Method for making a forming structure

• US 8,105,526 B2
• Filed: 07/29/2009
• Issued: 01/31/2012
• Est. Priority Date: 12/20/2002
• Status: Expired due to Term

• Current Assignee: The Procter & Gamble Company
• Original Assignee: The Procter & Gamble Company
• Inventors: Stone, Keith Joseph, Gray, Brian Francis, O'Neil, Julie Ann, Fiedeldey, Timothy Paul
• Primary Examiner(s): Vargot, Mathieu D.
• Application Number:
  US12/511,712
• Publication Number:
  US 20100019415A1
• Time in Patent Office: 916 Days
• Field of Search: 264/400, 264/482, 264/219, 264/494, 264/495, 264/496, 264/425, 430/320, 430/322, 430/394
• US Class Current: 264/400
• CPC Class Codes: A61F 13/15577 Apparatus or processes for manufacturing
• CPC Class Codes: A61F 13/51104 the top sheet having a three-dimensional cross-section, e.g. corrugations, embossments, recesses or projections
• 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 13/513 characterised by its function or properties, e.g. stretchability, breathability, rewet, visual effect; having areas of different permeability
• CPC Class Codes: B23K 2103/16 Composite materials , e.g. fibre reinforced
• 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: B23K 26/40 taking account of the properties of the material involved
• CPC Class Codes: B26F 1/26 Perforating by non-mechanical means, e.g. by fluid jet
• CPC Class Codes: B29C 2791/009 Using laser
• CPC Class Codes: B29C 33/00 Moulds or cores; Details thereof or accessories therefor
• 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: Y10T 428/24273 : including aperture
• CPC Class Codes: Y10T 428/24322 : Composite web or sheet

Abstract

A method for making a forming structure. The steps of the method include providing a forming unit, providing a backing film, providing a foraminous element, employing liquid photosensitive resin to form the forming structure, and laser machining a plurality of generally columnar protrusions into the forming structure.

Claims

1. 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 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 mask;

j) removing the 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; and

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

n) wherein a forming structure is formed comprising the foraminous element, and the continuous network of cured resin comprising the plurality of generally columnar protrusions extending from the first surface of the cured resin, wherein the columnar protrusions have an aspect ratio of at least 1 and adjacent protrusions have a center-to-center spacing between about 100 microns and 250 microns.

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

3. The method of claim 2, wherein the foraminous element is a woven screen.

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

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

6. The method of claim 5, wherein the flexible film is a polymer film.

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

8. The method of claim 1, wherein the columnar protrusions have a height of at least 50 microns.

9. 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.