Fly-cutting system and method, and related tooling articles

• US 9,562,995 B2
• Filed: 05/19/2010
• Issued: 02/07/2017
• Est. Priority Date: 08/06/2007
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Burke, James P., Campbell, Alan B., Ehnes, Dale L., Wertz, Daniel S.
• Primary Examiner(s): SWINNEY, JENNIFER B
• Application Number:
  US12/782,950
• Publication Number:
  US 20100227123A1
• Time in Patent Office: 2,456 Days
• Field of Search: 82/11.1, 821/31, 409/25, 409/26, 409/27, 409/28, 409/38, 409/50, 409/51, 409/56, 409/57, 409/75, 409/76, 409/165, 359/668, 359/669
• US Class Current: 1/1
• CPC Class Codes: B23C 2226/125 cubic [CBN]
• CPC Class Codes: B23C 2226/31 Diamond
• CPC Class Codes: B23C 3/30 Milling straight grooves, e.g. keyways
• CPC Class Codes: B23C 5/08 Disc-type cutters
• CPC Class Codes: B23Q 15/007 while the tool acts upon the workpiece
• CPC Class Codes: B29C 2793/0009 Cutting out
• CPC Class Codes: B29C 37/0057 Moulding single grooves or ribs, e.g. tear lines folding lines B29C53/06
• CPC Class Codes: G02B 5/045 Prism arrays
• CPC Class Codes: G02B 5/1852 using mechanical means, e.g. ruling with diamond tool, moulding
• CPC Class Codes: G05B 19/182 characterised by the machine tool function, e.g. thread cutting, cam making, tool direction control G05B19/21 - G05B19/40 take precedence
• CPC Class Codes: G05B 2219/50213 Grooving of different forms or parallel to each other, grooving cycle
• CPC Class Codes: Y10T 408/03 Processes
• CPC Class Codes: Y10T 408/909 Having peripherally spaced cutting edges
• CPC Class Codes: Y10T 409/108745 Cutting action along work axis
• CPC Class Codes: Y10T 409/303752 Process
• CPC Class Codes: Y10T 428/24355 Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
• CPC Class Codes: Y10T 428/24479 including variation in thickness
• CPC Class Codes: Y10T 82/10 Process of turning
• CPC Class Codes: Y10T 82/2529 Revolvable cutter heads
• CPC Class Codes: Y10T 82/2587 Turret type holder [e.g., multiple tools, etc.]

Abstract

Methods of fly-cutting a workpiece are disclosed, and in methods in which the position of a fly-cutting head or its associated cutting element is known as a function of time. Also disclosed are methods of forming features, such as grooves or groove segments, in a workpiece such as a cylindrical roll. The features may be provided according to one or more disclosed patterns. Articles made using tools machined in the manner described are also provided, such as polymeric film or sheeting that exhibit certain beneficial properties.

Claims

1. A polymeric article comprising:

an external surface having features formed by a cylindrical tool, wherein the tool has groove segments formed therein, wherein the features in the polymeric article have been imprinted by the cylindrical tool such that the features in the polymeric article correspond to the groove segments of the tool,

wherein the groove segments and the corresponding features in the polymeric article are arranged according to an integer brick pattern that defines a repeating pattern of groove segments, wherein the integer is greater than two,

wherein each of the groove segments and each of the corresponding features in the polymeric article defines a length and a width, the length being greater than the width and perpendicular to the width,

wherein groove segments and the corresponding features in the polymeric article adjacent to one another in a direction parallel to the width are offset in a direction parallel to the length by a fraction of the length, wherein the fraction is 1 divided by the integer,

wherein each of the groove segments and each of the corresponding features in the polymeric article has a beginning and an end along its length,

wherein the integer brick pattern repeats every integer number of rows such that the beginning and end of each groove segment in a row of groove segments is aligned with the beginning and end of groove segments in other rows of groove segments and the beginning and end of each corresponding feature in a corresponding row of features in the polymeric article is aligned with the beginning and end of features in other rows of features in the polymeric article, the other rows being offset from the row by an integer number of rows, and

wherein each of the groove segments and each of the corresponding features in the polymeric article has a radius of curvature between the beginning and the end corresponding to a cutting radius of a fly-cutting head used to form the groove segment.

2. The polymeric article of claim 1, wherein groove segments in the repeating pattern are interleaved with each other both longitudinally and circumferentially about the tool.

3. The polymeric article of claim 1,

wherein the features in the polymeric article formed by the tool were formed by more than one revolution of the tool, and

wherein the features in the polymeric article are characterized by the absence of a virtual seam in that, for each of the features in the polymeric article, the features formed closer to a first edge of the polymeric article are progressively sharper than the features formed closer to a second edge the polymeric article.

4. The polymeric article of claim 1, wherein the plurality of groove segments combine to form a series of adjacent and parallel grooves, wherein for each groove within the series of adjacent and parallel grooves, each groove segment within the groove is aligned with and adjoins adjacent groove segments within the groove such that the groove segments within the groove approximate a single continuous feature forming the groove.

5. The polymeric article of claim 4, wherein each groove in the series of adjacent and parallel grooves extend about an external surface of the tool in a helix.

6. The polymeric article of claim 4, wherein each groove in the series of adjacent and parallel grooves extend about an external surface of the tool in a direction parallel to a central axis of the tool.

7. The polymeric article of claim 1, wherein, for each of the groove segments, a depth of the groove segment is no greater than 15 microns such that, for each of the corresponding features in the polymeric article, a height of the corresponding feature is no greater than 15 microns.

8. The polymeric article of claim 7, wherein, for each of the groove segments, a length of the groove segment as measured between the beginning and the end of the groove segment is between 1 millimeter and 3 millimeters such that, for each of the corresponding features in the polymeric article, a length of the corresponding feature is between 1 millimeter and 3 millimeters.

9. The polymeric article of claim 1, wherein, for each of the groove segments, a length of the groove segment as measured between the beginning and the end of the groove segment is between 1 millimeter and 3 millimeters such that, for each of the corresponding features in the polymeric article, a length of the corresponding feature is between 1 millimeter and 3 millimeters.

10. The polymeric article of claim 9, wherein, for each of the groove segments, a depth of the groove segment is no greater than 5 microns such that, for each of the corresponding features in the polymeric article, a height of the corresponding feature is no greater than 5 microns.

11. The polymeric article of claim 9, wherein, for each of the groove segments, a depth of the groove segment is no greater than 3 microns such that, for each of the corresponding features in the polymeric article, a height of the corresponding feature is no greater than 3 microns.