Abstract: A process for rendering films, film composites, and articles made therefrom less resistant to passage of water vapor by passing a filled precursor film or film composite through the nip of interdigitating grooved rollers. The films or film composites are generally formed using a precursor film of a film forming polyolefin or polyolefin blend, with a relatively high filler loading and optionally an elastomer. A process is disclosed for making diapers or other disposable items where a relatively high water vapor is coupled with a resistance to liquid strikethrough. In one embodiment of the invention, the interdigitating grooved rollers are maintained in a temperature range of from about 91° F. to about 159° F.

Abstract: An automotive trim product is made as follows. A single or multiple layer sheet is extruded so as to include at least one color pigmented and/or metallized layer therein. Optionally, a clear coat may be laminated to the sheet, or may even be coextruded therewith. In certain embodiments, a roughened surface texture may be embossed into a major surface(s) of the sheet prior to lamination. In other embodiments, a design (e.g., logo) may be silk-screened onto the clear coat layer prior to lamination. The sheet, after optional lamination, is then thermoformed into a three-dimensionally shaped preform or article via vacuum forming or the like.

Abstract: An industrial process fabric is embossed in a device, such as a continuously operating two-roll calender having a preselected embossing pattern. The roll(s) of the calender may alternatively themselves be engraved or etched to provide the embossing. Embossing takes place with controlled temperature, pressure, speed and gap (between the rolls) settings. The fabric may be a forming, press, dryer or TAD fabric used in paper and pulp production, pulp forming fabric or an engineered fabric used to produce nonwoven textile products by meltblowing, spunbonding, hydroentangling or air laid needle punching.

Abstract: An apparatus and method for imprinting a hose (2) with a continuous grip enhancing texture is disclosed. The texturing device (C, C′) is comprised of a circular guide tube (8) through which the hose (2) to be textured is driven. The guide tube (8) is rotated, by a drive (4). Texturing means mounted at the exit end of the guide tube (8) are also rotated about the hose (2) as the texture is applied to the hose (2). The texturing of the hose is accomplished by at least one roller (6) mounted on a chuck (5) or by at least one scribing pen (28) mounted on a bracket (24).

Abstract: A bulky sheet material having three-dimensional protrusions comprises a first fiber layer and a second fiber layer provided on at least one side of the first fiber layer. The first fiber layer contains thermally shrunken heat-shrinkable fibers. The second fiber layer comprises heat non-shrinkable fibers. The first fiber layer and the second fiber layer are partly joined together at a large number of joints formed by fusion bonding. The joints are formed by melting and solidification of a heat fusible resin having a higher melting point than the shrinkage starting temperature of the heat shrinkable fiber. The second fiber layer forms a large number of protrusions between the joints by the heat shrinkage of the first fiber layer while leaving the joints as depressions.

Abstract: A mat of polymeric fibers is treated to alter a filtration surface by the application of heat and pressure. The filtration surface is heated to a temperature sufficient to soften the fibers and pressure is applied to compact the softened fibers in order to reduce the average pore size on or at the filtration surface.

Abstract: Apparatus and methods are provided for the embossing of a sheet of flexible graphite material between a pair of embossing rollers. The embossing rollers include a primary embossing roller and a backup roller. The primary embossing roller has an embossing pattern defined thereon. One or both of the rollers include a raised stabilization area adjacent a periphery of the embossing pattern. The raised stabilization area preferably has a roughened outer surface for better gripping the sheet of flexible graphite material. The raised stabilization areas apply a stabilizing force to the sheet adjacent the periphery of the embossing pattern, thereby limiting egress of the material laterally away from the embossing pattern. The roughened surfaces increase the grip of the raised areas upon the sheet, thus aiding in pulling the sheet between the rollers and also aiding in the application of lateral stabilization forces to the sheet.

Abstract: A method of manufacturing a non-woven fabric which is bulky caused by fiber-raised construction on the surface of a non-woven fabric includes adhering a non-woven web with its surface layer portion containing an easy-to-heat-melt component showing a property to be adhesive as heated to a smooth surface heated at the temperature for the easy-to-heat-melt component to show a property to be adhesive with the surface layer portion in contact with the smooth surface, and then raising the fibers of the non-woven web by peeling the non-woven fabric like web off the smooth surface so that a fiber-raised bulky state is generated, whereby a fiber-raised bulky structure is formed on the surface of the non-woven fabric.

Abstract: The photocurable resin composition in the first aspect of the invention comprises, as essential components, (A) a binder resin having photopolymerizable functional groups and (B) inorganic superfine particles in the order of sub-micron which can be dispersed in a colloidal form; the photocurable-resin composition in the second aspect comprises, as essential components, (C) a binder resin containing photopolymerizable functional groups and (D) hydrophobic fine silica particles; and the photocurable resin composition in the third aspect comprises, as essential components, (E) a binder resin containing acrylic resin and urethane acrylate resin and/or polyester acrylate having photopolymerizable functional groups and (F) an organometallic coupling agent.

Abstract: Embossed oriented thermoplastic films and a method of making same are described. The embossed oriented thermoplastic films have substantially the same mechanical properties as unembossed oriented thermoplastic films. The method includes providing an oriented thermoplastic film having first and second major surfaces, softening at least one of the first and second major surfaces to produce a softened surface, embossing the softened surface to produce an embossed oriented thermoplastic film, and cooling the embossed oriented thermoplastic film.

Abstract: Described is a method of indirect printing on a thermoplastic film having texture, wherein said method comprises: a) providing a heated thermoplastic melt; b) providing a tool having a molding portion that comprises a texture having a surface and a plurality of cavities in said surface, and that comprises a material having a surface energy sufficient to release ink; c) applying ink to said texture; d) substantially drying or curing said ink; e) contacting said thermoplastic melt with said molding portion having ink applied to it; f) forming a texture in said thermoplastic melt, wherein said texture comprises a plurality of protrusions and an area between said protrusions, that is the inverse of the texture of said molding surface; g) transferring said ink from said molding portion to said thermoplastic melt; h) quenching said thermoplastic melt to form a thermoplastic film; and i) removing said thermoplastic film from said molding portion.

Abstract: From about 50 to about 90% by weight of fibers, in particular wood fibers, and/or pellets made from cellulose or from wood, are mixed with from about 10 to about 50% by weight of a hot-curing resin, each of the percentages by weight being based on the total weight of the mixture. Instead of a single resin it is also possible to use a mixture made from two or more hot-curing resins. The mixture made from fibers and/or pellets and resin is kneaded and homogenized and then passed on to an extruder which has various heating zones in which the mixture is heated. Care has to be taken here that the maximum temperature, arising at the extruder exit, does not exceed about 120° C., since above this temperature the resin(s) begin(s) to cure.

Abstract: A woody formed article, characterized as being produced by admixing a woody material W and, as a binding agent, a fibrous and/or ribbon shaped thermoplastic resin R which is easy to be intertwined with the woody material W, and molding the resultant mixture. The thermoplastic resin R is preferably admixed in a state of being heated and melted. A method for producing a woody formed material, characterized in that it comprises providing a mat M of a raw material mixture Mx of a woody material W and a fibrous and/or ribbon-shaped thermoplastic resin R and subjecting the mat M to heat pressing, or comprises, in admixing the woody material W with the above fibrous thermoplastic resin R, stretching and thinning the resin R by means of a hot wind and/or a cold wind pressure, and admixing homogeneously it with the woody material W by utilizing a negative pressure zone due to the hot wind and/or the cold wind, to prepare a mat M of a raw material mixture Mx, and then subjecting the mat M to pressing.

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 process and apparatus for embossing thermoplastic products having precise microstructured surfaces including using a continuous press having upper and lower belts with the embossing pattern(s); feeding thermoplastic material through the press where heat and pressure are applied to form the embossed pressure microstructure, and cooling the embossed material, all while maintaining pressure. A continuous embossing tool is provided by welding segments together, the welds including interface material at the weld joint which is of a different material than the segment material to increase the tensile strength.

Abstract: A process of calendering a sheet or a film having at least one textured surface entailing passing a web of polymeric resin through a nip between a rigid roll and a resilient roll is disclosed. The inventive process comprises slowing down the cooling rate of the web by rolling its textured surface about the resilient roll. The rate of cooling is in comparison to a corresponding process where the web is rolled about said rigid roll. Products thus produced are suitable for making thermoformed articles having low gloss.

Abstract: Structured polyolefin coated substrates and processes for making the same are disclosed. A chill roll is used to impart a plurality of peaks which protrude outwardly from the polyolefin coating of the structured substrate. In addition, the chill roll surface is treated to impart a matte finish and thus to transfer a matte finish to the area surrounding the peaks of the polyolefin coating.

Abstract: A web of flexible material, such as paper and nonwoven material is embossed by printing the web in a selected pattern by bringing it into a first nip between an impression roll and a printing roll carrying a colorant in a selected pattern; subsequently embossing the web by bringing it into a second nip between a pattern roll and the impression roll, the pattern roll having a three dimensional pattern of alternating raised and recessed portions, the three dimensional pattern being interrupted by relatively smooth areas, so that the web will be embossed in selected areas while leaving other areas substantially unembossed; the pattern roll and printing roll being synchronized so that embossing occurs mainly in the areas of web that are not printed in the selected pattern. The printing and embossing steps may also be reversed so that the web is embossed before printing.

Abstract: A method and a device for production of a web with good breathing properties, for example having a nonwoven web based on plastic filaments and/or plastic fibers and a plastic film, applied on one side of the nonwoven web and containing at least one mineral filler. For the production of the good breathing properties, the web is stretched in the longitudinal direction of the same, in two successive steps, and an embossing is carried out, at least in certain sectors of the surface, between the two steps which effect the stretching in the longitudinal direction.

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: Methods are taught for manufacturing a press molded article (1) that comprises a profiled substrate layer (10) and a foamed layer (20). A substrate material (12) may be press molded with a foamable material (22) under pressure in order to join or attach the foamable material to the substrate material. In addition, a profile may be imparted to the substrate material during the press molding step, thereby forming the profiled substrate layer. After the press molding step has been completed, the foamable material is foamed and expanded, to thereby form the foamed layer. A skin material (32) optionally may be applied to the foamable layer before the press molding step. Optionally, embossed patterns may be imparted to the skin material during the press molding step, thereby forming an embossed skin layer (30) that is attached to the foamed layer.

Abstract: A machine and method for providing a folded liner for insertion into a pipe, comprises an upper section and a lower section. A flattened heated thermoplastic liner is fed downwardly through the upper section to the lower section, where it is redirected and fed substantially horizontally from the lower section. The flattened liner introduced to the upper section is broadly indented at one side of the liner and is then folded to provide loops disposed side-by-side in a substantially horizontal direction. A stabilizing assembly constrains the loops to maintain a desired orientation of the folded liner. The lower section redirects the liner so that the loops are stacked side-by-side in a substantially vertical direction. The liner is cooled as its leaves the lower section to maintain its cross-sectional configuration.

Abstract: A method for processing a film. The method impressing the whole surface or a selected surface of the film to form protuberant structures on the film by using a transfer and an impresser which has grain projections formed thereon, wherein the protuberant structures have a protuberant shape with an opening hole on the tip or without an opening hole on the tip.

Abstract: An method for producing a material useful for forming a component for an electrochemical fuel cell is provided. More particularly, the component is formed of a sheet of a compressed mass of expanded graphite particles. The component is treated with a water resistant additive sufficient to provide utility as a component in an electrochemical fuel cell. Preferably, the water resistant additive is a fluoropolymer material. More preferably, the water resistant additive is a polytetrafluoroethylene material. The treatment preferably occurs by coating and/or impregnating the water resistant material in the sheet of graphite particles.

Abstract: A method for shaping a slab of compressible or cellular polymer material, such as polyurethane foam, by cutting portions of the material from one surface uses a compression roller, a support surface, a blade and a moving patterned platform interposed between the compression roller and the support surface. The moving patterned platform, preferably an endless belt or a series of interconnected panels, defines at least one recess, and may define a pattern of recesses of complex or simple shapes and at various depths. When the slab of cellular polymer material is compressed between the compression roller and the support surface, a portion of the material fills the recess or recesses in the moving patterned belt. At least a portion of the compressed material within the recesses is then cut from the surface of the slab by the blade just as the slab emerges from between the compression roller and the support surface.

Abstract: Disclosed is a method of manufacturing a mechanically and chemically embossed surface covering having selectively textured surfaces. The method includes forming a web coated with a wear layer. The coated web is heated to a temperature at which the wear layer is cured, the foam layer expands, and the pattern is chemically embossed to form a surface covering having foamed regions and nonfoamed regions. The temperature gradient of the surface covering is adjusted such that there is a temperature gradient difference between the foamed and nonfoamed regions. A surface texture is then mechanically embossed into the wear layer and selectively set onto the wear layer substantially overlying the non-foamed regions.

Abstract: A method and apparatus are disclosed for producing a surface-structured, film semi-finished product made of a thermoplastic which is applied onto a prepared surface with numerous fine cavities provided in the form of pocket borings and is correspondingly shaped. The solidified plastic material is removed from the surface as a structured film, whereby the thermoplastic material which is inserted into the cavities and removed from the same forms a pile comprised of projections and naps. The projections which form the pile are stretch by combing, brushing, using a squeegee, and/or by squeezing by shearing in order to form naps.

Abstract: A method of producing optical storage media includes the steps of providing a supply of thixotropic material in liquid form; coating a sheet of plastic film with the thixotropic material in a layer of predetermined thickness; applying heat to the coating of thixotropic material and drying the same to a semi-solid state; providing an embossing face which contains a negative of a storage medium of information to be transferred; embossing the dried semi-solid coating of thixotropic material with the embossing face and thereby transferring the information to the semi-solid coating; and applying ultra violet energy to the embossed face of the semi-solid coating to cure the coating to a solid state.

Abstract: The present invention provides a stable material having enhanced extensibility and a method for making the same. A neckable material is fed in a first direction. The neckable material is subjected to incremental stretching in a direction perpendicular to the first direction. A tensioning force is applied to the neckable material to neck the material in a direction perpendicular to the first direction. The necked material is then subjected to mechanical stabilization to provide a stabilized extensible necked material. The stabilized extensible necked material is then passed between the peripheral surface of a cylinder which is driven in rotating motion and a device for pressing the stabilized extensible necked material against the peripheral surface of the cylinder. A retarding member retards the passage of the stabilized extensible necked material and directs the material away from the peripheral surface of the cylinder.

Abstract: A method for making embossed blanks for sample packages and other free-standing three dimensional display items from a sheet-type work material. The sheet-type work material has a top layer of sheet material, an intermediate layer of sheet material, and a carrier layer of sheet material. In operation, a printer prints an image onto the work material, which is then advanced to a processing mechanism where a creaser places indented fold lines into the work material, a knife cuts a blank from the work material, and an embosser embosses a design into the work material.

Abstract: Methods and apparatus for forming microstructures in the surface of polymeric web materials for use as optical memory substrates. The microstructures may be formed by laminating a hot stamper to a web of material with a selective time/temperature profile. The stamper may be heated to melt flow the surface of the web and stabilize before separation. The stamper may be carried by a support that is independent of the press. The web of polymeric material may be provided with a flow enhancer to improve image formation.

Abstract: A non-woven fiber pad having a convoluted surface formed by cutting a non-woven fiber batt having a plurality of low melt synthetic fibers. The non-woven batt is compressed generally toward a cutting device by a pair of counter-rotating drums having convoluted surfaces.

Abstract: The invention relates to a two-colored or multi-colored foam foil (50) on the basis of thermoplastic synthetic material, comprising at least one top layer and one sub-layer, whereby the sub-layer constitutes a foam layer (17) and the top layer exists in the form of a two-colored or multi-colored compact foil (4) of a carrier (15) and at least one additional layer (16), whereby the additional layer(s) (16) are surface-flush arranged in a corresponding recess (19) of the carrier (15) and both, carrier (15) as well as the additional layer(s) (16) each form a portion of the surface of the foil and are colored a different color. The invention relates, moreover, to a method as well as a device for the manufacture of the invention-specific two-colored or multi-colored foam foil (50).

Abstract: A process for producing an object made from plastic material with a mesh structure, wherein the mesh structure is deformed in at least one defined area, in such a manner that the original mesh structure of the area is eliminated and an essentially continuous structure and information can be introduced in this area.

Abstract: An method for producing a material useful for forming a component for an electrochemical fuel cell is provided. More particularly, the component is formed of a sheet of a compressed mass of expanded graphite particles. The component is treated with a water resistant additive sufficient to provide utility as a component in an electrochemical fuel cell. Preferably, the water resistant additive is a fluoropolymer material. More preferably, the water resistant additive is a polytetrafluoroethylene material. The treatment preferably occurs by coating and/or impregnating the water resistant material in the sheet of graphite particles.

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: Processes are provided for formation of complex shapes by embossing of a sheet of flexible graphite material. In one approach, a sheet of material is provided with a variable resin concentration across its width, and the position of the variable resin concentration is correlated with the position of embossing features which will result in thinner areas in the embossed articles. In a second approach, recesses are provided in the embossing rollers to accommodate material flow during embossing. These recesses result in protrusions formed on the articles, which protrusions must then be removed in a machining operation.

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

Abstract: A polished-piece holder is provided that does not easily stick or adsorb to a polishing pad of a polishing apparatus and reduces occurrences of production line troubles and therefore the number of failed polished pieces. A single sheet of a thermosetting resin impregnated fiber substrate or a laminated sheet formed by laminating a plurality of sheets of the thermosetting resin impregnated fiber substrate is formed under heat and pressure into a plate. The thermosetting resin impregnated fiber plate is then processed to form a polished-piece holder for holding pieces to be polished. The evaluation portion has a certain length in a direction of the average line. The thermosetting resin impregnated fiber plate has a surface roughness with a maximum wave height Ry of 10 &mgr;m or greater over an almost entire area of the surface layer.

Abstract: The invention relates to a method for shaping the surface of extruded profiles made of thermoplastic materials with a device which is profiled to the shaping surface such that it is complimentary to the demanded shaping dimensions and presses into the continuous profile. The invention provides a method and device with whose simple, economic and high uniformity permit a material-saving production of profiles while completely adhering to the required stability at the same time. To this end, the shaping device presses the desired shaping dimensions into the continuous profile such that the wall strength of the surrounding edges of the impressions is reduced and work-hardened. The profiles are cooled and shaped into a dimensionally stable state in such a way that the height of the impressions at least correspond to the halved wall strengths of the continuous profile.

Abstract: The present invention relates to a method intended for heat insulation of a pipe (1), comprising the following successive stages: depositing, on the outer surface of the pipe moving longitudinally, a thickness (3) of an insulating material made of elastomer having an elastic type behaviour, substantially without irreversible plastic deformation, forming at least one circumferential slot (4) in the thickness of the material, substantially orthogonally to the axis (2) of the pipe, coating the insulating material thickness with a sealed sheath. In a variant, the slot is machined in the thickness of the insulant. The invention further relates to a heat-insulated pipe.

Abstract: Processes and systems are provided 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 materials useful in producing components of fuel cells.

Abstract: A method and an apparatus for the manufacture of pipes of thermoplastics with transverse profile features comprises mold segment halves which are circulated by twos on a molding path. A conveying device of the type of a gantry crane is provided for recirculation of the mold segment halves. On a conveying bridge that bridges the molding path, provision is made for two conveying carriages, which are movable in opposite directions and crosswise of the direction of production and which have mounted on them a downward conveying arm with a holding device for a respective mold segment half. Provided downstream of the downstream end of the molding path are parking positions for additional mold segment halves, those of which that are closest to the molding path being carriages which are movable out of the path of displacement of the conveying arms.

Abstract: An unpainted thermoplastic material is provided. The unpainted thermoplastic material includes a microscopically deformed surface having a gloss less than about 3.0. A method of reducing gloss of a formed thermoplastic material is also provided. The method includes impacting a surface of the formed thermoplastic material with a particulate so as to effect light reflecting properties of the surface. The surface is microscopically deformed such that the light reflecting properties provide a gloss of less than about 3.0. The particulate is selected from the group consisting of baking powder, ice, sand, glass beads, and subliming particles.

Abstract: Films having a microreplicated topography are prepared from contacting a microembossed pattern to a layer of film. When an adhesion interface is established between the layer of film and a supporting substrate, the topography of the film surface controls the performance of the adhesion interface. Articles having microreplicated film surfaces are also disclosed that have an advantage of providing microchannels for fluid egress for an effective period of time. Multiple microembossed patterns produce microreplicated film surfaces having both microchannels for fluid egress and pegs for improved film properties.

Abstract: Curled decorative grass having a variety of configurations and methods for making such decorative grass is provided which, because of its increased bulk, can also be used as a packing material, an animal bedding, cat litter, mulch for soil and a media for plants. The curled decorative grass is produced by curling a substantially flat sheet of material and thereafter cutting the resulting curled sheet of material; or by cutting a pre-curled material.

Abstract: A method for producing filter paper, in particular filter paper for preparing brewed beverages such as coffee or tea employs the steps of producing initially a noncrimped paper of high strength and subsequently rendering this paper capable of filtering through perforation and/or stamping or stamped perforation. The above method is advantageous in that a high production speed of the paper-manufacturing machine results since a crimping device (crimping cylinder, crimping scraper) is no longer required. Accordingly, the bottleneck caused by the crimping device speed is eliminated.

Abstract: A process for embossing hydrophobic polymers with metallic embossing dies or embossing rolls, where the embossing dies or embossing rolls are hydrophobicized prior to the first embossing procedure. An embossing die or embossing roll for embossing hydrophobic polymers is also provided.

Abstract: A method of compressively modifying, such as by calendering, an uncreped throughdried tissue sheet is disclosed. The dried tissue sheet, initially supported by the throughdrying fabric, is removed from the throughdrying fabric and compressively modified. Thereafter, the compressively modified sheet is recombined with a papermaking fabric and carried to a reel section while supported by the fabric. The sheet is always, or substantially always, supported by a fabric or a roll surface to minimize opportunities for sheet breaks or otherwise adversely affecting sheet properties.

Abstract: Decorative grasses having a texture and/or appearance assimilating the texture and/or appearance of paper are disclosed, as are method for making such decorative grasses from materials wherein at least one surface of the materials is modified to assimilate the texture and/or appearance of paper.