Abstract: A method of winding a polymer film web around a cylindrical core, where the core is heated by blowing hot-air against the core prior to winding the polymer film web, and the polymer film web is wound around the heated core while blowing hot-air against the polymer film web. In another embodiment of the winding method, the polymer film is wound while knurled along both edge parts in the width direction of the film to form knurls so as to gradually decrease in the thickness thereof from one end of the film that contacts with the core toward the other end of the film. Furthermore, a heat treating method for annealing a film roll and a heat treating apparatus therefor are disclosed, which method comprises the steps of surrounding the film roll with heat insulating panels and blowing hot-air against the film roll in the direction along the core axis while rotating the core intermittently or continuously at a rotary speed of from 0.04 to 4 revolutions per hour.

Abstract: The present invention provides a method for recovering flatness of a web material which comprises heating a side edge portion of the web material at a temperature in a range from a glass transition temperature minus 40.degree. C. to a melting point of the web material for a period of from 1 to 600 seconds, and an apparatus for recovering flatness of a web material which comprises a plurality of conveying rollers for conveying the web material and a side edge portion heating means which surrounds and heats the side edge portion of the web material traveling through conveying rollers. According to the method and apparatus, the side edge portion(s) elongated by the previous heat treatment is recovered to a state similar to the central portion by reheating to correct the side edge portion(s), and thereby, flatness of the web material can be improved.

Abstract: A process for the extrusion of plastic plates with very finely structured surface using an extrusion system which is equipped with an extruder and a three roll polishing stack containing a roller with the structuring surface. The system is designed for coextrusion and the plastic plates are produced via two extruders as a coextrudate CX from a highly viscous basic molding compound BF and a low viscosity molding compound NF which is extruded on BF. The surface of said plates is structured via the three roll polishing stack. Fresnel lenses produced by the process may be used in solar collectors.

Abstract: A method for the production of a completely impregnated composite material having the surface thereof coated with a thermosetting resin and essentially consisting of a thermoplastic resin matrix including minute voids filled with a thermosetting resin and reinforcing fibers, which method comprises setting in place a roller and a collecting section disposed in the direction of the rotation of the roller, rotating the roller, feeding thermoplastic resin fibers and reinforcing fibers to the roller, causing the roller to throw a uniform mixture of the two types of fibers onto the collecting section, thereby forming a composite mat of the uniform mixture on the collecting section, then thermally compressing the composite mat and further solidifying the compressed composite mat by cooling and forming a composite material of the shape of a plate, further heating the composite material, thereby melting and expanding the thermoplastic resin forming the matrix, then cooling the expanded composite material, thereby form

Abstract: A process for producing an article by transferring to at least one surface of the article, a surface structure of a polymeric film, the surface structure comprising individual, randomly distributed elevations, so that the resultant article comprises the surface structure or a mirror image of the surface structure, the transferring comprising: a) applying the film to the article as a cover layer wherein a surface of the film comprising the structure faces outward from the article; or b) transferring the surface structure of the film to the article by applying a surface of the film having the structure to the article, so as to form a mirror-image of the structure on the molded body, and optionally removing the film; the process produces an article having at least one surface which exhibits antireflection properties.

Abstract: In a for the production of biaxially stretched films, a take-off roll 4 is arranged downstream of a draw-off roll 3 . A plastic melt is formed into an initial film by means of a slot die 1, cooled on the draw-off roll 3 and passed over the take-off roll 4 which has a predetermined surface roughness. The film is then biaxially stretched and heat-set.

Abstract: Absorbent articles containing absorbent cores of fluff pulp frequently contain wrinkles in the absorbent core that run from side to side of the article, typically normal to the machine direction in the manufacturing process. Side-to-side wrinkles are deleterious in that they provide large flow channels for urine or other body fluids to escape to the edge of the article. Frequently, such wrinkles are present after manufacturing, before the article has been folded or worn. The cause of the wrinkles is believed to be due to natural instabilities during compression of the fluff pad shortly after it is formed. Means for reducing cross-directional wrinkles include the use of grooved, drilled, or patterned compression rolls to densify the fluff pulp while providing opportunities for reduced in-plane displacement during compression or, if in-plane displacement does occur, providing paths for cross-directional displacement as well as machine-direction displacement so that continuous CD wrinkles cannot form.

Abstract: The invention relates to a process for the manufacture of a thermoplastic film which is grainy on its two faces, by passing thermoplastic material between two rolls essentially consisting of metal of high hardness. The invention also relates to a thermoplastic film obtained by this process, to the use of this film for the manufacture of an article for medical use and to this article itself. The thermoplastic material may be, for example, a vinyl chloride polymer or a polyolefin.

Abstract: A foil/composite sheet having a holographic image or diffraction grating image and a method for forming permits the party producing the final document to hot stamp a chip containing the holographic image directly on a substrate forming the major portion of the final document. The foil/composite sheet includes successively a plastic carrier film, a release coating, a hard lacquer coating, a soft lacquer coating, a layer of metal and an embossment receiving coating, the latter three of which become embossed with the holographic image when a heated embossing shim is pressed under pressure against the embossment receiving layer. A heat activatable adhesive is thereafter applied to the embossment receiving coating.

Abstract: An article that includes at least two networks of high strength fibers and a matrix material which impregnates the high strength fibers to form a composite element having a first plane profile and a second plane profile, wherein at least one of the first and second plane profiles has on its surface a textured pattern, and the matrix material is distributed substantially uniformly over the textured plane profile, and a method for making the composite element.

Abstract: A molded surface fastener comprises: a substrate sheet; and a multiplicity of engaging elements standing on one surface of the substrate sheet, each of the engaging elements being composed of a stem rising from the one surface of the substrate sheet, and an engaging head projecting from an upper end of the stem for detachably engaging a companion loop. After a surface fastener is manufactured on a die wheel by continuous injection molding as a primary-intermediate, a heating and pressing roller disposed downstream of the die wheel presses the engaging head, while heating, to bend the engaging head from the stem and, at the same time, to form a pair of protuberances projecting in opposite directions from opposite side edges of the top of the engaging head perpendicularly with respect to a direction lengthwise of the engaging head.

Abstract: The crispness or clarity of embossed tissue is improved by embossing the tissue twice in two successive embossing nips formed between a rigid engraved embossing roll and a resilient backing roll. The hardness of the resilient backing roll in the first embossing nip is less than the hardness of the resilient backing roll in the second embossing nip. This form of double nip embossing is particularly effective for embossing tissue webs having high bulk and resiliency, such as soft uncreped throughdried tissues, which cannot be satisfactorily embossed by conventional methods.

Abstract: A polyvinyl chloride resin sheet which is excellent in resistance to scratch, wear and slip and hence suitable for use as flooring materials, which has a thickness of 50-500 .mu.m; an embossed and matted surface of which roughness is 15-25 .mu.m; and a transmittance of not less than 75%, and which comprises: (a) polyvinyl chloride; (b) a plasticizer in an amount of 5-35 parts by weight per 100 parts by weight of polyvinyl chloride; and (c) short glass fibers having a diameter of 6-12 .mu.m and an average length of 0.2-1.0 mm in an amount of 0.5-30 parts by weight per 100 parts by weight of polyvinyl chloride. The resin sheet can be produced by calendering a composition containing components (a) and (b) along with glass fibers (c) having an average length of 2-12 mm. The calendered sheet is treated with an embossing roll whose peripheral velocity is 1.3-2.3 times that of the final calender roll.

Abstract: Roll-forming apparatus and method for more precisely shaping an extruded-plastic Fresnel lens. A drive/support roller is rotatably mounted to the support frame and the surface of which engages and rotates to support the smooth outer surface of an extruded arcuate, elongated linear Fresnel lens. A tooth-forming roller is rotatably mounted to the support frame and has an external profile with tooth-forming projections formed thereon for engagement with the grooves on the inner surface of the extruded sheet, said tooth-forming roller being positioned on the inner surface of the Fresnel lens opposite the drive/support roller and being loosely mounted on the support frame to track the grooves formed in the Fresnel lens to improve the profile of the lens section by sharpening the root radius and flattening the optical face of each lens section.

Abstract: Process for producing a silicone coated embossing roll for continuously embossing the surface of thermoplastic film. A laser beam is used to cut into the smooth silicone rubber surface of the roll, a pattern or design which replicates a negative of a leather grain, for example. The intensity of the laser beam and its movement is controlled by a signal generated by scanning the original leather grain. This process permits a simple and inexpensive way to produce an embossed structure in the silicone surface of an embossing roll, even when the structure to be repeated is extremely fine. No tedious manual steps are necessary to achieve the most natural possible reproduction in embossing.

Abstract: A web material which exhibits an elastic-like behavior along at least one axis when subjected to an applied and subsequently released elongation. The web material includes a strainable network having at least two visually distinct regions of the same material composition. The first region undergoes a molecular-level deformation and the second region initially undergoes a substantially geometric deformation when the web material is subjected to an applied elongation in a direction substantially parallel to the axis of elongation.

Abstract: A method of making ornamented elongate members, for example for picture frames, uses the steps of extruding a first material and cooling it so that it is substantially solid, extruding a second material along a surface of the first material, which is arranged to undergo a change enabling a firm bond to be formed between the materials, shaping the second material to produce surface ornamentation and cooling the first and second materials. This provides an inexpensive and quick way of producing ornamented members.

Abstract: The invention relates to a method for surface treatment of a weather strip, by which a surface appearance almost identical to an embossing process is obtained in a simplified way without requiring any post-treatment by, for example, an embossing roll, wherein a thin film compressed and deformed by causing thermoplastic resin powder grains 5, which are mixed with thermoplastic base resin 4 and are not completely melted at an extrusion molding temperature, to pass through a flow path 6 of die 1, is extrusion-molded on the surface of glass run 2, and the thin film portion is applied as a sliding plane 3 for door glass.

Abstract: The invention is a wound dressing prepared from alginate fibers which have good structural integrity, whereby layers are firmly joined together, e.g. by stitching or calendering at a plurality of points to produce a composite fabric.

Abstract: A method is provided for producing a thermoplastic resin sheet or film by hot-melting and then cooling a thermoplastic resin to form a sheet or film. The thermoplastic resin sheet or film is moved so that it is pressed against the outer surface of an external heated roll and against a heated, endless metal belt. The endless metal belt is disposed at one end around a moving, internal heating roll and at an opposite end thereof around a moving, internal cooling roll. The internal heating roll heats the endless metal belt to a temperature higher than the softening point of the thermoplastic resin and higher than the temperature of the external heating roll to thermally adhere the thermoplastic resin sheet or film to the external heated roll or the heated, endless metal belt. The thermoplastic resin sheet or film is then moved along on the external heated roll or belt into a high temperature zone.

Abstract: A polyolefin film for use as a sterilization wrap material which includes a film with a thickness of from about 0.005 mm to about 0.2 mm and having a plurality of discontinuous thinned regions. The thinned regions constitute at least about 25 percent of the surface area of the film. The thickness and area of the thinned regions are adapted to permit the passage of steam and water vapor through the film during steam sterilization. The film is made by a method which involves extruding a molten polyolefin film at a first temperature and passing the molten film through a nip. The nip includes an anvil roll and a pattern roll. The anvil roll has a smooth surface and the surface of the pattern roll is maintained at a temperature which is at least about 150.degree. C. lower than the first temperature and is selected to prevent sticking of the film to either roll.

Abstract: This invention relates to a method and apparatus for heat sealing polymer coated paperboard substrates using a uniform energy distributed light energy beam. Such structures of this type, generally, use lasers which allow a very accurate placement of the sealing energy and a controllable energy level.

Abstract: A system for the continuous production of asphalt-based roofing shakes which are tapered and embossed to resemble wood shakes in looks and function; and the shake made thereby. The continuous production system hot-mixes and extrudes the ingredients in a tapered layer on a conveyor belt for embossing and cutting. The system permits wood-shake type variety in size and appearance. The preferred shake includes perlite as a filler and chopped glass fibers as a reinforcer and may be internally colored.

Abstract: Synthetic foam compressed between a pattern roller and a smooth compression roller is driven against a cutting edge closely adjacent and tangent to the pattern surface but spaced from the compression roller to reproduce a three dimensional pattern roller surface on the foam sheet. Three dimensional patterns of arbitrary geometries including sharp edged, flat surfaced geometric solids can be reproduced on a foam surface.

Abstract: A battery separator for use in flooded cell type lead acid batteries comprising a backweb of a porous, acid resistant, embossable material with a plurality of ribs extending from at least one planar surface of the backweb. The ribs are located across the width of the backweb and extend in a direction substantially parallel to the longitudinal dimension of the backweb. Each rib is an embossed corrugated structure comprised of alternating ridges and furrows. The ridges and furrows are in non-parallel alignment to the longitudinal dimension of the separator, and preferably perpendicular thereto. The ribs are formed on a substantially flat battery separator backweb by passing the backweb through the nip formed by a pair of opposed embossing rollers.

Abstract: Nonwoven sheet materials, and pressure sensitive adhesive tapes formed from nonwoven sheet materials are provided. The nonwoven sheet materials comprise a randomly interlaced fibrous web of tensilized nonfracturable staple fibers and binder fibers, wherein the fibrous web is pattern embossed, and is interbonded by a chemical bonding agent, physical entanglement, or a combination thereof, and further wherein the nonwoven sheet material is readily finger-tearable in the cross web direction. Methods of making nonwoven sheet materials and adhesive tapes are also provided.

Abstract: In an apparatus and process for manufacturing a thermoplastic sheet or film having superior optical characteristics such as improved transparency, gloss and surface smoothness, a thermoplastic sheet is extruded, passed between a cast drum and an endless metallic belt while being compressed and subjected to a primary cooling by the belt and drum. The sheet or film is secondarily cooled in a water bath, after which it is dewatered and subjected to a thermal treatment at a temperature in the range of 40.degree. C. below, to 15.degree. C. above the thermal deformation temperature of the resin sheet to produce the improved sheet of the invention. In addition to producing a film or sheet with improved characteristics, the apparatus of the invention allows production of sheets or films at a rate up to about 10 m/min.

Abstract: An apparatus for producing single-sided knurls on a web or substrate without heat. The apparatus includes a conventional knurling wheel and a knurling wheel having its points ground down. A nip is formed by these two wheels and an edge of the web is passed through the nip. The resulting knurl has raised features on only one side of the web. The knurls are thinner than conventional two sided knurls and minimize fluting to the web.

Abstract: A process for the extrusion of plastic plates with very finely structured surface using an extrusion system which is equipped with an extruder and a three roll polishing stack containing a roller with the structuring surface. The system is designed for coextrusion and the plastic plates are produced via two extruders as a coextrudate CX from a highly viscous basic molding compound BF and a low viscosity molding compound NF which is extruded on BF. The surface of said plates is structured via the three roll polishing stack. Fresnel lenses produced by the process may be used in solar collectors.

Abstract: A porous film manufacturing apparatus regularly forms a large number of non-through pores with a fine opening width of sub-.mu.m to several tens .mu.m at a high density in elongated films made of various materials, with almost no deterioration in the essential characteristics of the film materials.

Abstract: Disclosed is a polyester film having a surface layer whose major component is polyester A. Protrusions are formed on the film surface originating from the crystallization of polyester A. The number of protrusions formed on the surface of the film is not less than 5.times.10.sup.3 /mm.sup.2, and the ratio N.sub.R of the number of protrusions to the number of particles contained in a surface layer forming the surface of the film is not less than 5. Since most of or the whole of the protrusions are formed by utilizing the crystallization of polyester A without relying particles, generation of voids can be prevented and fine and uniform protrusions having excellent chipping resistance and scratch resistance can be formed.

Abstract: Method for making laminated glass, whereby a film (2) of polyvinyl butyral is applied between the glass layers (1) whose surface has obtained a roughness at a temperature above 120.degree. C.

Abstract: A method of making sanitary products giving a high wearing comfort includes the step of forming three superposed interconnected layers (14, 15, 16). The outer layers (14, 16) are made of hydrophobic fibers and the intermediate layer (15) is made of hydrophilic fibers. The top sheet of the sanitary product is constructed of the layer (16), and has flow lines throughout the layer. The flow lines are made by an embossing roller (21) having a pattern of raised ridges. The ridges are provided with a wetting agent which, when applied to the front sheet (16), neutralizes the hydrophobicity of the fibers and provides a pattern of hydrophilic flow lines which allow a body liquid to flow through the top sheet (16).

Abstract: Process for producing a flexible, planar carrier coated with a porous adhesive layer, characterized in thata) a flowable adhesive composition is applied to an intermediate carrier having the following properties:it has a microscopically undulating, pleated, fissured or furrowed surfacethe adhesive composition can be easily detached from the surface thereofit is essentially air-impermeable,b) the microscopic air or solvent inclusions resulting, after coating the intermediate carrier, between the adhesive composition and the intermediate carrier are expanded by increasing the temperature until the surface of the adhesive composition bursts, andc) the adhesive composition is subsequently transferred from the intermediate carrier onto the final carrier.

Abstract: An absorbent article, such as a sanitary napkin, a diaper, training pants, an incontinent garment or a bedpad is disclosed for absorption of human exudate. The absorbent article includes an absorbent having a homogeneous composition with an essentially constant density in the x-y plane. The absorbent has at least two distinct portions which are integrally joined together by a junction line and each portion has a thickness different from an adjacent portion. The absorbent is folded on the junction line to obtain a variable density along the z axis. The folded absorbent also has a uniform capillary size in the x-y plane and a variable capillary size in the z direction. The absorbent article further includes a liquid-permeable cover which is positioned adjacent to at least one surface of the absorbent. A method of forming the article is also disclosed.

Abstract: A gas permeability control film having a barrier property against water, bacteria, and viruses, an oxygen gas permeation amount controlled to fall within the range of 10.sup.3 to 10.sup.7 cc/m.sup.2 .multidot.24 hours.multidot.25.degree. C., and a controlled carbon dioxide gas permeation amount. The gas permeability control film has an organic film in which non-through pores having an average opening width falling within the range of 0.5 .mu.m to 150 .mu.m are formed at a density of 500 to 200,000 pores/cm.sup.2.

Abstract: Blanks serving for the production of insulating material and folding packs have to be provided with folding and bending lines. These folding and bending lines in the plastic foam must not break when the blank is folded. This is achieved according to the invention by embossing the folding and bending lines for forming the blank into the "fresh" web of material which for the most part still contains expanding agent. The folding and bending lines formed in this way have surprisingly proved to form durable hinge lines in the plastic foam material and make it possible to fold up the blank for forming a folding carton without it breaking or cracking.

Abstract: Retroreflective prisms are formed with windows thereon by removing a portion of the prism mold on one prism pair leaving the apex of the prism intact. In this manner smaller prisms are formed adjacent larger prisms. Optionally, the optical axis of the prisms may be tilted with respect to one another, preferably in a negative direction. The smaller prisms with windows provide increased brightness and optimize the retroreflection light.

Abstract: Tissue sheets, such as are useful for facial or bath tissue, can be embossed with a fine scale embossing pattern to increase bulk with a minimal loss in strength. The fine scale embossing pattern contains at least about 15 discrete intermeshing embossing elements per square centimeter (100 per square inch) and can enable the tissue manufacturer to produce premium quality tissues having adequate softness, bulk and strength from conventional tissue basesheets without layering or throughdrying equipment. Depending on the starting basesheet material, tissues having a unique balance of properties can be produced, especially for conventional wet-pressed basesheets.

Abstract: An apparatus and a method for producing a floor mat carrying a group of projections with a predetermined shape on a reverse surface to be contacted with a floor, by passing a molding resin material through a nip between a press roll and a mold roll are disclosed.

Abstract: A process is provided for creating a watermark on a polymeric sheet. The sheet is passed between abutting rollers, at least one of said rollers having a recessed and/or raised motif, to form an impression on the sheet corresponding to the motif, and then orienting by stretching the sheet. The impressed and oriented sheet has dark areas corresponding to the raised portions and light areas corresponding to recessed portion of the motif.

Abstract: A continuous rotary method for surface shaping of resilient material such as synthetic foam. Three dimensional surface geometries of well defined and arbitrary shapes are obtained by pressing foam against a die roller to compress some foam portions to a reduced thickness against raised portions of the die and extrude other foam portions into depressions of the die, and cutting away the extruded portions. The compressed portions return to an uncompressed state after passage against the die roller and form raised areas on the foam surface around depressions corresponding to the cut away portions of foam.

Abstract: A method of manufacturing a carpet pad and the apparatus for the same are shown. A frame is provided to which is mounted a conveyor belt. The conveyor belt feeds a first liner sheet along a conveyor path from a forward end to a rearward end. A foam spray assembly is connected to an uncured polymeric foam supply having a spray nozzle mounted adjacent to the forward end of the conveyor path. The spray nozzle dispenses uncured, resilient polymeric foam as a generally uniform layer on a surface of the first liner sheet. A second conveyor belt mounted to the frame is located along the conveyor path and spaced apart from the second conveyor belt a selected distance. The second conveyor belt is parallel to the first conveyor belt and feeds the second liner sheet along the conveyor path so that the second liner sheet is positioned over the layer of foam.

Abstract: Optical recording mediums are prepared by extrusion molding. In the extrusion molding, a thermoplastic resin heated to a given temperature is pressed between a roll stamper and a roll opposite thereto. A gap between the roll stamper and the roll is precisely defined by belt members fixed on each side of the roll where the roll does not come into touch with the thermoplastic resin. The joints of the respective belt members are formed at positions different from each other on the periphery of the roll. Alternatively the gap may be defined by cutting the roll substrate at a part on which the stamper member is fixed, or by interposing endless belts with a given thickness between the roll stamper and the roll. The stamper member provided on the roll stamper is reduced in stress, and has a surface precision of 10 .mu.m or less.

Abstract: A thin soft film material having fibers and/or particulates embedded therein is disclosed. A process for effecting such embedding utilizing hydrosonics is also disclosed.

Abstract: A multi-layer sheet is formed of a urethane film extruded onto a textured substrate. The film and substrate are pressed together causing the film to adopt the texture of the substrate. The substrate can be peeled away from the film leaving a textured, non-tacky surface.

Abstract: A plurality of embossing rollers different in circumferential arrangement pitch of uneven portions formed thereon for embossing are provided, and the embossing rollers are urged against an outer circumferential surface of a plastic web so that a plurality of stripes of embossed surface portions are formed on each of the opposite side edges of the plastic web, the embossed surface portions being different from each other in the arrangement pitch of uneven portions.

Abstract: A process for production of a bag having linear ribs uses an apparatus for forming linear ribs which comprises a plate mold having linear protrusions on both faces thereof and upper and lower female molds placed at both sides of the mold, having penetrated linear cavities at positions corresponding to those of the linear protrusions and capable of opening and closing as desired. Multi-layer resin films are inserted between the plate mold and the female molds. The molds are heated and pressed to each other to prepare multi-layer resin films having linear ribs. A bag is produced using the multi-layer resin film having linear ribs thus prepared. Ribs convex to the outside can be formed on the multi-layer film comprising a layer of a resin having a low melting point at the inside and a layer of a resin having a high melting point at an outer side thereof. The self-supporting bag produced by the process has a higher stiffness.

Abstract: An apparatus and method for producing an optical recording medium or an optical recording medium substrate sheet forms an photo-curable resin layer on at least one of a substrate sheet and a stamper which undergoes elastic deformation. The stamper bears a pattern corresponding with preformatting information and is brought into close contact with the substrate sheet wherein the photo-curable resin layer is interposed between them and cured.

Abstract: A foam mattress pad of adjustable size has an initial predetermined length, width and thickness. The pad is provided with punched areas or holes, preferably in rows or columns forming a guide for cutting or tearing away strips of foam material to decrease the size dimensions of the pad. In a preferred embodiment, the holes are formed in rows or columns in the base of troughs between peaks of a convoluted surface of the mattress pad. The holes in the troughs may be separately punched or cut before or after the foam is convoluted. Preferably, the holes in the troughs are formed as the foam is cut by the band knife blade during one pass between convolute rollers. Longer projecting fingers are applied to some portions of the convolute roller to achieve the holes in the bases of the troughs.