus of the invention;
Figure 2 shows an enlarged elevational view of the male embossing pattern on the embossing roll;
Figure 3 shows a side elevational view of the male embossing pattern taken along'line 3-3 of Figure 2;
Figure 4 shows a side elevational view of the heater means used in the current invention.
Figure 5 is a photograph of a plan view of the product of the invention magnified 36 times;
Figure 6 is a cross sectional view taken through section lines 6-6 in Figure 5; and Figure 7 is a cross-sectional view taken through'section lines 7-7 in Figure 6.
While the following disclosure of the preferred embodiments of the current invention illustrates the best mode presently known to the'inventor of the method and apparatus of his invention, the inventor does not limit the scope of his invention to the embodiment expressly disclosed, but defines the scope of his invention according to the claims following this specification.
Detailed Description 'of_the'Inve_ ion An example of apparatus to make the embossed and perforated film of this invention can be seen in Figure 1. All elements.
of the apparatus are attached to a main frame of conventional 11333;~1 design which i~ omitted rom the dra~ings to more clearly show the invention. As seen, a fi]m 10 is taken from a storage means 11, here an unwind roll, and unwound over idler ro~l 12 onto an embossing roll 13. The film 10 is heated by a heating means 14 prior to contact with embossing roll 13 and is subsequently placed in intimate contact with rotating embossing roll 13. A first pressure roll 15 adjacent embossing roll 13 is in contact with film 10 and applies pressure to film 10 to put film 10 in intimate contact with the embossing surface 16 of embossing roll 13 and to conform to the raised knobs on the male patterned embossing surface 16 of embossing roll 13. The film 10 is pulled forward by the rotation of embossing roll 13 ~hile in intimate contact with embossing surface 16~ While the film is still in contacting relation with the embossing surface 16, a perforating roll 17 contacts the film on the raised portions formed in the film conforming to the outer surface 16 of the embossing roll 13 to perforate the apices of the bosses in the film.
The film 10 remains in contacting relation with the embossing surface 16 as it rotates with the embossing roll and a second pressure roll 18 contacts the film 10 adjacent embossing roll 13 and causes the perforated filn to con~orm to the surface of the raised knobs of the male patterned embossing surface 16 of embossing roll 13. The film 10 is taken off from embossing roll 13 over idler roll 19 and goes into storage.
The ilm made by the method and apparatus of the present invention is made from polyethylene film manufactured by VisQueen Division, Ethyl Corporation, Baton Rouge, Louisiana.
In the apparatus shown in Figure 1, the film has a thickness of 0.001 inches (0.025 mm) and has a width of 12 inches (305 mm). Although the embodiment of the invention described here utilizes polyethylene, the method and apparatus of the current invention also can be used with other thermoplastic films.
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The storage means 11 for the film is an unwind roll and thefilm is unwound by surface tensioning with an unwind tension of approximately 0.1 to 0.7 pounds (0.44 - 3.1 N) of tension over the full film width.
Heating means 14 comprises air heating nozzles. The nozzle comprises a lower plenum 20 and an upper plenum 21 ~see Figure 4) fabricated from thin stainless steel sheet metal.
The lower plenum 20 is tapered and forms a slot 22 having a width of approximately 0.1 inches (2.5 mm) and a length of 12 inches (305 mm). The heating means 14 is mounted such that the width dimension of this slot 22 preferably overlies the entire width of the film 10. Upper plenum 21 has openings for electric heaters 23 which heat air to be blown through the slot 22. The electric heaters have a rating of I5 6 kilowatts at 240 volts to heat air to a maximum of 1200F
(650C). The air heaters are manufactured by GTE Sylvania Emmissive Products, Exeter, New Hampshire. Air temperature is controlled through thermocouples 24 in lower plenum 20 and voltage control loops (not shown) to the air heaters 23. The heaters discharge about 115 SCFH of air per lineal inch of slot length (1.28 standard m3 per hour per lineal cm of slot length) at a temperature typically controlled at `~
360F (182C). Slot 22 of the nozzle is positioned -approximately 0.5 inches to 1 inch (13 - 25 mm) above the thermoplastic film as seen in Figure 1.
After being heatec, the film is placed in intimate contact with the embossing surface 16 of embossing roll 13. Embossing roll 13 rotates in a clockwise direction about rotatable axle 25 pulling film 10 with it. Embossing roll 13 is powered by conventional means not shown.
Embossing surface 16 is a male patterned embossing surface having a plurality of embossing knobs comprising closely packed truncated cones 26. As seen in Figure 2, cones 26 are in close packed array with the center of rotation of each truncated cone forming an equilateral triangle with the 33~1 g other centers of rotation of the close packed cones having a dimension A equal to 0.040 inches (1.02 mm) and an angle B
between sides equal to ~0. Figure 3 shows a cross-sectional view of the embossing surface 16 through section line 3-3 in Figure 2. As seen in Figure 3, truncated cones 26 have a base diameter C equal to 0.040 inches (1~02 mm) and a top diameter D equal to 0.010 inches (0.25 mm), an angle of incline of opposite sides of the cones E equal to 90 and each cone has a height from the base to the flat trlmcated surface F equal to 0.015 inches (0.38 mm). Embossing roll 1 13 has approximately 217,420 bosses on its embossing surface.
The flat apices 26a of the truncated cones 26 form an outside peripheral circumferential surface in embossing roll 13 wi~h an outside diameter of 8.030 (203.96 mm) inches and a roll dia~eter across the cone bases of 8.000 (203.20) inches. s~hile the diame~er shows truncated cones as the raised knobs in the embossing surface, one skilled in the art could also utilize other shapes for the raised embossing knobs.
Embossing roll 13 is a hollow steel cylinder having a hollow interior space 27 and water passages 28 through axle 25 for the passage of water through embossing roll 13 facili-tating cooling the surface of the roll. The steel roll is made of No. 4142 steel hardened to Rockwell Scale C58. In a preferred embodiment, embossing roll 13 has an outside diameter of 8.030 inches (203.96 ~m), and inside diameter of 5.12 inches (130 m~), a total roll width of l3.0 inches (330 mm) and an embossing surface 16 width of 12.0 inches (304 mm). A steel roll with an outer embossing surface of close packed cones can be purchased from Inta-Roto, Inc., Richmond, Virginia. The embossing surface having a series of close packed cones,must be shaped on its outer cylindrical surface to create an embossing pattern of truncated cones of the dimensions specified above.
Embossing roll 13 is driven through a chain transmission by a 0.5 horsepower (0.37 kw) variable speed DC motor. The surface speed of embossing roll 13 is 31 feet per minute 11333'~
(15.7 cm/sc). Pressure rolls 15 and 18, and perforating ', roll 17 are ro~ated through friction arising from contact with embossing roll 13. The embossing roll 13 may be sprayed with silicone oil prior to contact with the film to facilitate release of the film from the roll after perforation.
First pressure roll 15 is a silicone rubber coated steel cylinder rotating about axis 29 which is fitted in bearings 30. For clarity, only one side o the apparatus is shown and only one of a pair of mechanisms mounted on any roller is shown. Bearings 30 are slidably mounted in channels 31 and can be moved in channels 31 by pressure cylinders 32.
Pressure cylinders 32 can be used to adjust the position of bearings 30 and thus adjust the pressure applied to the film 10 at the'nip of pressure roll 15 and embossing roll 13.
Pressure roll 15 is made'of cold rolled steeI and has an elastomeric coating 33 consisting of silicone rubber having a hardness of 50 Durometer on the A scale. First pressure roll 15 has a silicone rubber coat 33 with an outside diameter of 8.0 inches (203 mm) applied to a steel cylinder having an outside diameter of 7.5 inches (190 mm), and an inside diameter of 5.5 inches (140 mm) and a roll width of 15.00 inches (381 mm). Silicone rubber coat 33 has a width on the cylinder of 13 inches (330 mm). --The'first pressure roll 15 functions to force heat softened film 10 ag~inst embossing surface 16 where it acquires an , embossed shape matching embossing surface 16. Embossing surface 16 causes the film to have a series of bosses shaped as truncated cones across the entire width of the film to be used as an end product.
After the film is embossed onto the embossing surface of embossing roll 13 and has acquired the shape of the truncated cones 26 of embossing surface 16, the film is then contacted with the outer circumferential surface 17a of perforating .
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3 3~ ~
roll 17 to perforate each boss on the film on the truncated surface 26a of each cone. The perforating roll 17 is a hollow steel roll ground to a smooth surface on the outside and inside. The roll is made ~rom ~o. 4130 steel tubing / 5 hardened to a hardness of Rockwell Scale C-35. The perforating roll 17 has an outside diameter of 4.0 inches (102 mm), a wall thickness of 0.16 inches (4.06 mm) and the length of 10.00 inches (254 mm). The inside circumferential wall of the perforating roll 17 is blackened to allow for increased heat absorption.
Inside the perforating roll 17 extending throughout the length of the perforating roll 17 is a heater 34. ~eater 34 is a quartz infrared lamp which heats the roll to a temperature of 300~-500~F (149-260C,).
Perforating roll 16 freely rotates without an axle and is pressed against embossing roll 13 and held captive by twb solid rolls 35 and 36. Roll 35 is mounted on axles 37, roll 36 is mounted on axles 38 and axles 37 and 38 are mounted on frames 39. Frames 39 are'pivotally mounted to the main frame via pivot 40 so as to move'about pivot 40 to apply pressure to the'perforating roll 17. On the opposite end of frane 39 from pivot 40 are mounted two pressure cylinders 41 which are also mounted on the'main frame.' Pressure cylinders 41 are adjustable to vary the pressure which is exerted against perforating roll 17 by solid rollers 35 and 36 and thus vary the` pressure'exerted by perforating roll 17 against the film on embossing roll 13. Perforating roll 17 rotates freely and is not supported by an axle or similar apparatus. Perforating roll 17 is kept in lateral alignment with embossing roll 13 by two cam followers (not shown) which contact the axial edges of the rotating perforating roll 17.
The perforating roll is a resilient, flexible roll with a wall thickness calculated to provide deflection necessary to il33321 : ` ' maintain full leng~h contact with ilm 10 on the embossing surface 16 of embossing roll 13. The perforating roll must contact the embossing roll over its entire width in order to perforate the film over the entire width of interest. It has been found that when a load of 90 pounds per lineal inch (158 N per lineal cm) is applied to the perforating roll 17, through rolls 35 and 36 by cylinders 41, it will maintain contact with embossing roll 13 across the entire width of the embossing roll 13 and result in a total deflection of the perforating roll 17 of approximately 0.00,7 inches (0.18 mm).
Contact of the heated outer circumferential surface of the perforating roll 17 with the film embossed upon the truncated surfaces 26a of the truncated cones 26 on embossing surface 16 create holes or perforations in the film on the truncated surface 26a of the cones of the embossing surface at the area of the nip between the embossing roll 13 and perforating roll 17.
~ fter the film has been perforated by perforating roll 17, the'film maintains registration and contact with'the male patterned embossing surface 16 of the embossing roll 13 as it rotates. The film is contacted by a second pressure roll 18. The second pressure roll 18 forces the film back over --, the truncated cones 26 of the embossing surface 16 to conform the film to the embossing surface 16 to ensure tha~ any residual memory in the thermoplastic film has not caused the film to lose its embossed shape during perforation.
The s'econd pressure roll 18 is a hollow aluminum roll having hubs 42 welded on the ends of the roll and moun~ed on shaft 43. Roll 18 has a silicone rubber coating 44 around the outside circumferential surface of the roll 18. Shaft 43 ~; is supported by bearings attached to pivoting members 45.
Members 45 are pivotally mounted to the ~ain frame via pivots 46 on one end of each mcmber 45 and by pressure cylinders 47 attached to members 45 at pivots 48 on the other end. Cylinders 47 are attached to the main frame.
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Pressure cylinders 47 are adjustable to move pivoting member 45 and roll 18 against film 10 which is still in registration and contact with embossing surface 16 of embossing roll 13.
By adjusting pressure cylinders 47, pressure roll 18 can be pressed against film 10 to cause the film to conform to the ~; embossing surface 16 of embossing roll 13.
Second pressure roll lS is made of aluminum alloy having a cylindrical silicone rubber coating 44 of a hardness of 50 Durometer on the A scale. The aluminum roll has an outside diameter of 4.5 inches (114 mm~, an inside diameter of 3.5 inches (89 mm), the silicone rubber coat has an outside diameter of approximately 5 inches (127 mm) and the width of both the roll and its rubber coating is 10 inches (254 mm).
During operations, pressure roll 18 CQntaCtS film 10 directly and is driven by friction of contact with film 10 on embossing roll 13.
After a second embossing of the film caused by pressure applied to film 10 by pressure roll 18, the film is wound off on embossing roll 13 and over idler roller 19 to a rewind stand in its embossed condition.
. .
In the method of this invention, the film 10 is rolled from storage means 11 and passes under the slot 22 of heating means 14. Heating means contacts the thermoplastic film 10 with hot air to preheat the film between 200-300F
(93-149C). Film 10 is then applied to the embossing surface 16 of embossing roll 13 through the application of - pressure by pressure roll 15. Hydraulic cylinders 32 apply approximately 4600 pounds (20460 ~) of force through pressure roll 15 to film 10 on embossing surface 16 of embossing roll 13. Contact length of the nip be~een the pressure roll 15 and em~ossing roll 13 is 13 inches (330 mm) and the resulting specific loading is 350 pounds per lineal inch (613 M per lineal cm).
1 1 ~ 3 32~
.
The pressure from pressure roll 15 places the film in intimate contact with and conforms it to the raised knobs of the male patterned embossing surface 16 of embossing roll 13. The circulating water in embossing roll 13 maintains the temperature at the outer circumferential surface of the embossed surface 16 between 100 and 175~F (38-79C). I~ere the film is in intimate contact with embossing surface 16, the film will stay at essentially the temperature of the outer embossing surface 16 substantially throughout the distance that it rotates in contact with the embossing surface 16.
The temperature of film 10 momentarily rises to a higher temperature durîng contac~ with the perforating roll 17, As the film is rotated near the perforating roll, it will be heated by radiant heat from perforating roller 17 and the temperature of the film will rise above the surface temperature of the embossing roll during exposure to infrared radiation rom perforating roll 17.
After the film has been conformed to embossing surface 16 from the pressure applied by pressure roll 15, the film then rotates with embossing roll 13 through the nip of contact with perforating roll 17. Perforating roll 17 is heated by internal heater 34s which is a quartz lamp, which heats the contact surface of the perforating roll 17 to a temperature between 300-500F (149-260C) and preferably to a temperature of 475F (246C). Perforatîng roll 17 is pressed against film 10 on embossing roll 13 through the action of air cylinders 41 pivoting frame 17 and applying pressure to the perforating roll through rolls 35 and 36. Total force applied to press perforating roll 17 against embossing roll 13 is about 900 pounds (4000 ?a) and the contact length between the two rolls is 10 inches (254 mm), yielding a specific loading applied by the perforating roll of 90 pounds per lineal inch (158 `~I per lineal cm). Pressure exerted by the perforating roll on the film on embossing 113332~
surface lG e,~ ru(les the ilm material out of the con~act area o i-he peroratirlg roll 17 and ~hc flat surfaces 26a of the ~rurlca~e(l cones 26 on embossing surEace 16. The material ex~lude~3 from the hole area forms a grommet-like reinforcing ri~ aroun~l ~he perforatibn~
In areas close to, bu~ not in contact with the perforating roll, the film 10 is heated due to radiation from the surface of the perforating roll 17. Because some thermoplastic films have memory, the heat may cause the embossed material to begin to reform into a flat shape and lose its embossing.
Because of this memory, it is advantageous to subject the film to a second pressurizing force which causes the film tb reconform to the embossing surfacP 16.
After leaving the nip of the embossing roll 13 and the ; 15 perforating roll 17, a film 10 rotates with the embossing roll to a nip with a second pressure roll 18 and embossing rol] 13.
At the nip between the second pressure roll 18 and embossing roll 13, pressure is exerted on roll 18 by pressure cylinders ~' 47 and pivoting frame 45 to cause the film 10 to be embossed into intimate'contact with the male patterned embossing, ,~ surface 16. Silicone rubber surface 44 of pressure roll 18 forces the film to reac~uire the shape of the truncated cones ~6 on embossing surface 16. Pressure cylinders 47 exert a total force of around 3200 pounds (14230 ~) on pressure roll 18 over the contact length between roll 13 and pressure roll 18 of about 10 inches (254 mm). This results in a specific loading ~pplied by the second pressure roller 18 to film 10 of appro~i~ately 320 pounds per lineal inch ~560 N per lineal cm). The second embossing step causes film 10 to conform to the embossing surface 16 of embossing roll 13 and retake the orm of truncated cones 26.
After leaving the nip of second pressure roll 18 and embossing roll 13, film 10 passes over idler roller 19 and . _ , . . .. . . .. ..... . .. .. _ .. __ ~_ __ ~333 is wound into ~ roll on the rcwind stand (not shown). Once leaving the surface o embossing roll 13, ~he film re~urn.s to ambient tempcrature.
The resulting product from this method is a film embossed with a closely packed array of truncated cones wherein the tip of each truncated cones is perforated. T.he resulting product has cones having a pitch of approximately 0.040 inches (1.02 mm); the included angle of the sides of each cone is approximatelY 90; each cone havin~ a ~erforation in i~9 - 10 apex with a diameter of approximately 0.010 to 0.012 inches (0.25 - 0.30 mm); the aperture in each.cone being. . --slightly eliptical; and the resulting truncated cones on the embossed film havîng a cone height slightly less than cone 26 on the embossing surface 16 of embossing roll 13.
As ~an be seen by one skilled in the art, the geometry of the bosses in the embossed film can be varied by varying the geometry on perforating surface 16 of embossing roll 13.
The embossed and perforated film resulting from the application of the above disclosed method results in therrnoplastic film having a plurality of tapered bosses having perforations in the tips of each boss. The film -.
can be used in combination with absorbent means to create an absorbent device wherein the film is located adjacent to the absorbent means with the tapered perforated bosses facing into the absorbent means. The bosses present a structure having decreasing cross section to liquid which transports the liquid into the abosrbent means, through the - perforations, by capillary action. The shape of the pore prevents movement of liquid through the perforated bosses from 3Q the absorbent means to outside the thermoplastic filrn. The perforated bosses freely allow the passage of vapor thoughout the perforated film.
xample - A perforated, embossed film is made by the method of this invention on apparatus si.milar to that disclosed in Figure 1.
1~333~
, VisQucen polyet,hylene film, 12 inches (305 n~) wide and 0.001 inclles (0.025 mm~ thick, is unwound from unwind roll 11 ,-over an idler roll 12 and onto an embossing roll 13. The embossing roll will pull the film from the unwind roll at a film tension of approximately 0.4 pounds (1.78 N) over the full film width. The film is heated by heating means 14, air heaters, which are located approximately ~.7 inches (17.8 n~l) above the film to heat the film by directing a jet of hot air against the film in a direc~ion approximately perpendicular to the film direction. The air heaters direct 115 SCFH per inch width of-film (1.28 meter3 hour/lineal cm of slot length at a nozzle temperature of 359 F (182 C).
The thermoplastic film is pulled through the apparatus by the rotation of the embossing roll 13,which has a surface speed of 31 feet per minute (15.75 centimeter per second). , The embossing surface 16 of the embossing roll is heated by contact with the'perforating roll 17 and the warm'film and has a surface temperature in the center of 130 F (54.4 C).
The film is er.~bossed over the male patterned embossing surface 16 of embossing roll 13 through the pressure applied to the film by first pressure roll 15. Pressure is applied by cylinder 32 to the first pressure roll 15 to yield a specific loading on the first pressure roll 15 of 352 pounds per lineal inch (616 N/cm) to force the film over the embossing surface 16. The central portion of the first pressure roll is heated to 144 F (62.2 C) by residual heat on the embossing roll as a result from contact with a perforating roll and as a result of contact with heated air being emitted by heating means 14 which is located adjacent the 30 pressure roll.
As the film rotates around embossing surface 16 of the embossing roll 13, it is perforated by contact with,perfol-ating roll 17. The temperature of the outer circumferential surface of the perforating roll is 476 F-(247 C)''which, on contacting -35 the film overlaid on the embossing surface, melts the film . _ _ _ . . , . . . _ ..... ... ~ . . . , . _ _ _ ~ 18 -an~ extrudes it frolll the surface ~o perforate the film.
Thc perfora~ing roll is sprayed wi~h small amounts of silicone oil to prevent the thermoplastic ilm rom sticking to the surface of the perforating roll. Prcssure cylinder 41 exerts prcssure on frame 39 through the solid rolls 35 and 36 to apply pressure to the perforating roll 17 yielding a specific-loading of the perforating roll against the film overlaid on the embossing roll of 91.3 pounds per lineal inch (160 N/cm).
. .
The polyethylene film rotates around with and in intimat~
contact with male patterned embossing surface 16 on embossing roll 13 where it is embossed for a second time as a result of pressure applied by a second pressure roll 18 to conform the film to the male patterned embossing surface 16. Pressure cylinder 47 exerts pressure on the second embossing roll through members 45 to yield a specific loading on the second pressure roll 18 of 326 pounds per lineal inch (570 N/cm).
The second embossing steps conforms the film to the surface of the male patterned embossing surface to yield an embossed and perforated film.
The final resulting product of a film resulting from the _ application of this method through the use of the above disclosed apparatus yields an e~bossed and perforated film as seen in Figures 5 - 7, consisting of a close packed triangular array of truncated cones 48 with perforated truncated top surfaces 49. The triangular array of close packed cones have a base diameter C equal to 0.04 inches (1.02 mm) having an included top angle E of 90 and having perforation on the apex of each cone which is slightly -30 eliptical, with a major axis of approximately 0.012 inches (0.305 mm) in the direction of web movement and ~ minor axis o approximately 0.011 inches (0.279 mm) in a perpendicular direction. The cone height is slightly less than the cone height of the embossing sur~ace 16 ~0.015 inches (0.038 m~)3.
The melting and cxtruding of thermoplastic film at the top of 26a o each truncated cone yields a grotmnet-like structure 50 around cach pcroration.
1~33321 The mctllocl and apparat~us described above as can be seen by one skillcd in ~:he art, are merely e~emplary and:may be varied within the scopc of the invention.
What is claimed is:
. ~ . ,
Claims (37)
1. A method to produce an embossed thermoplastic film and to perforate the tips of the bosses thereof, comprising the following steps:
(a) supplying a heated, deformable-thermoplastic film to a male patterned embossing surface having a multiplicity of raised knobs with apices which define a raised surface;
(b) conforming the thermoplastic film into intimate contact with the raised knobs of the male patterned embossing surface to produce an embossed film having a multiplicity of raised bosses;
(c) perforating the bosses of the film by pressing the tips of said raised bosses between said apices of said knobs and a heated perforating surface to form apertures in the apices of said raised bosses, while maintaining registration and contact between said film and said raised knobs;
(d) cooling said embossed film to a less deformable state while maintaining registration and contact between said embossed film and said raised knobs;
and (e) removing said embossed film from said male patterned embossing surface.
(a) supplying a heated, deformable-thermoplastic film to a male patterned embossing surface having a multiplicity of raised knobs with apices which define a raised surface;
(b) conforming the thermoplastic film into intimate contact with the raised knobs of the male patterned embossing surface to produce an embossed film having a multiplicity of raised bosses;
(c) perforating the bosses of the film by pressing the tips of said raised bosses between said apices of said knobs and a heated perforating surface to form apertures in the apices of said raised bosses, while maintaining registration and contact between said film and said raised knobs;
(d) cooling said embossed film to a less deformable state while maintaining registration and contact between said embossed film and said raised knobs;
and (e) removing said embossed film from said male patterned embossing surface.
2. The method as claimed in Claim 1 wherein said conforming comprises applying a first pressure to said film through a first pressure roll by interposing the film between the surface of a first pressure roll and the embossing roll causing it to conform to male patterned embossing surface.
3. The method as claimed in Claim 1 wherein after the step of perforating the film there is the step of a second conforming of the raised bosses in the film to the raised knobs of the male patterned embossing surfaces.
4. The method as claimed in Claim 3 wherein the step of a second conforming of the film comprises applying pressure to the film on the embossing surface by applying pressure to a second pressure roll and interposing the film between the second pressure roll and the embossing roll.
5. The method as claimed in Claim 1 wherein the heated perforating surface is a resilient hollow metal roll.
6. The method as claimed in Claim 5 wherein there is the step of heating the resilient, hollow metal roll through radiant heat provided by radiant heat means inside the hollow resilient metal roll.
7. The method as claimed in Claim 5 wherein there is the step of rotating the perforating roll freely against the male patterned embossing surface.
8. The method as claimed in Claim 1 wherein there is the step of heating the thermoplastic film before supplying the film to the embossing surface.
9. The method as claimed in Claim 4 wherein there is the step of maintaining the thermoplastic film in at least registration and contact with the peripheral surface of the embossing surface during the period from the first conforming of the film into bosses in intimate contact with the raised knobs of the male patterned embossing surface, through perforating the boss and the second conforming of the film into intimate contact with the raised knobs of the male patterned embossing surface.
10. Apparatus to produce an embossed thermoplastic film and to perforate the tips of the bosses thereof, comprising:
(a) means to supply a heated continuous thermoplastic film;
(b) a male patterned embossing roll having a multiplicity of raised knobs defining a peripheral surface on said embossing roll.
(c) means to conform a thermoplastic film to the raised knobs of the male patterned embossing roll to produce an embossed film having a multiplicity of raised bosses;
(d) a heated perforating surface means contacting the film conformed to said peripheral surface of said knobs to perforate the film on said peripheral surface; and (e) means, while maintaining registration and contact between said embossed film and said raised knobs, to cool said embossed film to a less deformable state.
(a) means to supply a heated continuous thermoplastic film;
(b) a male patterned embossing roll having a multiplicity of raised knobs defining a peripheral surface on said embossing roll.
(c) means to conform a thermoplastic film to the raised knobs of the male patterned embossing roll to produce an embossed film having a multiplicity of raised bosses;
(d) a heated perforating surface means contacting the film conformed to said peripheral surface of said knobs to perforate the film on said peripheral surface; and (e) means, while maintaining registration and contact between said embossed film and said raised knobs, to cool said embossed film to a less deformable state.
11. The apparatus claimed in Claim 10 wherein there is a means to heat the continuous thermoplastic film.
12. The apparatus as claimed in Claim 10 wherein the means to conform a thermoplastic film to the raised knobs of the male patterned embossing roll comprises a first pressure roll.
13. The apparatus as claimed in Claim 10 said heated perforating surface means comprises a hollow resilient metal roll.
14. The apparatus as claimed in Claim 13 wherein said perforating roll is heated by a radiant heating means located inside said hollow resilient metal roll.
15. The apparatus as claimed in Claim 14 wherein there are a plurality of roll means adjacent the perforating roll and capturing said perforating roll between said embossing roll and said roll means, said perforating roll rotating freely.
16. The apparatus as claimed in Claim 11 wherein said means to heat a thermoplastic film comprises a means to direct a heated jet of air onto the thermoplastic film.
17. The apparatus as claimed in Claim 10 and 16 wherein said raised knobs of said embossing roll comprise truncated cones in close-pack array.
18. The apparatus as claimed in Claim 11 wherein there is a second means to conform the perforated film to the raised knobs of the male patterned embossing roll.
19. The apparatus as claimed in Claim 18 wherein said second means to conform the perforated film to the raised knobs of the male patterned embossing roll comprises a second pressure roll.
20. The apparatus as claimed in Claim 19 wherein said first and second pressure rolls are rotably mounted on a first and second frame means, respectively, movably mounted on the main frame and said first and second frame means are mounted on a first and second means to vary pressure applied to said film through said first and second rolls.
21. The apparatus as claimed in Claim 15 wherein said plurality of roll means arcerotably mounted a third frame means pivotally mounted to the main frame said third frame means mounted to a third means to vary pressure applied to said roll means.
22. The apparatus as claimed in Claim 14 wherein there is a means to maintain said perforating roll in lateral alignment with said embossing surface of said embossing roll.
23. The method as claimed in Claim 1 wherein the film supplied is polyethylene.
24. The method as claimed in Claim 8 wherein the thermoplastic film is initially heated to a temperature of between 200° -300° F.
25. The method as claimed in Claim 6 wherein the resilient, hollow metal roll is heated by radiant heat means inside the hollow resilient metal roll to a temperature of between 300° - 500° F,
26. The method as claimed in Claim l wherein there is the added step of cooling the embossing surface by a cooling means to a surface temperature between 100° -175° F.
27. The apparatus as claimed in Claim 10 wherein there is a cooling means to cool the surface of the male patterned embossing roll to a temperature of between 100° - 175° F,
28. The method as claimed in Claim 1 wherein the step of perforating the film is performed by applying a heated perforating surface to a thermoplastic film overlaid on a male patterned embossing surface at a pressure of 90 pounds per lineal inch.
29. The apparatus as claimed in Claim 15 wherein said perforating roll is applied against said thermoplastic film on said male patterned embossing surface at a pressure of 90 pounds per lineal inch applied as a result of the pressure applied by said plurality of roll means to said perforating roll.
30. The apparatus as claimed in Claim 16 wherein said means to direct a heated jet of air onto the thermoplastic film heats the thermoplastic film to a temperature of between 200° - 300° F.
31. The apparatus as claimed in Claim 12 wherein said first pressure roll is rotatably mounted on an axle means which is slidably mounted and has a means to vary pressure applied on the thermoplastic film interposed between said male patterned embossing surface and said first pressure roll.
32. The apparatus as claimed in Claim 19 wherein said second pressure roll is rotatably mounted on an axle means which is pivotally mounted on a frame means having a means to vary pressure applied to said thermo-plastic film interposed between said second pressure roll and said male patterned embossing surface.
33. The apparatus as claimed in Claim 15 wherein said plurality of roll means adjacent said perforating roll are rotatably mounted on axle means mounted on a pivotally mounted frame means having a means to vary pressure applied by said plurality of roll means to said perforating roll.
34. The method as claimed in Claim 2 wherein said step of applying a first pressure to said film applies a pressure of 350 pounds per lineal inch to the thermoplastic film overlaid on male patterned embossing surface.
35. The apparatus as claimed in Claim 20 wherein said first means to vary pressure to said first pressure roll applies a pressure of 350 pounds per lineal inch to said thermoplastic film overlaid on said male patterned embossing surface.
36. The method as claimed in Claim 4 wherein the step of a second conforming of the film comprises applying 320 pounds per lineal inch of pressure by the second pressure roll against the embossed thermoplastic film on the male patterned embossing surface.
37, The apparatus as claimed in Claim 20 wherein said second means to vary pressure on said thermoplastic film by said second pressure roll applies 320 pounds per lineal inch to said thermoplastic film overlying said male patterned embossing surface.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US05/967,194 US4272473A (en) | 1978-12-07 | 1978-12-07 | Method for embossing and perforating a running ribbon of thermoplastic film on a metallic pattern roll |
| US967,194 | 1978-12-07 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1133321A true CA1133321A (en) | 1982-10-12 |
Family
ID=25512444
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA341,246A Expired CA1133321A (en) | 1978-12-07 | 1979-12-05 | Method and apparatus for embossing and perforating a running ribbon of thermoplastic film on a metallic pattern roll |
Country Status (4)
| Country | Link |
|---|---|
| US (1) | US4272473A (en) |
| JP (1) | JPS5825577B2 (en) |
| CA (1) | CA1133321A (en) |
| DE (1) | DE2948376A1 (en) |
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| WO2019031159A1 (en) * | 2017-08-09 | 2019-02-14 | セーレン株式会社 | Embossing device and embossing method |
| EP3744296A4 (en) * | 2018-01-26 | 2021-10-27 | Zuiko Corporation | Sheet, device for manufacturing sheet, and method for manufacturing sheet |
Family Cites Families (12)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE597115C (en) * | 1930-11-05 | 1934-05-17 | Hermsdorf Schomburg Isolatoren | Design of the roughening of the putty surfaces known as "fish skin" in ceramic bodies, in particular insulators and roller presses for this purpose |
| US2689378A (en) * | 1951-03-10 | 1954-09-21 | Elizabeth Muth | Process for embossing plastic sheet materials |
| US3214502A (en) * | 1960-08-08 | 1965-10-26 | Kendall & Co | Method and apparatus for making adhesive tapes |
| US3243488A (en) * | 1962-07-06 | 1966-03-29 | Kendall & Co | Method of perforating thermoplastic sheets |
| US3323983A (en) * | 1964-09-08 | 1967-06-06 | Kimberly Clark Co | Apparatus for embossing multi-ply paper sheets |
| US3584572A (en) * | 1968-02-19 | 1971-06-15 | Anthony Apicella | Method, apparatus and die adapted to simultaneously heat stamp, emboss and cut |
| US3566726A (en) * | 1968-06-13 | 1971-03-02 | Pantasote Co Of New York Inc T | Method of making perforated film |
| US3560601A (en) * | 1968-11-25 | 1971-02-02 | Ford Motor Co | Process for manufacturing porous thermoplastic sheet material |
| US3718725A (en) * | 1970-11-17 | 1973-02-27 | Int Knitlock Corp | Method for making hook fabric material for fasteners |
| US3917785A (en) * | 1971-01-27 | 1975-11-04 | Johnson & Johnson | Method for producing nonwoven fabric |
| US3753352A (en) * | 1971-05-21 | 1973-08-21 | Phillips Petroleum Co | Perforate conduit |
| US4151240A (en) * | 1976-10-19 | 1979-04-24 | The Procter & Gamble Company | Method for debossing and perforating a running ribbon of thermoplastic film |
-
1978
- 1978-12-07 US US05/967,194 patent/US4272473A/en not_active Expired - Lifetime
-
1979
- 1979-12-01 DE DE19792948376 patent/DE2948376A1/en not_active Withdrawn
- 1979-12-05 CA CA341,246A patent/CA1133321A/en not_active Expired
- 1979-12-06 JP JP54157496A patent/JPS5825577B2/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| JPS5825577B2 (en) | 1983-05-28 |
| DE2948376A1 (en) | 1980-06-26 |
| US4272473A (en) | 1981-06-09 |
| JPS55111224A (en) | 1980-08-27 |
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| MKEX | Expiry |