WO2000078848A1 - Flexible, cut resistant, and abrasion resistant sheet material and method for making same - Google Patents
Flexible, cut resistant, and abrasion resistant sheet material and method for making same Download PDFInfo
- Publication number
- WO2000078848A1 WO2000078848A1 PCT/US2000/016180 US0016180W WO0078848A1 WO 2000078848 A1 WO2000078848 A1 WO 2000078848A1 US 0016180 W US0016180 W US 0016180W WO 0078848 A1 WO0078848 A1 WO 0078848A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- sheet
- amorphous
- regions
- crystalline regions
- sheet material
- Prior art date
Links
- 239000000463 material Substances 0.000 title claims abstract description 88
- 238000000034 method Methods 0.000 title claims abstract description 16
- 238000005299 abrasion Methods 0.000 title claims abstract description 15
- 239000011159 matrix material Substances 0.000 claims abstract description 17
- 238000004519 manufacturing process Methods 0.000 claims abstract description 6
- 239000012530 fluid Substances 0.000 claims description 10
- 230000002745 absorbent Effects 0.000 claims description 7
- 239000002250 absorbent Substances 0.000 claims description 7
- 238000002425 crystallisation Methods 0.000 claims description 7
- 230000008025 crystallization Effects 0.000 claims description 7
- 238000009877 rendering Methods 0.000 claims 1
- 239000002131 composite material Substances 0.000 description 5
- 230000008569 process Effects 0.000 description 5
- 230000004048 modification Effects 0.000 description 4
- 238000012986 modification Methods 0.000 description 4
- 229920000139 polyethylene terephthalate Polymers 0.000 description 4
- 238000013459 approach Methods 0.000 description 3
- 239000000835 fiber Substances 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 230000001681 protective effect Effects 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 238000004891 communication Methods 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 230000000994 depressogenic effect Effects 0.000 description 2
- 230000001788 irregular Effects 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 238000000149 argon plasma sintering Methods 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 230000001427 coherent effect Effects 0.000 description 1
- 238000004049 embossing Methods 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 238000005530 etching Methods 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 230000009477 glass transition Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 239000002648 laminated material Substances 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000005488 sandblasting Methods 0.000 description 1
- 238000009987 spinning Methods 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B2038/0052—Other operations not otherwise provided for
- B32B2038/0088—Expanding, swelling
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/02—Cellular or porous
- B32B2305/026—Porous
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/58—Cuttability
- B32B2307/581—Resistant to cut
Definitions
- the present invention relates sheet materials which are not only flexible, but also cut resistant and abrasion resistant.
- the present invention further relates to methods for manufacturing such sheet materials.
- sheet materials having durable wear and tear characteristics such as cut resistance and abrasion resistance are desirable.
- One such example is the use of protective sheet materials for countertops during food preparation operations.
- the sheet material also be flexible to conform to irregular and/or non-planar supporting surfaces and to be more easily stored, dispensed, and manipulated during use.
- the present invention provides a sheet of crystallizable material having opposed first and second surfaces, the sheet comprising: (a) a plurality of crystalline regions located in the first surface; and (b) an amorphous matrix surrounding and separating the crystalline regions from one another.
- the present invention also provides a method of making a flexible, cut resistant, and abrasion resistant sheet material, the method comprising the steps of: (a) providing a sheet of crystallizable amorphous material having opposed first and second surfaces; (b) crystallizing discrete regions of the first surface of the sheet of material, the discrete regions being separated from one another by a continuous amorphous matrix.
- Figure 1 is a plan view of a representative sheet of material in accordance with the present invention.
- Figure 2 is an elevational sectional view of the sheet of material of Figure 1;
- Figure 3 is an elevational sectional view of another embodiment of a sheet material in accordance with the present invention.
- Figure 4 is an elevational sectional view of a further embodiment of a sheet material in accordance with the present invention.
- Figure 5 is an elevational sectional view of yet another embodiment of a sheet material in accordance with the present invention.
- Figure 6 is an elevational sectional view of the sheet material of Figure 5 utilized as a protective cover layer in an absorbent composite sheet;
- Figure 7 is a schematic illustration of a process suitable for manufacturing the sheet material of Figure 5.
- Figure 1 depicts a representative embodiment of a sheet material 10 in accordance with the present invention.
- the sheet material 10 has a three-dimensional cross-section which includes a plurality of defined regions 20 which are surrounded by and separated from one another by a continuous matrix 30.
- the sheet 10 has a first surface 25 and an opposing second surface 35, both of which are substantially planar in the embodiment of Figures 1 and 2.
- the sheet 10 is unitarily formed from a crystallizable material of the desired gauge or thickness and having the desired mechanical and chemical properties.
- the plurality of regions 20 exhibit crystalline properties and define crystalline regions of the sheet within the first surface.
- the remainder of the sheet comprises the continuous matrix 30 which surrounds and separates the crystalline regions from one another. In contrast to the crystalline regions, the continuous matrix exhibits substantially amorphous properties and defines an amorphous matrix.
- Crystalline regions such as those depicted in Figure 1 may take any form, size, and arrangement desired, either regular or irregular.
- the regions may share a common size and/or shape, or may differ from each other. They may also be arranged in a regular repeating array pattern, or may be irregularly arranged.
- the regions form an amorphous pattern such as those developed for the prevention of nesting in wound rolls of three dimensional sheet products. Such patterns have been disclosed in commonly- assigned, co-pending (allowed) U.S. Patent Application Serial No.
- a unitary sheet of crystallizable material exhibits a certain degree of flexibility when in an un-crystallized or amorphous state
- crystallization of the sheet of material results in a significant reduction in flexibility and may in fact result in a substantially brittle material.
- the sheet of material exhibits a certain degree of cut resistance and abrasion resistance when in an amorphous state
- crystallization of the sheet of material may result in a significant increase in both cut resistance and abrasion resistance.
- the sheet material includes a plurality of crystalline regions which exhibit desirable cut resistance and abrasion resistance properties located within an amorphous matrix which exhibits desirable flexibility properties.
- Such sheets exhibit overall flexibility characteristics intermediate those of a fully crystallized sheet and a fully amorphous sheet. Without wishing to be bound by theory, it is believed that the difference in flexural behavior is proportional to the percent area of the first surface occupied by the crystalline regions, the degree of crystallization, and the degree to which the crystalline regions penetrate the thickness of the sheet as they extend inwardly from the first surface to or toward the second surface.
- the crystalline regions extend inwardly from the first surface toward the second surface a distance less than the thickness of the sheet material, such that the second surface in a location corresponding to the location of the crystalline regions in the first surface remains substantially amorphous in nature, comparable to the amorphous nature of the continuous amorphous matrix.
- the crystalline region forms a very thin protective shell over the amorphous material below, while in the other limiting case the crystalline regions fully penetrate the thickness of the sheet and extend throughout the material from the first surface to the second surface.
- Figure 3 depicts another embodiment of a sheet material according to the present invention.
- the thickness of the sheet material is greater in the crystalline regions 20 than in the continuous amorphous matrix 30, such that the crystalline regions extend upwardly to form a first surface above the continuous amorphous matrix.
- the continuous amorphous matrix is depressed between the crystalline regions to form a network of reduced thickness material, further enhancing the flexibility of the sheet.
- the second surface as shown in Figure 3, remains substantially planar.
- Figure 5 depicts an elevational sectional view of yet another embodiment of a sheet material in accordance with the present invention.
- the continuous amorphous matrix 30 is depressed below the surface formed by the crystalline regions 20 to define a network of valleys 40.
- the sheet material 10 of Figure 5 is a three-dimensional macroscopically- expanded sheet material having a caliper much greater than the thickness or gauge of the material from which it is made.
- the valleys 40 have a wall thickness comparable to that of the crystalline regions 20, and the crystalline regions extend substantially fully through the thickness of the material forming the raised portions of the sheet material between the valleys.
- the valleys 40 may optionally include a plurality of apertures 50 to provide a degree of porosity to the sheet, such as to make the sheet fluid pervious.
- FIG. 5 illustrates one potential application for the sheet materials of the present invention, more particularly, the embodiment of Figure 5.
- the sheet material 10 is utilized as a cut resistant and abrasion resistant cover layer in a composite sheet material 60 which includes an absorbent layer 70 and a fluid impervious backing layer 80, each of which may be secured to one another via adhesive or other suitable methods.
- the apertures 50 provide fluid communication between the surface of the sheet material 10 and the absorbent layer, such that if the composite sheet material is utilized as a cutting surface during food preparation or other tasks the sheet material 10 will protect the absorbent layer 70 yet still provide fluid communication so that fluids released from the food may be absorbed.
- the backing layer 80 in turn protects underlying surfaces.
- Crystallization of the crystalline regions may be accomplished by any suitable means depending upon the particular material utilized.
- a thermally- crystallizable material may be crystallized by the addition of external heat via infrared or laser impingement devices.
- the thermal impingement device may be precisely focused on discrete regions, or a mask may be employed to block the thermal energy from certain areas of the material.
- the material may also be conductively heated.
- FIG 7 illustrates one suitable process for manufacturing a sheet material in accordance with the embodiment of Figure 5.
- the formed polyethylene terepthalate (PET) sheet is be made by a process commonly called "pressure forming.”
- pressure forming the starting material 100 (preferably 0.010" thick amorphous PET) is fed from a supply roll 110 and heated until it is soft with an infrared or hot air heat source 120. The heated sheet is then passed between the mold 130 and a pressure box 140. The pressure box clamps against the film and the mold, and then pressure is applied to the film. Because the mold has a number of small holes drilled through it, air escapes from between the film and the mold, and the film conforms to the mold shape.
- the film After the film cools, it is removed from the mold and is preferably cut into sheets 200 via sheeting cutter 150.
- the final step of crystallizing the tops of the lands is accomplished by heating the tops of lands above the glass transition point of the PET and holding this temperature while crystallization occurs. This can be accomplished with a hot iron, hot roller, or by obliquely directed infrared radiation at station 160.
- the sheet may need to be fluid pervious.
- "dimples" are formed in the bottom of the grooves because the film is drawn down into the air passage holes in the mold. These dimples can be skived off with, for example, a spinning blade as might be found in a common wood planer. After the skiving operation, the sheet will have holes in the bottoms of the grooves allowing fluid passage.
- the sheet materials of the present invention it may be desirable to modify one or more surface regions of the sheet material to improve the aesthetic appearance and tacile impression presented to a consumer to thereby improve the consumer acceptance of such sheet materials.
- the outward surfaces of the sheet materials may appear and feel comparatively smooth and shiny, and thereby "plastic-like". It may therefore be desirable for such applications to modify the surface to reduce the "plastic-like" impression and make the surface more "natural” and aesthetically pleasing.
- Representative approaches for such surface modification include providing an embossed (or debossed) "microtexture” or other fine-scale texturing superimposed on and unitarily formed with the land areas of the sheet material.
- Such texturing serves to scatter reflected light and create a matte surface finish, and may be accomplished in a number of ways such as embossing with a male or female surface, sanding, sandblasting, etching with a chemical, etc.
- Another representative approach is the use of a sheet or other web externally applied to and laminated to the upper surface of the sheet material.
- This laminated sheet may be a woven, non-woven, formed film, expanded film, or other essentially two-dimensional substrate that essentially bonds to the sheet material to reduce the gloss and interrupt the smooth tactile impression of the sheet.
- Light scattering may be the means of reducing the gloss, but other techniques may be employed such as color differences between the sheet material and the laminated sheet.
- Particles and/or fibers added to the outwardly-facing surface of the sheet material may also serve to change the surface gloss and/or tactile impression.
- These particles and/or fibers may be of organic or inorganic origin and may be directly adhered (by melt fusion) or indirectly adhered by use of an intermediate adhesive.
- the particles and/or fibers are preferably adhered to the uppermost surface of the sheet material, and in the case of a three- dimensionally formed sheet material, may be applied to the valley regions as well as the land regions.
- the foregoing surface modification approaches may be employed prior to, during, or after the crystallization steps or the three-dimensional forming steps are accomplished.
Landscapes
- Laminated Bodies (AREA)
- Manufacture Of Macromolecular Shaped Articles (AREA)
Abstract
Description
Claims
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU57346/00A AU5734600A (en) | 1999-06-18 | 2000-06-13 | Flexible, cut resistant, and abrasion resistant sheet material and method for making same |
JP2001505602A JP2003503524A (en) | 1999-06-18 | 2000-06-13 | Flexible, cut-resistant, and abrasion-resistant sheet material, and method of manufacturing the same |
EP00942773A EP1194477A1 (en) | 1999-06-18 | 2000-06-13 | Flexible, cut resistant, and abrasion resistant sheet material and method for making same |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US33649599A | 1999-06-18 | 1999-06-18 | |
US09/336,495 | 1999-06-18 | ||
US09/358,136 | 1999-07-20 | ||
US09/358,136 US6451410B1 (en) | 1999-06-18 | 1999-07-20 | Flexible, cut resistant, and abrasion resistant sheet material and method for making same |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2000078848A1 true WO2000078848A1 (en) | 2000-12-28 |
Family
ID=26990235
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2000/016180 WO2000078848A1 (en) | 1999-06-18 | 2000-06-13 | Flexible, cut resistant, and abrasion resistant sheet material and method for making same |
Country Status (4)
Country | Link |
---|---|
EP (1) | EP1194477A1 (en) |
JP (1) | JP2003503524A (en) |
AU (1) | AU5734600A (en) |
WO (1) | WO2000078848A1 (en) |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3956254A (en) * | 1970-10-12 | 1976-05-11 | Leco Industries Limited | Thermoplastic crystalline free films |
EP0753606A2 (en) * | 1995-07-03 | 1997-01-15 | J.W. Suominen Oy | Method of regulating the internal transport of adjuvants and additives of a polymer |
-
2000
- 2000-06-13 AU AU57346/00A patent/AU5734600A/en not_active Abandoned
- 2000-06-13 WO PCT/US2000/016180 patent/WO2000078848A1/en not_active Application Discontinuation
- 2000-06-13 JP JP2001505602A patent/JP2003503524A/en not_active Withdrawn
- 2000-06-13 EP EP00942773A patent/EP1194477A1/en not_active Withdrawn
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3956254A (en) * | 1970-10-12 | 1976-05-11 | Leco Industries Limited | Thermoplastic crystalline free films |
EP0753606A2 (en) * | 1995-07-03 | 1997-01-15 | J.W. Suominen Oy | Method of regulating the internal transport of adjuvants and additives of a polymer |
Also Published As
Publication number | Publication date |
---|---|
EP1194477A1 (en) | 2002-04-10 |
JP2003503524A (en) | 2003-01-28 |
AU5734600A (en) | 2001-01-09 |
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