Abstract: Processes for making micro-textured webs. The process comprises providing a precursor web; providing a pair of mated forming structures, including a first forming structure and a second forming structure, wherein at least the first forming structure comprises voids, and wherein at least the second forming structure comprises protrusions; and moving the web through a deformation zone of the mated forming structures, wherein the voids of the first forming structure engage with the protrusions of the second forming structure at an engagement position. Discrete three-dimensional elements are formed in the web as the protrusions on the second forming structure engage with the voids on the first mating structure. At least one protrusion has center-to-center spacings of less than about 800 microns with at least three of its adjacent protrusions.

Abstract: Apparatus for making micro-textured webs. The apparatus comprises a pair of mated forming structures having a first forming structure, a second forming structure, and a deformation zone; wherein at least the first forming structure comprises voids, and wherein at least the second forming structure comprises protrusions wherein at least one protrusion has center-to-center spacings of less than about 800 microns with at least three of its adjacent protrusions. The voids of the first forming structure are engagable with the protrusions of the second forming structure at an engagement position to form a micro-textured web. In another embodiment, the apparatus comprises a pair of counter-rotating rollers wherein the first roller comprises grooves having a length, wherein the length of the grooves are oriented at an angle different from the machine direction.

Abstract: A formed web comprising discrete three-dimensional elements formed therein, wherein at least some of the discrete three-dimensional elements comprise chads with corresponding apertures, wherein the aperture has a perimeter, wherein the chad has a length, wherein the chads are attached along a portion of the aperture perimeter which forms a connection segment, wherein the connection segment is less than about 50% of the entire aperture perimeter, and wherein the web comprises a film.

Abstract: A system for controlling the strength of seals imparted to workpiece layers by a sealing roll and an anvil roll, the sealing roll and the anvil roll arranged on opposing sides of a conveyed web of workpiece layers, heating elements provided on at least one of the rolls, temperature sensors provided on the at least one of the rolls, and a controller in communication with the sensors and in operable communication with the heating elements. The sealing roll includes a textured sealing surface, the textured sealing surface being divided into a plurality of regions, the texture of a first of the regions being different from a texture of a second of the regions. By controlling the temperature of the respective regions, detrimental effects of anvil wear on the strength of the seal imparted to the workpiece layers may be offset, increasing the service life of rolls.

Abstract: A system for controlling the strength of seals imparted to workpiece layers by a sealing roll and an anvil roll, the sealing roll and the anvil roll arranged on opposing sides of a conveyed web of workpiece layers, heating elements provided on at least one of the rolls, temperature sensors provided on the at least one of the rolls, and a controller in communication with the sensors and in operable communication with the heating elements. The sealing roll includes a textured sealing surface, the textured sealing surface being divided into a plurality of regions, the texture of a first of the regions being different from a texture of a second of the regions. By controlling the temperature of the respective regions, detrimental effects of anvil wear on the strength of the seal imparted to the workpiece layers may be offset, increasing the service life of rolls.