Apparatus and method for making a forming structure

• US 20050191496A1
• Filed: 03/28/2003
• Published: 09/01/2005
• Est. Priority Date: 12/20/2002
• Status: Active Grant

• Current Assignee: The Procter & Gamble Company
• Original Assignee: The Procter & Gamble Company
• Inventors: Gray, Brian Francis, Gross, Sarah Beth, O'Neil, Julie Ann, Stone, Keith Joseph, Fiedeldey, Timothy Paul
• Granted Patent: US 7,303,861 B2
• Time in Patent Office: Days
• US Class Current: 428/411.1
• CPC Class Codes: A61F 13/15731 Treating webs, e.g. for giving them a fibrelike appearance, e.g. by embossing
• CPC Class Codes: A61F 13/51121 characterised by the material
• CPC Class Codes: A61F 13/512 characterised by its apertures, e.g. perforations
• CPC Class Codes: A61F 13/5122 and comprising secondary apertures, e.g. macro-apertures in combination with microapertures
• CPC Class Codes: B23K 2103/16 Composite materials , e.g. fibre reinforced
• CPC Class Codes: B23K 2103/30 Organic material
• CPC Class Codes: B23K 2103/42 Plastics B23K2103/16 takes precedence
• CPC Class Codes: B23K 2103/50 Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
• CPC Class Codes: B23K 26/0006 taking account of the properties of the material involved B23K26/32, B23K26/40 take precedence
• CPC Class Codes: B23K 26/06 Shaping the laser beam, e.g. by masks or multi-focusing
• CPC Class Codes: B23K 26/361 for deburring or mechanical trimming B23K26/351 takes precedence
• CPC Class Codes: B23K 26/382 by boring
• CPC Class Codes: B23K 26/384 of specially shaped holes
• CPC Class Codes: B26F 1/26 Perforating by non-mechanical means, e.g. by fluid jet
• CPC Class Codes: B29C 2791/009 Using laser curing using laser B29C2035/0838, welding using laser beams B29C65/16
• CPC Class Codes: B29C 59/025 Fibrous surfaces with piles or similar fibres substantially perpendicular to the surface
• CPC Class Codes: B29C 59/06 using vacuum drums for thermoforming B29C51/225
• CPC Class Codes: B29C 59/16 by wave energy or particle radiation , e.g. infrared heating B29C59/007 takes precedence
• CPC Class Codes: B29L 2031/4878 Diapers, napkins
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: G03F 7/0015 : Production of aperture devices, microporous systems or stamps
• CPC Class Codes: G03F 7/26 : Processing photosensitive materials; Apparatus therefor G03F7/12 - G03F7/24 take precedence
• CPC Class Codes: Y10T 428/24174 : including sheet or component perpendicular to plane of web or sheet
• CPC Class Codes: Y10T 428/24273 : including aperture
• CPC Class Codes: Y10T 428/31504 : Composite [nonstructural laminate]

Abstract

A method for making a forming structure having columnar protrusions extending therefrom comprising the steps of exposing a liquid photosensitive resin to light having an activating wavelength thereby inducing partial curing of the photosensitive resin to form a monolithic slab of partially-cured photosensitive resin; and, including the step of inducing partial curing of a plurality of protrusions on the monolithic slab such that they are joined to and integral with the monolithic slab. The method can further comprise the step of laser etching a plurality of apertures through the forming structure.

Claims

1. A method for making a forming structure having columnar protrusions extending therefrom, the method comprising the steps of:

a) providing a forming unit;

b) providing a backing film;

c) providing a foraminous element;

d) juxtaposing the foraminous element and the backing film with respect to the forming unit so that the backing film is interposed between the foraminous element and the forming unit;

e) providing a liquid photosensitive resin;

f) applying a coating of the liquid photosensitive resin to the foraminous element;

g) juxtaposing in contacting relationship with the coating of photosensitive resin a first transparent mask;

h) controlling a first thickness between the backing film and the fist mask of the coating to a preselected value;

i) exposing the liquid photosensitive resin to light having an activating wavelength through the first mask thereby inducing partial curing of the photosensitive resin to form a monolithic slab of partially-cured photosensitive resin;

j) removing the first mask;

k) repeating steps (a)-(j) one time with a different, second mask replacing the first mask in steps (g)-(h) and a second thickness in step (h), the second thickness being defined between the backing film and the second mask and being greater than the first thickness, and, in step (i) inducing partial curing of a plurality of protrusions on the monolithic slab such that they are joined to and integral with the monolithic slab, and removing the second mask in step (j);

l) immersing the foraminous element and partially cured resin thereon in an oxygen-free environment;

m) exposing the foraminous element and partially cured resin thereon to light having an activating wavelength to fully cure the partially cured resin, resulting in the forming structure having columnar protrusions extending therefrom.

2. The method of claim 1, further comprising the step of laser etching a plurality of apertures through the forming structure.

3. The method of claim 1, wherein the foraminous element is made of a material chosen from the group consisting of metal and polymer.

4. The method of claim 3, wherein the foraminous element is a woven screen.

5. The method of claim 1, wherein the liquid photosensitive resin is UV light activatable, and the light source is a UV light source.

6. The method of claim 1, wherein the backing film is a flexible film.

7. The method of claim 6, wherein the flexible film is a polymer film.

8. The method of claim 1, wherein the preselected value for the first thickness is between 1 mm and 2 mm.

9. The method of claim 1, wherein the second mask comprises a plurality of transparent regions defining an opaque continuous network.

10. The method of claim 9, wherein the transparent regions of the second mask each comprise a uniform pattern of discrete regularly-spaced geometric shapes.

14. The method of claim 1, wherein the protrusions have a height of at least 75 microns and an aspect ratio of at least 1.5 and the forming structure has a first surface defining a first surface area and the forming structure comprises at least about 2325 protrusions per square centimeter of first surface area.

11. The method of 1, wherein the columnar protrusions have an aspect ratio of at least 1.

12. The method of claim 11, wherein the columnar protrusions have a height of at least 50 microns and adjacent protrusions have a center-to-center spacing of at least about 100 microns.

13. The method of claim 12, wherein the center-to-center spacing is between about 100 microns and 250 microns.

15. A method for making an apertured forming structure having columnar protrusions extending therefrom, the method comprising the steps of:

a) providing a forming unit;

b) providing a backing film;

c) providing a foraminous element;

d) juxtaposing the foraminous element and the backing film with respect to the forming unit so that the backing film is interposed between the foraminous element and the forming unit;

e) providing a liquid photosensitive resin;

f) applying a coating of the liquid photosensitive resin to the foraminous element;

g) juxtaposing in contacting relationship with the coating of photosensitive resin a mask comprising both opaque and transparent regions, the transparent region being continuous, and defining a plurality of discrete opaque regions;

h) controlling a first thickness of the coating between the backing film and the mask to a preselected value;

i) exposing the liquid photosensitive resin to light having an activating wavelength through the mask thereby inducing partial curing of the photosensitive resin in those regions which are in register with the transparent regions of the first mask;

j) removing the first mask;

k) removing un-cured resin from the foraminous element and partially cured resin;

l) exposing the foraminous element and partially cured resin thereon to light having an activating wavelength to fully cure the partially cured resin, resulting in the forming structure having a continuous network of cured resin defining a first surface having a first surface area, and further defining a plurality of discrete apertures therein;

m) laser machining into the first surface of the continuous network of cured resin a plurality of generally columnar protrusions.

16. The method of claim 15, wherein the foraminous element is made of a material chosen from the group consisting of metal and polymer.

17. The method of claim 16, wherein the foraminous element is a woven screen.

18. The method of claim 15, wherein the liquid photosensitive resin is UV light activatable, and the light source is a UV light source.

19. The method of claim 15, wherein the backing film is a flexible film.

20. The method of claim 19, wherein the flexible film is a polymer film.

21. The method of claim 15, wherein the preselected value for the first thickness is between 1 mm and 2 mm.

23. The method of claim 15, wherein the columnar protrusions have a height of at least 50 microns and adjacent protrusions have a center-to-center spacing of at least about 100 microns.

24. The method of claim 23, wherein the center-to-center spacing is between about 100 microns and 250 microns.

25. The method of claim 15, wherein the protrusions have a height of at least 75 microns and an aspect ratio of at least 1.5 and the forming structure has a first surface defining a first surface area and the forming structure comprises at least about 2325 protrusions per square centimeter of first surface area

22. The method of 15, wherein the columnar protrusions have an aspect ratio of at least 1.

26-29. -29. (canceled)