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  Soft filmUSPTO Application #: 20080061479Title: Soft film Abstract: The invention relates to a method of making a film, and to a die for making the film. The fluid die includes a fluid feed manifold connected to a housing having positioned therein at least one fluid feed channel in fluid communication with the fluid feed manifold. The housing also includes at least one profiling block within the fluid feed channel. (end of abstract)
Agent: Troutman Sanders LLP - Atlanta, GA, US Inventors: Andrew D. Maschino, Marcelo S. Copat USPTO Applicaton #: 20080061479 - Class: 264504000 (USPTO) Related Patent Categories: Plastic And Nonmetallic Article Shaping Or Treating: Processes, Direct Application Of Fluid Pressure Differential To Permanently Shape, Distort, Or Sustain Work, Perforation By Differential Fluid Pressure; Or Smoothing, Scoring, Or Cutting Of Green Concrete With Fluid Pressure The Patent Description & Claims data below is from USPTO Patent Application 20080061479. Brief Patent Description - Full Patent Description - Patent Application Claims
FIELD OF THE INVENTION [0001] Embodiments of the present invention relate to an improved personal care coverstock such as a topsheet for use in body contacting articles such as baby diapers, adult incontinent absorbent articles, sanitary napkins or panty liners, facial wipes, body wipes, and the like. Embodiments of the invention are directed to the improved coverstocks, the method of making improved soft films, and the apparatus used in the method. BACKGROUND OF THE INVENTION [0002] It is known to vacuum-form two-dimensional sheets to create three-dimensional formed films, by causing a softened or molten polymer sheet to conform to the shape of a forming screen. Commonly utilized apertured formed film topsheets are disclosed in, for example U.S. Pat. Nos. 3,929,135, 4,324,246, 4,342,314, 4,252,516, 4,535,020, 5,591,510, and U.S. patent application Ser. No. 10/082,040 filed Feb. 20, 2002. The formed films described in these publications are formed by application of a fluid pressure differential where the fluid preferably is air to thereby cause the polymer sheet to conform to the screen and also to cool. A preferred feature of these formed films is that the polymer crystallizes, or "sets" after the molten polymer has been formed. The resultant formed film therefore is said to have "memory." Memory enables the formed film to regain its original form after non-deforming forces are applied to it, for example while the film is stored in the form of a wound roll. A disadvantage of vacuum formed films is that the body contacting surface of the film my have a plastic feeling that can feel both sticky and hot to the wearer of the article. [0003] It also is known to utilize high pressure water jet systems, known as hydroforming systems, to cause two-dimensional polymeric films to conform to forming screens in order to create three-dimensional films. U.S. Pat. Nos. 4,609,518, 4,629,643, 4,695,422, 4,778,644, and 4,839,216, all to Curro (referred to herein as "Curro") and assigned to Procter & Gamble, and U.S. Pat. Nos. 5,770,144, 6,022,607, and 6,240,817 assigned to McNeil, describe a multitude of film designs created by the combination of forming screens using high pressure water jet systems. In these systems, pressurized water is ejected from nozzles projecting water onto the surface of a polymeric film causing it to conform to the surface of an underlying support screen. The screen has indentations or perforations disposed on its surface. As the screen rotates it causes subsequent portions of the film to pass under the water jet causing subsequent portions of the film to conform to the screen. An advantage of this method of making formed films is that the number of protrusions that can be made in a specific surface area of film is greater than what is possible in a vacuum formed film process. Another advantage is that by utilizing water to deform crystalline film high levels of energy are applied to the film thereby causing more work and making the film softer. A disadvantage of known hydroformed films is that liquid jets apply forming energy unevenly across the film surface causing variation in the important film properties that limits the functionality of the film. [0004] The description herein of certain advantages and disadvantages of known materials, and methods of their preparation, is not intended to limit the scope of the present invention. Indeed, the present invention may include some or all of the methods and materials described above without suffering from the same disadvantages. SUMMARY OF THE INVENTION [0005] It is a feature of an embodiment of the invention to improve the functional performance of hydroformed films by providing a film with improved properties. It is another feature of an embodiment of the invention to provide a cost effective method of making improved hydroformed soft film. It is an additional feature of an embodiment of the invention to provide an apparatus that improves hydroforming efficiency and quality, and lowers equipment and film production cost. [0006] Embodiments of the inventions described herein are directed to improved hydroforming methods and to an apparatus for forming films. A preferred embodiment comprises use of a liquid die to apply forming energy to a film while the film is positioned over a screen with indentations. [0007] Additional embodiments of the inventions described herein also are directed to improved films resulting from the application of the methods described herein, whereby the films exhibit less variation in their properties and are less costly to produce than films made with liquid jets using the same screens. BRIEF DESCRIPTION OF THE DRAWINGS [0008] FIG. 1 illustrates a side view of a known liquid jet hydroforming system. [0009] FIG. 2 is a perspective view of a known liquid jet hydroforming system shown without a forming screen. [0010] FIG. 3 depicts a liquid jet pattern. [0011] FIG. 4 illustrates various known liquid jet pattern footprints (A-E). [0012] FIG. 5 illustrates a side view of a liquid die hydroforming system of the invention. [0013] FIG. 6A illustrates a side view of a liquid die of the invention. [0014] FIG. 6B illustrates a top view of a liquid die of the invention. [0015] FIG. 7 depicts a detailed side view of a liquid die of the invention showing liquid profiling blocks. [0016] FIG. 8 illustrates two liquid die pattern footprints of the invention. [0017] FIG. 9 illustrates the body of a liquid die of the invention constructed from two parts. [0018] FIG. 10 illustrates one part of a two-part liquid die body incorporating liquid flow channels. [0019] FIG. 11 illustrates a side view of a liquid die of an embodiment of the invention. [0020] FIG. 12 illustrates a side view of a liquid die of another embodiment of the invention. Continue reading... Full patent description for Soft film Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Soft film patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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