Abstract: In a method for perforating a thin film (14), in particular a plastic film, in which the film (14) is quided over a perforating cylinder (10), with the result that perforations are formed in the film (14), a thin-walled hollow cylinder (10) which comprises at least one layer (52) of fibre-reinforced plastic is used, the fibres in which layer are oriented at least in one direction. A fibre-reinforced cylinder of this type has the required rigidity and is not expensive.

Abstract: A plastic product is fabricated from plastic sheets by heat sealing the plastic sheets to form an enclosure member. In order to strengthen the heat-sealed joints of the plastic sheets, the plastic sheets are thickened at portions where the heat-sealed joints are to be formed. Preferably, the heat-sealed joints are formed in such a manner that the cross-section of the heat-sealed joints is smaller than that of the thickened portions of the plastic sheet, thereby preventing effectively the non-thickened portions of the plastic sheets from being affected adversely by the heat sealing process.

Abstract: An optical structure and method for forming same includes a plurality of first cured portions and a plurality of second cured portions that are formed from a same light-curable material. The first plurality of cured portions is cured to a first amount. The plurality of second cured portions is cured to a second amount. The first amount is sufficiently different than the second amount to result with discontinuities on the surface of the structure. The lenticular layer can include a prism layer having random discontinuities on the peaks. The discontinuities can also be formed on a window side of the prisms.

Abstract: An improved method for embossing expanded graphite sheet material including removing at least a portion of the gas from within the material by exposing the material to a pressure less than atmospheric pressure, and then embossing the material.

Abstract: A production line for the manufacture of strips of vinyl siding comprises an extruder extruding a strip of hot plastic material, such as vinyl. Next, an embosser supplies a decorative pattern to the heated strip. A cooling apparatus receives the heated strip and immerses the strip in a water bath to lower the temperature to a selected temperature range. The material, now reduced in temperature, is then passed to a former having dies creating joining runs in the cooled, embossed siding strip. Finally the strip runs through a final cooling tank which chills the strip to harden the joining runs created by the former. The cooling apparatus consists of a water bath tank with entry and exit guides for the strip, which are mounted above the level of the water in the water bath tank.

Abstract: A process of forming a soft and resilient web exhibiting a substantially continuous pattern of debossments or apertures is disclosed. The process comprises locally heating process to melt predetermined points of the web. The process includes: continuously bringing the web in contact relation with a forming structure exhibiting a substantially continuous pattern of apertures corresponding to the debossments or apertures of the web; locally heating the region of the web at the predetermined points along the surface of the web by an energy source to give the web temperature above its melting temperature; applying a substantially uniform fluid pressure differential to the locally heated web at least in those areas to be debossed or apertured, whereby the web is debossed or apertured at the predetermined points and generally maintains its surface structure at least in those areas in which the web is not debossed or apertured; and removing the debossed or apertured web from the forming structure.

Abstract: A process and apparatus for creating an acoustically absorbent porous panel comprises the steps of dispensing cement and fibers with a dry mixer to create a dry mix and aqueous mixing water, surfactant and air with an aqueous mixer to create a foam. The process and apparatus provides for combining and mixing the foam and dry mix in a combining mixer to form a foamed cementitious material comprising on a wet basis about 53% to about 68% by weight cement, about 17% to about 48% by weight water, about 0.05% to about 5% by weight fibers, and about 0.01% to about 10% by weight surfactant. The foamed cementitious material is then dried or cured in a drying chamber. The dried foamed cementitious material may then textured with an embossing roller. The cementitious material provides good acoustical performance with enhanced durability and moisture resistance.

Abstract: Tool rolls and methods of using the tool rolls to manufacture articles with one or more structured surfaces are disclosed. The tool rolls include an outer surface that, when used in connection with materials of the proper viscosity or formability, can form a structured surface on an article. Because the tools are manufactured in roll-form, they can be advantageously used in continuous manufacturing processes. Alternatively, discrete articles may be processed using the tool rolls. The tool rolls are constructed of a cylindrical base roll and are wrapped with one or more continuous wires in a modified undulating helical pattern. The modified helical pattern results in the distance between the first wire and a reference plane transverse to the longitudinal axis of the base roll sequentially increasing and decreasing at least once when moving in one direction about a circumference of the base roll.

Abstract: A continuous process for imparting a striking glittering or sparkling appearance to a roll of initially non-glittering cube corner sheeting includes exposing the sheeting to a combination of heat and pressure. The process includes passing the sheeting through an extended heated zone and applying pressure to the sheeting after it has been heated. At least one belt is employed to support or carry the sheeting as the sheeting is passed through the heated zone and as the pressure is applied. In one embodiment the sheeting is sandwiched between a pair of endless belts that pass through the extended heated zone, the nip, and a cooling zone downweb of the nip. The process is particularly advantageous for converting rolls of non-glittering cube corner sheeting into rolls of glittering cube corner sheeting.

Abstract: An apparatus for producing a thermoplastic film having low-birefringent, low stress and at least one polished surface for optical media applications as well as low stress film for non-optical applications using a continuous extrusion process. The apparatus consists of a novel calendering roll in a calendering roll stack wherein, at least one roll consists of an inner steel shell, a resilient covering over the inner steel roll and a multi-layer metal sleeve outer covering of at least two layers. The metal sleeve preferably consists of three layers. The inner layer of the multi-layer outer sleeve is preferably nickel, the intermediate layer is preferably copper and the outer layer is preferably chrome with a highly polished surface. The film produced by the process has a retardation value (birefringence times thickness) of less than about 100 nanometers and a surface roughness of less than about 4 microinches.

Abstract: Processes are provided for formation of complex shapes by embossing of a sheet of flexible graphite material. In one approach, a sheet (26) of material is provided with a variable resin concentration across a selected dimension of the sheet, and the position of the variable which will result in thinner areas in the embossed articles. In a second approach, recesses are provided in the embossing rollers (30 and/or 32) to accomodate material flow during embossing. These recesses result in protrusions formed on the articles, which protrusions must then be removed in a machining operation.

Abstract: It is to provide a method of manufacturing a rubber crawler which enhances a degree of freedom in the handling in a vulcanization-shaping of a crawler part and largely improves vulcanization shapability and operability and facilitates an arrangement of an auxiliary device or the like.

Abstract: A method of making an embossed optical sheet material includes: providing an optically anisotropic, uniaxially oriented polymer substrate having a first major surface and a second major surface; heating a patterned tool using radiant energy from a radiant energy source, wherein the pattern comprises a plurality of parallel raised microstructures having a longitudinal direction; pressing the tool against the first major surface of the polymer substrate such that the longitudinal direction of the raised microstructures is substantially parallel to the direction of orientation of the polymer substrate, to soften the first major surface of the polymer substrate and emboss groove-shaped microchannels into the polymer substrate; cooling the embossed polymer substrate; and separating the tool from the polymer substrate; wherein the orientation of the polymer substrate is unchanged throughout the polymer substrate and first major surface.

Abstract: Lids, for example lids for machine-lidding of e.g. beakers, dishes, menu dishes, goblets, small packages etc., containing a substrate material featuring, with respect to a container on which the lids are used, a smooth outward facing surface bearing printing. On the inward facing side of the lid is a sealing layer deposited by extrusion laminate coating. The sealing layer exhibits on the free surface embossing with a depth of roughness of up to 50 &mgr;m. The embossing is transferred to the sealing layer in the form of a roughness pattern on the cooling roll on depositing the laminate coating of the substrate material and extruded sealing layer. The free side of the substrate material is smooth and exhibits no embossing. Printing on the free surface is therefore of higher quality. The extruded sealing layer on the substrate material exhibits embossing on the free side. If the lids are drawn from a stack of lids, for example in a filling machine, the embossing allows them to be separated individually.

Abstract: A method of embossing a sheet material includes: heating at least a portion of the sheet directly or indirectly with radiant energy from a radiant energy source; pressing a tool against the heated portion of the sheet, thereby patterning a surface of the sheet; and separating the sheet and the tool. The radiant energy may travel through a solid material that is relatively transparent to radiation, on its way to being absorbed by a relatively-absorptive material. The relatively-transparent material may be an unheated portion of the sheet, and the relatively-absorptive material may be either the tool or the heated portion of the sheet. Alternatively, the relatively-transparent material may be the tool, and the relatively-absorptive material may be all or part of the sheet. The method may be performed as one or more roll-to-roll operations.

Abstract: A method for producing an embossed PVA film, which includes embossing the film such that the crystallinity index of the emboss top is 0.50-0.90. The invention provides an embossed PVA film superior in resistance to blocking even when in a rolled state, in appearance to show the high quality of products, and in resistance to pinholes.

Abstract: A method for treating a film by providing a structure including a substrate and an array of upstanding projections each of which includes multiple contact points. The structure is pressed against the surface of a polymeric film to cause deformation or rupture of the film. The film may then be pressed to partially reseal the perforations. The structure can be produced by electroplating a mould which includes an array of elements of dimensions corresponding to the projections of the desired structure.

Abstract: A process for preparing a molded, textured, spunlaced, nonwoven web is provided and wipes made therefrom. Also provided is an apparatus for making molded, textured, spunlaced, nonwoven web. Molded, textured, spunlaced, nonwoven webs prepared by the inventive process and apparatus are also provided. Also provided is a molded, textured, spunlaced, nonwoven web.

Abstract: Plastic panels for exterior use on buildings are made by forming a plastic sheet at an elevated temperature, overlaying an exterior surface portion of the formed sheet with a coloring sheet having a preselected color, and thermally bonding the coloring sheet to the formed sheet. The coloring sheet preferably comprises a vinyl resin plastisol and pigment particles. Both the formed sheet and the vinyl resin in the plastisol preferably comprise polyvinyl chloride (PVC). Use of the coloring sheet enables color changes to be accomplished quickly and inexpensively so that manufacturers are able to maintain smaller inventories of the finished product while still satisfying customer needs.

Abstract: A method of manufacturing a micro embossed sheet having a fine emboss pattern, in which a sheet, to which an emboss pattern is overlaid on a sheet0fed embossing plate with a emboss pattern formed thereon, said embossing plate and said sheet are held and pressed by a pair of rolls provided in the top and rear surface sides of said embossing plate to transcribed the emboss pattern onto said sheet, and said sheet is separated from the embossing plate after the transcription.

Abstract: Flat textured or roughened blanks are used in injection molding processes to provide in-mold labels and similar decoration. This provides decorated article that has a desired texture, for example, that of a football or basketball, with custom graphics behind the texture. They may be configured into (preferably but not necessarily tapered) self-supporting sleeves, by joining opposite sides together at a seam or other interface. The sleeves may be used in applications such as inserts for injection molded containers, attachments to existing objects; components of containers manufactured using modified paper cup technology, or glued onto existing paper or plastic cups or containers. Other articles could be produced, such as recording media (e.g, DVD) cases, lunch boxes, food and other consumer packages, or any other type of injection blow molded or impact molded product.

Abstract: A surface for an object has base structure (10) which can be synthetically produced, a first type of projections (12) and a second type of projections (16). The projections of each respective type lie adjacent to one another. This structural surface provides a self-cleaning surface which is cost-effective to produce and has excellent dirt-resistant properties. The adjacent projections of the first type (12) are in close contact with one another. The projections of the first and second types (12, 16) are located on a common side, facing away from the object. The projections of the second type (16) are arranged on the projections of the first type. The invention also relates to a method for producing the surface and to its use.

Abstract: A method and an apparatus for sheet embossing are disclosed that imparts the same strain on each side of the sheet independent of pattern pick-up. By balancing the plastic deformation at each surface the stresses in the formed material are well controlled and, in fact, greatly improve the sheet flatness, material internal stress, surface corrosion and other properties associated with this balanced process. Controlled sheet shape is important to the industrial handling of material on conveyers, spoolers, stackers and other transport devices. Current industrial practice often mandates the use of sheet levelers that reform the surface through a series of rollers that plastically force the material flat, however, not at controlled stress. With the invention, expensive levelers are often not necessary and, as such, the overall process becomes more efficient.

Abstract: Method for producing decorative grass, such as Easter grass, from a sheet or web of material having printed material and/or embossed patterns thereon. The printed material and embossed patterns may be in register or out of register with one another. A method for producing decorative grass having the appearance of a blend of decorative grasses is also disclosed.

Abstract: A multilayer polymer film has an optical stack including a plurality of alternating polymer layers with skin layers having mechanical, optical, or chemical properties differing from those of the layers in the optical stack. In one embodiment, the multilayer polymeric film has one or more holograms that provide attractive and useful optical effects.

Abstract: A rotary embossing method and apparatus for use on hollow profiles having a predetermined dimension and number of sides, the embossing method includes the following steps. First, placing at lease one internal support having a predetermined dimension inside the hollow profile, and second, embossing the hollow profile on at least one of the predetermined number of sides using a rotary embosser. In alternate embodiments, the embossing method further includes the step of heating or cooling the rotary embosser, and the addition of connection means that are fixably attached to the internal support and to an extrusion die, whereby the connection means allow for continuous rotary embossing of the hollow profiles.

Abstract: A three-layer microwavable, plastic wrap having a core layer between a cling layer and a release layer. The cling layer comprises a base resin and an effective amount of a hydrocarbon tackifier to provide sufficient cling to different surfaces such as aluininum, stainless steel, ceramic, plastic and laninated cardboard. The release layer includes an effective amount of an anti-blocking agent to facilitate dispensing of the wrap from a dispensing roll.

Abstract: A method for making a bulky web. A web is fed in a first direction. The web is subjected to incremental stretching in a direction perpendicular to the first direction to provide a bulky web. The bulky web is then stabilized to provide a stabilized bulked web, Optionally, the bulky web may be gathered after it has been subjected to incremental stretching.

Abstract: A process for embossing a flexible graphite sheet, and the flexible graphite article produced thereby is presented.

Abstract: Polyolefin/filler breathable films may be produced by machine or transverse direction orientation using interdigitating grooved rollers. Biaxial orientation to similarly produce breathable films may be accomplished by the same method. By heating the rollers, the breathability of the film is increased without increasing the depth of engagement of the interdigitating rollers.

Abstract: Processes and systems to reduce sticking of graphite materials and particularly resin impregnated graphite materials to forming tools, such as an embossing roller, during a process of manufacturing articles from the graphite materials. In one embodiment, an aerosol spray non-stick material is intermittently sprayed upon the embossing rollers. In a second embodiment, one or more sheets of thin flexible solid non-stick material, such as polyethylene, are sandwiched between the graphite material and the embossing rollers. The system is particularly useful for manufacturing material useful in producing components of fuel cells.

Abstract: Disclosed are adhesive formulations as creping process aids for producing an absorbent creped cellulosic sheet having a high level of surface-perceived softness that comprises continuously forming a web of cellulosic papermaking fibers, adhering said web to a thermal drying means by means of adhesive compositions comprising polymers having at least one primary or secondary amine group in the backbone such as chitosan, plolyvinylamine, polyvinyl alcohol-vinyl amine and polyaminoamide in combination with crosslinking agents such as zirconium compounds having a valence of plus four including ammonium zirconium carbonate, zirconium acetylacetonate, zirconium acetate, zirconium carbonate, zirconium sulfate, zirconium phosphate, potassium zirconium carbonate, zirconium sodium phosphate and sodium zirconium tartrate and creping said treated web from said thermal drying means.

Abstract: Multilayer polymeric shells for spas, bathtubs and shower enclosures having a textured and marbled surface layer. The shells are produced by forming by extrusion a multilayer polymeric sheet having a marbled appearing top layer, passing the sheet between rollers to impart a textured surface to the marbled top layer of the sheet, and thermoforming the sheets into the structural shells for spas, bathtubs and shower enclosures.

Abstract: A method for producing an embossed sheet having a fine emboss pattern with high productivity and safety. The cooled and solidified base sheet 25 is pressed by the rotating pressing roll 24 and the embossing roll 23 while laminating the molten resin 27 on the embossing roll side surface of the base sheet.

Abstract: Disclosed is both a method and apparatus for controlling and measuring an embossed texture on a decorative article. The embossed textured article includes both peaks and valleys that are measured and quantified to determine a profile of the textured article. Typically, the textured article comprises both chemically and mechanically embossed areas. The method uses moving average subtraction and peak/valley determinations to eliminate web flutter that often distorts the quantification of the mechanically embossed texture. The resulting profile may then be used to control a desired embossed profile.

Abstract: The present invention provides a stable material having enhanced extensibility and a method for making the same. A tensioning force is applied to a neckable material to neck the material. The necked material is then subjected to mechanical stabilization to provide a stabilized extensible necked material. The stabilized extensible necked material is easily extended in a direction parallel to the direction necking.

Abstract: The invention concerns a method for producing a microporous film with strong isotropic tendency permeable to gases and impermeable to aqueous liquids, consisting of at least one layer, comprising the following successive steps: preparing a mixture consisting of a polyolefin matrix containing at least a polymer and at least a mineral and/or organic filler; extruding at least a ply by hot-casting the mixture; pre-stretching the ply with a drag roll; cooling and solidifying the pre-stretched ply, using the drag roll; drawing the solidified ply at sufficient temperature for forming the microporous film.

Abstract: The present invention describes an advantageous way of lubricating polyvinylchloride during an extrusion process.

Abstract: A method for shaping a slab of polyurethane foam (80) cuts portions of the foam material from one surface. A moving patterned platform (32) is interposed in a gap formed between a compression roller (56) and a drive roller (18) and defines at least one recess (36). The slab is introduced into the gap and foam material is compressed into the recess. At least a portion of the compressed material within the recess is then cut from the surface of the slab by a blade (76) just as the slab emerges from the gap to produce a profile-cut surface with a shaped portion corresponding to the shape of the recess in the patterned platform.

Abstract: The present invention is directed to a low-linting laminated nonwoven fabric comprised of a reticulated film layer and an associated absorbent layer, which is suitable for medical, hygiene, and industrial applications, wherein said nonwoven fabric performs to absorb liquids, such as human exudates, while significantly reducing the amount of particulates released. The reticulated film of the invention is comprised of a series or network of small, geometrically profiled, depressed areas, wherein the depressed areas of the film are able to collect liquids such as blood, and channel such liquids through openings in the film layer into the associated absorbent layer.

Abstract: Disclosed is an embossing method and material made by the method, including at least a pair of embossing rolls having unmatched embossing patterns engraved independently from each other, and having enlarged sidewall clearances between adjacent, inter-engaged protrusions and recessions of the embossing patterns. The sidewall clearances can range from about 0.002″ (about 0.050 mm) to about 0.050″ (about 1.27 mm). The width of the protrusions can be greater than about 0.002″ or about 0.050 mm. The peripheral surface of at least one of the embossing rolls can comprise a metal, a plastic, a ceramic, or a rubber. Also disclosed is an embossed web material capable of being used as a wrap material for food products, made by the above process.

Abstract: The self-cleaning surfaces of objects have an artificial surface structure of elevations and depressions wherein the distances between said elevations are in the range of from 5 to 200 &mgr;m, and the heights of said elevations are in the range of from 5 to 100 &mgr;m, and at least said elevations consist of hydrophobic polymers or permanently hydrophobized materials, and said elevations cannot be detached by water or by water containing detergents.

Abstract: A patterned element for use in an embossing and adhesive application process. The patterened element comprises a material having an pattern disposed thereon, wherein the material comprises a polymer and has a Shore A hardness of greater than about 70, and has a critical surface energy of less than about 30 dynes/cm.

Abstract: Curled decorative grasses having a texture or appearance simulating the texture or appearance of paper on at least a portion of one surface thereof are disclosed, as are methods for making such curled decorative grasses from materials wherein at least a portion of one surface of the materials is modified to simulate the texture or appearance of paper.

Abstract: Method for producing decorative grass, such as Easter grass, from a sheet or web of material having a decorative pattern thereon. The decorative pattern may be printed material and/or embossed patterns thereon, or a non-linear side edge that provides the decorative grass with a contoured configuration.

Abstract: A laminate is provided that is highly conformable to the contours of a wearer's body when used in a personal care absorbent article or a medical article. The laminate is extendible in its cross direction to a width at least 25% greater than an original, unstretched width upon application of a stretching force and exhibits little or no retractive force in the cross direction once they have been stretched. Elastic elements are placed to provide stretch and recovery in the machine direction of the laminate without affecting the inelasticity of the cross direction. When the garment is worn, the laminate is extendible only in one axis where needed to provide a substantially perfect fit on the wearer while the retractive force provided in a second axis of the laminate helps ensure snug fit.

Abstract: A microchamber structure (100) comprising a base layer (120), a lid layer (130), and at least one microchamber (140) having a cross-sectional shape with a depth (d) of less than 1000 microns and a width (w) of less than 1000 microns. The base layer (120) includes a depression (122) and the lid layer (104) includes a projection (132) positioned within the depression (122) to together define the cross-sectional shape of the microchamber (140).

Abstract: Apparatus and method for control of dimensions of formed building blocks during manufacture. A frame forms an opening, through which runs a conveyor carrying the blocks. An elongated, horizontally-aligned roller is positioned a desired distance above the conveyor surface. While the blocks are still in a “wet” or uncured state, and therefore relatively malleable, they are carried through the opening and pass beneath the horizontal roller, which deforms or “squeezes” the blocks down to the precise desired vertical dimension.

Abstract: A method (110) of manufacturing footprint tiles (10) having the steps of: rolling (112) tile base (12) to a predetermined uniform thickness; imprinting (114) by utilizing a plate or roller with a plurality of convex footprints and exerting pressure upon the rolled tile base (12) forming a plurality of concave footprint impressions (14) into the tile base (12); cutting (116) by utilizing a plate or roller with a plurality of blades complementarity positioned to the plurality of concave footprint impressions (14) and exerting pressure upon the rolled tile base (12) forming individual foot print tiles (10); and drying (120) the individual foot print tiles (10).

Abstract: Provided is a method for manufacturing a thermoplastic resin sheet bearing an embossed pattern, which employs a manufacturing apparatus having a first roll having an elastic material coated surface, a mirror-faced metal, endless belt, which is wound around the first roll and a second roll, and a third roll so provided that the metal, endless belt is wrapped partially around the third roll, which contacts the first roll via the metal, endless belt and which has an embossed pattern formed on one surface. According to this method, the thermoplastic resin sheet, partially melted, is fed between the metal, endless belt, which contacts the first roll, and the third roll. The elastic member is elastically deformed by application of a pressing force between the first and the third roll, while face pressure welding the thermoplastic sheet by using the first and the third rolls to transfer the embossed pattern and to cool the thermoplastic resin sheet. A surface temperature for the third roll of from 0° C.