WO2014143924A1 - Structures de films stratifiés de façon discontinue dotées de caractéristiques visuelles améliorées - Google Patents

Structures de films stratifiés de façon discontinue dotées de caractéristiques visuelles améliorées Download PDF

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Publication number
WO2014143924A1
WO2014143924A1 PCT/US2014/028109 US2014028109W WO2014143924A1 WO 2014143924 A1 WO2014143924 A1 WO 2014143924A1 US 2014028109 W US2014028109 W US 2014028109W WO 2014143924 A1 WO2014143924 A1 WO 2014143924A1
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WO
WIPO (PCT)
Prior art keywords
film
ribbed
ribs
laminated
laminated film
Prior art date
Application number
PCT/US2014/028109
Other languages
English (en)
Inventor
Michael G. Borchardt
Theodore J. Fish
Kenneth Cisek
Robert T. Dorsey
Original Assignee
The Glad Products Company
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US13/838,394 external-priority patent/US9393757B2/en
Application filed by The Glad Products Company filed Critical The Glad Products Company
Priority to AU2014228052A priority Critical patent/AU2014228052B2/en
Priority to CN201480022422.7A priority patent/CN105121151B/zh
Priority to CA2903883A priority patent/CA2903883C/fr
Publication of WO2014143924A1 publication Critical patent/WO2014143924A1/fr
Priority to HK16100266.9A priority patent/HK1212299A1/xx

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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 form; Layered products 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 form; Layered products 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
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products 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 a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
    • B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
    • B29C55/18—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets by squeezing between surfaces, e.g. rollers
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • 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
    • B32B38/0012—Mechanical treatment, e.g. roughening, deforming, stretching
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/05—Interconnection of layers the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection
    • 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
    • B32B38/0012—Mechanical treatment, e.g. roughening, deforming, stretching
    • B32B2038/0028—Stretching, elongating
    • 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
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/402—Coloured
    • 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
    • B32B2432/00—Cleaning articles, e.g. mops, wipes
    • 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
    • B32B2439/00—Containers; Receptacles
    • 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
    • B32B2555/00—Personal care
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
    • B32B37/153—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is extruded and immediately laminated while in semi-molten state

Definitions

  • films with a white color may employ a pigment such as titanium dioxide (Ti02).
  • Ti02 titanium dioxide
  • Other conventional mechanisms involve using multiple, very low gauge films in a laminate structure, where at least one of the films is colored.
  • the aforementioned types of color additions to film, and the types of film structures are not typically well-suited for some applications and/or have proven to be problematic for various reasons in addition to those noted above.
  • one color changeable laminate structure (or “laminate”) includes a pair of films in intimate contact with each other, and further includes a color generating film positioned adjacent one of the films. So long as the films are in intimate contact with each other, the laminate generates an interference color. However, absent intimate contact between the films, no color is generated. Thus, the color changeable laminate may not be well-suited for use in environments where, for example, delamination of the films is possible. As well, production processes for this structure can be difficult, and in some cases must be strictly controlled to ensure intimate contact throughout the entirety of the laminated films.
  • Another laminate displays a color change when the laminate is bent. This is achieved with a color generating metal disposed on a film of the laminate.
  • the metal is in intimate contact with an anodic film, and creates color by light interference absorption effects. Absent intimate contact between the metal and the anodic film however, the color generation effects are not achieved.
  • production processes can be difficult, and in some cases must be strictly controlled to ensure intimate contact between all portions of the metal and the anodic film.
  • this laminate may not be well- suited for environments where: the use of metal is undesirable or impractical; delamination of the metal and anodic film is possible; and/or, it is desired to maintain the color of the laminate notwithstanding temporary or permanent changes to the geometry of the laminate.
  • a further laminate structure can be constructed to display an irreversible color change upon delamination of two films in intimate contact with each other. Absent intimate initial contact between the films however, the color generation effects are not achieved. Thus, production processes must be strictly controlled to ensure intimate contact between the films so that when the films are delaminated, the desired effect is achieved. As well, this laminate may not be well-suited for environments where it is desired to maintain the color of the laminate notwithstanding temporary or permanent changes to the geometry of the laminate. Finally, this laminate structure may necessitate user intervention to effect the delamination necessary for achievement of the irreversible color change.
  • One or more embodiments within the scope of the invention may be effective in overcoming one or more disadvantages in the art.
  • One example embodiment is directed to a discontinuously laminated film that includes a first film portion that is ribbed, a second film portion that is un-ribbed; and a region of discontinuous lamination between the first film portion and the second film portion.
  • the region of discontinuous lamination includes a plurality of regions where the first and second film portions are bonded together, and the region of discontinuous lamination also includes a plurality of regions where the first and second film portions are not bonded together.
  • Improved strength in the end product is manifest, and is conveyed visually to the end user.
  • Figure 1 discloses aspects of an MD machine and associated MD rolling process
  • Figure 2 is a detail view of the MD machine of Figure 1, and discloses aspects of the operation of the MD machine relative to a film;
  • Figure 2a is another detail view illustrating the formation of indicia on a portion of a film, a rib in this case, by a tool such as a ring roller;
  • Figure 2b is a detail view of the MD machine of Figure 1, and discloses aspects of the operation of the MD machine relative to a film;
  • Figures 3a-l and 3a-2 depict a first example of a film, referred to herein as
  • Film ⁇ ' suitable for use in constructing one or more discontmuously laminated structures, where the film in Figures 3a-l and 3a-2 is an un-stretched film;
  • Figures 3b-l and 3b-2 depict a first variation of Film 'A,' where the film has been ring rolled in the machine direction;
  • Figures 3c-l and 3c-2 are another depiction of the first variation of Film
  • Figures 3d-l and 3d-2 depict a second variation of Film 'A,' where the film has been ring rolled first in the machine direction, and subsequently in the transverse direction;
  • Figures 4a- 1 and 4a-2 depict a second example of a film, referred to herein as Film ' ⁇ ', suitable for use in constructing one or more discontmuously laminated structures, where the film in Figures 4a- 1 and 4a-2 is an un-stretched film;
  • Figures 4b-l and 4b-2 depict a first variation of Film 'B,' where the film has been ring rolled in the machine direction;
  • Figures 4c- 1 and 4c-2 depict a second variation of Film 'B,' where the film has been ring rolled first in the machine direction, and subsequently in the transverse direction;
  • Figures 5a-l and 5a-2 depict a third example of a film, referred to herein as Film 'C,' suitable for use in constructing one or more discontmuously laminated structures, where the film in Figures 5a-l and 5a-2 is an un-stretched film;
  • Figures 5b-l and 5b-2 depict a first variation of Film 'C,' where the film has been ring-rolled in the machine direction;
  • Figures 5c-l and 5c-2 depict a second variation of Film 'C,' where the film has been ring rolled first in the machine direction, and subsequently in the transverse direction;
  • Figures 6a- 1 and 6a-2 depict a fourth example of a film, referred to herein as Film ⁇ ,' suitable for use in constructing one or more discontinuously laminated structures, where the film in Figures 6a- 1 and 6a-2 is an un-stretched film;
  • Figures 6b- 1 and 6b-2 depict a first variation of Film ⁇ ,' where the film has been ring rolled in the machine direction;
  • Figures 6c- 1 and 6c-2 depict a second variation of Film ⁇ ,' where the film has first been ring rolled in the machine direction, and subsequently in the transverse direction;
  • Figures 7-1 and 7-2 depict a first example of a discontinuously laminated film structure including a ribbed outer film and a black inner film;
  • Figures 8-1 and 8-2 depict a second example of a discontinuously laminated film structure including a ribbed outer film having white ribs and associated indicia, and a black inner film;
  • Figures 9-1 and 9-2 depict a third example of a discontinuously laminated film structure including a ribbed outer film having white ribs and associated indicia, and a black inner film;
  • Figures 10-1 and 10-2 depict a fourth example of a discontinuously laminated film structure including a ribbed outer film having black ribs and associated indicia, and a white inner film;
  • Figures 11-1 and 11-2 depict a fifth example of a discontmuously laminated film structure including a ribbed outer film having black ribs and associated indicia, and a white inner film;
  • Figure 12 is an example process suitable to form a discontmuously laminated film structure
  • Figure 13 is another example process suitable to form a discontmuously laminated film structure.
  • Example embodiments of the invention generally concern laminated polymer film structures. More particularly, at least some embodiments are directed to discontmuously laminated film structures with improved visual characteristics, while other embodiments are directed to methods for producing such discontmuously laminated film structures.
  • the films and discontmuously laminated film structures disclosed herein may be employed in a variety of different end products, examples of which include, but are not limited to, grocery bags, trash bags, sacks, yard waste bags, packaging materials, feminine hygiene products, baby diapers, adult incontinence products, sanitary napkins, bandages, food storage bags, food storage containers, thermal heat wraps, facial masks, wipes, and hard surface cleaners.
  • Films and discontinuously laminated film structures within the scope of this disclosure may possess or exhibit a variety of different physical, visual, and/or optical characteristics.
  • the visual and/or optical characteristics may be achieved without the use, for example, of metal layers, color generating laminates, delamination, and/or bending of the film structures.
  • film structures do not require intimate contact between all portions of their films in order to provide such visual and/or optical characteristics.
  • Illustrative examples of effects such as visual appearances that may be manifest in various embodiments of a discontinuously laminated film structure include: a film with a ribbed outer layer, where a contrast in color and/or color intensity is apparent between the ribs and the webs between the ribs; a two-toned discontinuously laminated film structure with an outer film having silver or metallic webs interposed between white ribs, and a black inner film, such as may be produced by discontinuous lamination of a black inner film with a ribbed precursor film that is clear and has white ribs; a discontinuously laminated film structure with silver, metallic or grey webs interposed between black ribs, such as may be produced by discontinuous lamination of a white inner film with a ribbed precursor film that is clear and has black ribs; and, a discontinuously laminated film structure that includes a coextruded film with an outer layer having black ribs and white webs, and the coextruded film further including a white inner layer. More
  • the aforementioned rib, web, and film colors are provided by way of example.
  • the inner film need not be black, or white, but may be any other color(s), and can be translucent, transparent, or substantially opaque.
  • discontinuously laminated film structures and products within the scope of this disclosure may include one or more of the following, in any suitable combination: two or more films discontinuously laminated to each other over at least a portion of each film; two or more films discontinuously laminated to each other over at least a portion of each film, one of the films being ribbed and manifesting a contrast in color and/or color intensity between the ribs and webs between the ribs; one or more ribbed films; one or more un-ribbed films; one or more inner films; one or more inner films with a coloring agent; one or more white inner films; one or more black inner films; one or more outer films; one or more outer films with a coloring agent; one or more substantially colorless outer films; one or more ribbed outer films; white ribs; black ribs; one or more plastic films; one or more thermoplastic films; ribs having a coloring agent; ribs having a voiding agent; a first film having a first region
  • a discontinuously laminated film structure includes a ribbed precursor film laminated together with another film.
  • a discontinuously laminated film structure includes a ribbed precursor film, one example of which is a coextruded ribbed precursor film, laminated together with another film, and the ribbed precursor film includes a plurality of layers.
  • a discontinuously laminated film structure includes a ribbed precursor film laminated together with another film, and the ribbed precursor film includes a plurality of layers of LLDPE
  • a discontinuously laminated film structure includes an extruded ribbed precursor film laminated together with another film, and the extruded ribbed precursor film exhibits a contrast in color and/or color intensity between the ribs and the webs between the ribs.
  • a discontinuously laminated film structure includes an extruded ribbed precursor film laminated together with another film.
  • a discontinuously laminated film structure includes a ribbed precursor film laminated together with another film, and the ribs of the ribbed precursor film are generally parallel to a machine direction.
  • a discontinuously laminated film structure includes a ribbed precursor film laminated together with another film, and the discontinuously laminated film structure further includes one or more indicia perceptible by one or more senses of a user.
  • a discontinuous ly laminated film structure includes an extruded ribbed precursor film laminated together with another film, and the discontinuously laminated film structure further includes one or more indicia perceptible by one or more senses of a user.
  • a discontinuously laminated film structure includes a ribbed precursor film laminated together with another film, and the discontinuously laminated film structure further includes one or more indicia visually perceptible by a user.
  • a discontinuously laminated film structure includes a ribbed precursor film laminated together with another film that is colored.
  • a discontinuously laminated film structure includes a ribbed precursor film laminated together with another film that is black or white.
  • a discontinuously laminated film structure includes a ribbed precursor film that includes one or both of a stress-sensitive coloring agent and a voiding agent and is laminated together with another film.
  • a discontinuously laminated film structure includes a ribbed precursor film that includes a stress-sensitive agent and is laminated together with another film.
  • a discontinuously laminated film structure includes an extruded ribbed precursor film that includes a stress-sensitive agent and is laminated together with another film.
  • a ribbed precursor film includes a stress-sensitive agent.
  • an end product includes any of the aforementioned discontmuously laminated film structures and/or precursor films.
  • a ribbed precursor film is discontmuously laminated together with another film and the resulting discontmuously laminated film structure is stretched.
  • a ribbed precursor film is discontmuously laminated together with another film and the resulting discontmuously laminated film structure is stretched in one or both of an MD direction and a TD direction.
  • a ribbed precursor film is discontmuously laminated together with another film and the resulting discontmuously laminated film structure is stretched first in an MD direction and then in a TD direction.
  • a ribbed precursor film is folded and stacked on another folded film, and the stack is ring rolled, the ring rolling including MD or TD ring rolling, in any order.
  • a ribbed precursor film is folded and stacked on another folded film, and the stack is ring rolled, the ring rolling including MD or TD ring rolling, in any order, and then one film is inserted into the other film, and the resulting book structure is ring rolled, the ring rolling of the book structure including MD or TD ring rolling, in any order,
  • a ribbed precursor film is folded and stacked on another folded film, and the stack is ring rolled, the ring rolling including MD or TD ring rolling, in any order, and then one film is inserted into the other film, and the resulting book structure is ring rolled, the ring rolling of the book structure including MD or TD ring rolling, in any order, and any of the ring rolling processes can be hot or cold processes.
  • a ribbed precursor film is discontmuously laminated together with another film and the resulting discontmuously laminated film structure is stretched so as to produce one or more indicia perceptible by a user.
  • a ribbed precursor film including a stress-sensitive agent is discontmuously laminated together with another film and the resulting discontmuously laminated film structure is stretched such that a change involving the stress-sensitive agent is perceptible by a user.
  • a ribbed precursor film is discontmuously laminated together with another film and the resulting discontmuously laminated film structure is subjected to further processing which produces indicia in the discontmuously laminated film structure.
  • rib embraces a portion of extra resin on a surface of a given precursor film, which portion is an integral portion of the film, and before any subsequent hot or cold forming process on the film, such as a ring rolling process.
  • the "rib,” e.g., reference 201 in Figure 1 of a ribbed film, e.g., reference 200 in Figure 1, may be formed in accordance with implementations of the present invention via extrusion of molten resin through an appropriate die having one or more sets of grooves for forming corresponding ribs.
  • a "ribbed film” refers to a film that has been extruded in molten form with one or more ribs, and therefore comprises the one or more extruded ribs independent of any other striations or rib-like formations that may occur via any other hot or cold forming process after the initial extrusion/formation of the rib(s) of the ribbed film.
  • Such other striations or rib-like formations from subsequent forming processes are referred to herein generally as "ripples(s).” See, for example, reference 208 of Figures 1 and 2a.
  • rib In terms of the physical configuration of a "rib,” the scope of the invention is not limited to any particular form, size or orientation thereof. In general however, the ribs extend outwardly a distance from a surface of the film. In this structure, a web is defined between consecutive ribs.
  • the ribs may or may not have a generally triangular cross-section, but it will be appreciated that, for example, an extrusion die can be configured to produce a rib having any desired cross-sectional shape.
  • discontinuously laminated structures and discontinuous lamination processes embrace, among other things, lamination of two or more films where the lamination is not continuous, that is, the lamination is discontinuous, in one or more directions.
  • Such directions may include, for example, one or both of the machine direction (MD), and the transverse direction (TD) which is generally orthogonal to the MD.
  • discontinuous lamination includes lamination of two or more films with repeating bonded patterns broken up by repeating un-bonded areas in one or both of the machine direction and the transverse direction of the film.
  • machine direction refers to the direction along the length of the film, or in other words, the direction of the film as the film is formed during extrusion and/or coating.
  • transverse direction refers to the direction across the film or perpendicular to the machine direction.
  • DD diagonal direction refers to the direction that is not aligned with either the length or the width of the film.
  • a wide variety of films and discontmuously laminated film structures may be employed to achieve various desired visual characteristics and/or physical characteristics, such as tactile characteristics.
  • An illustrative example of a discontmuously laminated film structure includes at least two films, or portions thereof, that are discontmuously laminated to each other. That is, the two films cooperatively define both regions of intimate contact between the adjacent films, and regions of non- intimate contact between the adjacent films.
  • the two or more films may include a ribbed film that is discontmuously laminated to a film that includes a coloring agent and is un- ribbed.
  • One or more of the films of a discontmuously laminated film structure may be plastic or other flexible material(s).
  • one or more films of a discontmuously laminated film structure may be a coextruded, ribbed film, although other example films may be ribbed films may be used that are not produced by coextrusion.
  • the scope of the invention is not limited to any particular type of ribbed film.
  • discontmuously laminated film structures which include, as one of their films, a film that itself has a discontmuously laminated structure, are considered to fall within the scope of the invention.
  • the discontmuously laminated film structures and their constituent films may comprise any flexible or pliable material, including thermoplastic materials that can be formed or drawn into a film.
  • discontinuously laminated film structures within the scope of the invention include a plurality of films, one or more of which may be thermoplastic. Each individual film may itself include a single layer or multiple layers. Adjuncts may also be included, as desired. Examples of such adjuncts include coloring agents such as pigments, dyes, and dilute pigments, slip agents, voiding agents, anti-block agents, tackifiers, and combinations of the foregoing.
  • thermoplastic material of the films of one or more implementations can include, but are not limited to, thermoplastic polyolefms, including polyethylene, polypropylene, and copolymers thereof.
  • exemplary copolymer olefins include, but are not limited to, ethylene vinylacetate (EVA), ethylene methyl acrylate (EMA) and ethylene acrylic acid (EAA), or blends of such olefins.
  • polymers suitable for use as films in accordance with the present invention include elastomeric polymers. Suitable elastomeric polymers may also be biodegradable or environmentally degradable. Suitable elastomeric polymers for the film include poly(ethylene-butene), poly(ethylene-hexene), poly(ethylene-octene), poly(ethylene -propylene), poly(styrene-butadiene-styrene), poly(styrene-isoprene- styrene), poly(styrene-ethylene-butylene-styrene), poly(ester-ether), poly(ether-amide), poly(ethylene -vinylacetate), poly(ethylene-methylacrylate), poly(ethylene-acrylic acid), poly(ethylene butylacrylate), polyurethane, poly(ethylene-propylene-diene), ethylene- propylene rubber, and combinations of the foregoing.
  • any other process(es) that produces laminated films that cooperate to define regions of intimate contact between adjacent films, and regions of non-intimate contact between adjacent films may be employed, and the scope of the invention is not limited to any particular production process(es).
  • various of the foregoing bonding techniques can be combined to create a film and/or discontinuously laminated film structures.
  • pressure and heat bonding processes can be combined, either simultaneously or serially, to form a film and/or discontinuously laminated film structure.
  • manufacturers may form individual films to be discontinuously laminated together so as to provide improved strength characteristics using a wide variety of techniques.
  • a manufacturer can form a precursor mix of the thermoplastic material including any optional additives.
  • the manufacturer can then form the film(s) from the precursor mix using conventional flat extrusion, cast extrusion, or coextrusion to produce monolayer, coextruded bilayer, or multilayered films.
  • the resulting film will be discontinuously bonded to another film at a later stage.
  • a manufacturer can form the films using other suitable processes, such as, a blown film process to produce monolayer, bilayer, or multilayered films, which are subsequently discontinuously laminated with another film at a later stage. If desired for a given end use, the manufacturer can orient the films by trapped bubble, tenterframe, or other suitable processes. Additionally, the manufacturer can optionally anneal the films.
  • a manufacturer can use multiple extruders to supply different melt streams, which a feed block can order into different channels of a multi-channel die.
  • the multiple extruders can allow a manufacturer to form a multi- layered film with films having different compositions.
  • Such multi-layer film may later be discontinuously laminated with another film, which may or may not be multi-layer itself, to provide a discontinuously laminated film structure.
  • the die can be an upright cylinder with a circular opening, and the die may include geometric features about its internal diameter that can form various structures on the film. As disclosed elsewhere herein, one example of such a geometric feature is a set of teeth disposed about the internal diameter of the die which may cause the formation of ribs on the film as the molten plastic is passed through the die.
  • rollers can pull molten plastic upward away from the die.
  • An air-ring can cool the film as the film travels upwards.
  • An air outlet can force compressed air into the center of the extruded circular profile, creating a bubble. The air can expand the extruded circular cross section by a multiple of the die diameter.
  • This ratio may be referred to as the "blow-up ratio," or BUR.
  • BUR blow-up ratio
  • the example film 200 may be a multi- layered film and may comprise any of the materials disclosed herein.
  • the film 200 may comprise two or more individual layers (not specifically shown in Figures 1 and 2), such as a ribbed precursor layer and other layers.
  • the individual layers of the multi-layer film 200 may each be formed in whole or in part, by extrusion, for example.
  • a ribbed precursor film may include ribs 201 formed by an extrusion process, that is, extruded ribs. As indicated in Figure 1, the ribs 201 may extend generally parallel to the machine direction, but that is not required.
  • the film 200 can have an initial thickness or starting gauge
  • the starting gauge 202, as well as the respective gauges of the individual layers can be substantially uniform along the length of the film 200.
  • Figures 1 and 2 disclose portions of a machine 100 that can implement an MD ring rolling process that partially discontinuously laminates individual adjacent layers of film 200 by passing the film 200 through a pair of MD intermeshing rollers 102 and 104. As a result of MD ring rolling, the film 200 is also intermittently stretched in the machine direction MD.
  • Figure 1 discloses that the first roller 102 and the second roller 104 can each have a generally cylindrical shape, and are operable to rotate in opposite directions about respective parallel axes of rotation 102a and 104a that may be generally parallel to the transverse direction TD and generally perpendicular to the machine direction MD.
  • the rollers 102 and 104 each include a respective plurality of radially protruding ridges 106 and 108 that extend along the respective rollers 102 and 104 in a direction generally parallel to the axes of rotation 102a and 104a.
  • the respective tips 106a and 108a of ridges 106 and 108 can have a variety of different shapes and configurations, including the rounded shape as shown in Figure 2.
  • the tips 106a and 108a of the ridges 106 and 108 can have sharp angled corners. As further indicated in Figures 1 and 2, the ridges 106 are separated by grooves 110, while the ridges 108 are separated by grooves 112.
  • the ridges 106 and 108 are staggered relative to each other so that the grooves 110 can receive at least a portion of the ridges 108 as the rollers 102 and 104 intermesh with each other.
  • the grooves 112 can receive at least a portion of the ridges 106.
  • the configuration of the ridges 106 and 108 and grooves 110 and 112 can prevent substantial contact between ridges 106 and 108 during intermeshing such that little or no rotational torque is transmitted during operation.
  • the configuration of the ridges 106 and 108, and of the grooves 110 and 112 can affect the amount of stretching and the bond strength resulting from partially discontinuous lamination as the film passes through the rollers 102 and 104.
  • the pitch and depth of engagement of the ridges 106 and 108 can determine, at least in part, the amount of incremental stretching and partially discontinuous lamination caused by the intermeshing rollers 102 and 104.
  • the pitch 114 is the distance between the tips of two adjacent ridges on the same roller.
  • the depth of engagement (DOE) 116 is the amount of overlap between adjacent ridges 106 and 108 of the rollers 102 and 104 during intermeshing.
  • various parameters of the machine 100 may be selected and implemented depending upon the effect(s) desired to be achieved.
  • the ridge pitch and/or DOE may be varied as necessary. Merely because these parameters, and others, may be varied however, such variations will not necessarily be evident to one of ordinary skill in the art, and may, in some instances at least, be arrived at only after substantial experimentation and trials.
  • the direction of travel of the film 200 through the intermeshing rollers 102 and 104 is generally parallel to the machine direction and generally perpendicular to the transverse direction.
  • the ridges 106 and 108 incrementally stretch the film 200 in the machine direction.
  • stretching the film 200 in the machine direction can reduce the gauge of the film and increase the length of the film 200.
  • the film 200 may rebound after stretching such that the gauge of the film 200 is not substantially decreased.
  • stretching the film 200 in the machine direction can reduce the width of the film 200. For example, as the film 200 is lengthened in the machine direction, the width of the film 200 can be reduced in the transverse direction.
  • the ridges 106 of the first roller 102 can push film 200 into the grooves 112 of the second roller 104, and the ridges 108 of the second roller 104 can also push the film 200 into the grooves 110 of the first roller 102.
  • the pulling of the film 200 by the ridges 106 and 108 can stretch the film 200.
  • the rollers 102 and 104 need not necessarily stretch the film 200 evenly along its length. Specifically, the rollers 102 and 104 can stretch the portions of the film 200 between the ridges 106 and 108 more than the portions of the film 200 that contact the ridges 106 and 108, as indicated in Figure 2a.
  • the rollers 102 and 104 can cooperate to form a series of machined ripples 208 in the film 200 such that the film 250 includes relatively thicker portions alternating with relatively thinner portions.
  • the ripples 208 in this particular example are disposed generally parallel to the transverse direction.
  • the ripples 208 are generally orthogonal to the ribs 201, but such an arrangement is not required.
  • the finished film 200 may be a rippled film of multilayer, or single layer, construction.
  • the finished film 200 may, in at least some embodiments, have a laminated structure, although such a structure is not required nor implemented in every case.
  • various desirable visual effects and characteristics may be achieved through selection and processing of various films that make up a multi-layer implementation of the film 200.
  • FIG. 2a details are provided concerning aspects of an example machine and process which may be useful in creating various indicia on a film, such as a ribbed film for example.
  • a film such as a ribbed film for example.
  • the ridges 106 and 108 may temporarily or permanently compress portions of the ribs 201.
  • the compressions 210 may, but need not, be generally orthogonal to the direction of the ribs 201.
  • the compressions 210 of the ribs 201 constitute one example of indicia, discussed in more detail elsewhere herein.
  • the color, size, number, geometry and orientation of the compressions 260 may depend on one or more of the particular ring rolling process performed, roller pitch, DOE, material(s) of the film, and pigments and/or voiding agents present in one or more films.
  • a stretching process such as MD ring rolling is one example of method suitable to implement partially discontinuous lamination of a film, such as a multi-layer film for example, by incremental stretching of the film in the machine direction.
  • a stretching process such as TD ring rolling is another suitable method of discontinuously or partially discontinuously laminating a film such as a multi-layer film for example, by incremental stretching of the film in the transverse direction.
  • Stretching processes such as TD ring rolling and MD ring rolling, may be used together, alone, or in conjunction with other processes.
  • a TD ring rolling machine and associated process may be similar, respectively, to the MD ring rolling machine and associated process, though the rollers of a TD ring rolling machine include ridges and grooves that extend generally parallel to the MD direction, rather than orthogonal to the MD direction, as in the case of an MD machine and process.
  • a TD ring rolling process may produce a film having corrugations that are generally parallel to the MD direction.
  • Figures 3a-l through 3d-2 and the corresponding text provide details concerning an example ribbed film laminate structure referred to herein as Film ' A.
  • Film ' A the left-side portion of the film is shown on a white background, and the right-side portion of the film is shown on a black background, to better disclose various aspects of the film.
  • Figures 4a- 1, 4b- 1, 4c-l, 5a-l, 5b-l, and 5c-l In Figures 6a-l, 6b-l and 6c-l, only a black background is used.
  • Film 'A' is an extruded film that comprises three layers of linear low-density polyethylene (LLDPE), having a layer structure of A:B:A, wherein the layer ratio for the three layers is about 20:60:20. That is, the outer two layers, or skin layers, each have a thickness of about 20 percent of the total thickness of Film ⁇ ', while the core layer has a thickness of about 60 percent of the total thickness of Film ⁇ '.
  • LLDPE linear low-density polyethylene
  • Figures 3a-l through 3d-2 further show that both the core layer and the skin layers are un-pigmented.
  • the ribs of Film 'A' averaged about 6.5 mils tall, with an average spacing between extruded ribs 302 of about 0.336 inches.
  • the thickness of the web 304 between consecutive extruded ribs 302 was targeted to be about 0.50 mils thick.
  • the extruded ribs 302 appear translucent as a result of their relative thickness, and as a result of its thinness, the web 304 between the extruded ribs 302 appears to be nearly colorless.
  • Film 'A' is disclosed that reflects an absence of post-extrusion processing, such as MD or TD ring rolling. As illustrated, the ribs 302 have a hazy appearance, and the web 304 between the ribs 302 is largely translucent. [00110] Figures 3b-l, 3b-2, 3c-l and 3c-2 further disclose that different effects can be achieved in, for example, the appearance and/or feel of a ribbed film by varying the post-extrusion tools and/or processing employed in connection with the film. Such tools and/or processing can include one or more of DOE, tooth pitch, tooth shape, and ring rolling including one or more of TD, MD and DD ring rolling.
  • Figures 3b- 1, 3b-2, 3c- 1 and 3c-2 disclose an implementation in which Film 'A' was stretched by an MD process using a 200 pitch tool and a DOE of about 150 mils. MD stretching with these parameters resulted in the web 304 having a hazier appearance, relative to the un- stretched embodiment of Figures 3a- 1 and 3a-2, while the ribs 302 experienced no substantial change in color or haze. This is particularly apparent when referring to the right hand side of Figures 3a-l, 3a-2, 3b-l and 3b-2, where Film 'A' is disposed on a black background.
  • Figures 3d-l and 3d-2 disclose the embodiment of Figures 3b- 1, 3b-2, 3c-l and 3c-2 after that embodiment was further subjected to a TD ring rolling process with a 40 pitch tool and DOE of about 20 mils.
  • the additional TD ring rolling process produced no substantial change in the haze of the web 304 between the ribs 302.
  • this process produced no substantial color change in the extruded ribs 302 or web 304 between the extruded ribs 302.
  • Figures 4a-l and 4a-2 disclose aspects of another film referred to herein as
  • LLC linear low-density polyethylene
  • the ribs 402 of Film 'B' average about 6.5 mils tall, with an average spacing between ribs 402 of about 0.336 inches.
  • the thickness of the web 404 between the ribs 402 was targeted to be about 0.50 mils thick.
  • the example of Fig. 4a indicates that, absent any ring rolling, the ribs 402 of Film 'B' have a hazy translucent appearance due to the presence of the CaC0 3 and the thickness of the ribs 402, while the web 404 between the ribs 402 was hazy but nearly colorless.
  • Figures 4b- 1 and 4b-2 indicate the effect on Film 'B' of the performance of an MD ring rolling process.
  • Figure 4b illustrates the effect on Film 'B' after application of an MD ring rolling process using a 200 pitch tool and a DOE of about 150 mils.
  • MD ring rolling and consequent stretching of Film 'B' under these parameters resulted in a relatively hazier appearance of the web 404 between the ribs 402, while the ribs 402 took on a visibly enhanced white color.
  • Figures 4b- 1 and 4b-2 further show that the ribs 402 each comprise a white "stitch" or cross pattern that intermittently crosses each rib 403.
  • Figures 4c- 1 and 4c-2 illustrate Film 'B' after the application, to the film of Figures 4b- 1 and 4b-2, of a TD process using a 40 pitch tool and a DOE of about 20 mils. As indicated, that TD process produced no significant change in the ribs 402, or in web 404.
  • Film 'C is an extruded ribbed film that comprises three layers of linear low-density polyethylene (LLDPE), having a layer structure of A:B:A, wherein the layer ratio for the three layers is about 20:60:20.
  • LLDPE linear low-density polyethylene
  • the ribs 502 of Film 'C average about 6.5 mils tall, with an average spacing between ribs 502 of about 0.336 inches.
  • the thickness of the web 504 between the ribs 502 was targeted to be about 0.50 mils thick.
  • Film 'C comprises a black coloring agent that causes the ribs 502 to appear black.
  • Film C comprises a core layer (layer B of layer structure A:B:A) that was un-pigmented, albeit with skin layers (layers A of structure A:B:A) that contained a dilute pigment, about 0.5 percent black masterbatch in this example.
  • a dilute pigment having a concentration in the range of about 0.25 percent to about 3.0 percent may provide acceptable results in this and/or other embodiments.
  • concentrations in a range of about 0.25 percent to about 2.0 percent may be useful in some instances, and concentrations in a range of about 0.25 percent to about 1.0 may be particularly useful in some instances.
  • Figures 5b- 1 and 5b-2 show the effects of applying an MD stretching process, to the film of Figures 5a- 1 and 5a-2, where the ribs 502 are colored, but otherwise comprise no voiding agents that might change or enhance color with stress.
  • the MD ring rolling was performed using a 200 pitch tool and a DOE of about 150 mils.
  • Figures 5b- 1 and 5b-2 show that applying MD stretching under these parameters can produce some intermittent deformation of the film at uniform points along the ribs 502, and a corresponding hazier appearance of the ribs 502, but otherwise produce no color change to the ribs 502.
  • the web 504 can become hazier as well, but otherwise undergo no color change.
  • Film ' ⁇ is a ribbed film.
  • Film 'FT is an extruded film that comprises three layers of linear low-density polyethylene (LLDPE).
  • LLDPE linear low-density polyethylene
  • Film 'FT has a layer structure of A:B:A. The layer ratio for the three layers is about 20:60:20.
  • the core layer comprised about 6 percent black masterbatch, and the skin layers contained about 20 percent CaC03 masterbatch.
  • the ribs 602 of Film ⁇ ' averaged about 6.5 mils tall, with an average spacing between ribs 602 of about 0.336 inches.
  • the thickness of the intervening film 604 between the ribs 602 was targeted to be about 0.50 mils thick.
  • a TD stretching process with a 40 pitch tool at about 20 mils DOE, performed subsequent to the MD stretching process resulted in no color change to the ribs 602 or to the film between the ribs 62, as compared with the film of Figures 6b- 1 and 6b-2.
  • discontinuously laminated film structures may be employed in the construction of discontinuously laminated film structures.
  • discontinuously laminated film structures that each employ one of the example films disclosed herein.
  • the aforementioned discontinuously laminated film structures are presented only by way of example and are not intended to limit the scope of the invention in any way. With attention now to Figures 7-11, details are provided concerning some example discontinuously laminated film structures.
  • Film Structure 1 (Structure 1) production parameters included MD RR, Insertion, TD RR. Structure 1 was created with the outer layer being un-stretched ribbed Film 'B' described above in connection with Figures 4a-4c.
  • the inner layer was a 0.5 mil 0.920 density LLDPE black film containing approximately 5 percent carbon black masterbatch. Prior to insertion of the black inner film into the outer film, the C-folded films were stacked one upon the other and MD ring rolled at 190 DOE with a 200 pitch tool. The black inner film was then inserted into the un-pigmented outer film and the composite TD ring rolled at 20 DOE with a 40 pitch tool.
  • Structure 1 On viewing the laminated structure, Structure 1 appeared as two toned, having white ribs 702 interconnected by metallic or silver webs 704 on the outside with a black inner film 706. In addition, the white ribs 702 were visually discontinuous, with a small white "star” or dot 708 on the rib 702 where the MD tool contacted the rib 702.
  • Laminated Film Structure 2 (Structure 2) production parameters included Insertion, MD, and TD RR. Structure 2 was created with the outer film being un-stretched ribbed Film 'B' described above. The inner film was a 0.5 mil 0.920 density LLDPE black film containing about 5 percent carbon black MB. The black inner film was inserted into the un-pigmented ribbed outer film, and the resulting composite structure was then MD ring rolled at 190 DOE with a 200 pitch tool, followed immediately by TD ring rolling at 20 DOE with a 40 pitch tool.
  • this sequence of insertion and ring rolling may be advantageous inasmuch as insertion of films prior to ring rolling can help to better maintain the structural integrity of the involved films, and also help reduce the presence of entrained air between the films.
  • Structure 2 appeared as being two toned, having white ribs 802 interconnected by metallic-looking webs 804 on the outside with a black inner film 806.
  • the white ribs 802 were visually discontinuous, with a small white "star” or dot 808 on the rib 802 where the MD tool contacted the rib 802.
  • Laminated Film Structure 3 (Structure 3) production parameters included Insertion, and MD RR.
  • Structure 3 is the same as Structure 2 described above except without TD RR.
  • Structure 3 was similar to as described in Structure 2 above, except the webs 902 between the ribs 904 alternate in and out of plane in a strongly visible zigzag manner in the machine direction. Also, Structure 3 was thicker than Structure 2, owing to lack of TD stretching in the production of Structure 3.
  • Laminated Film Structure 4 (Structure 4) production parameters included MD RR, Insertion, and TD RR. Structure 4 was created with the outer film being un-stretched ribbed Film 3 described above.
  • the inner film was a 0.5 mil 0.920 density LLDPE white film containing approximately 5 percent white MB. Prior to insertion of the white inner film into the outer ribbed film, the C-folded films were stacked one upon the other and MD ring rolled at 190 DOE with a 200 pitch tool. The white inner film was then inserted into the ribbed outer film and the resulting composite TD ring rolling at 20 DOE with a 40 pitch tool.
  • Structure 4 appeared as being two toned, having black ribs 1002 interconnected by silver webs 1004 on the outside with a white inner film 1006.
  • the black ribs 1002 appeared discontinuous, with an apparent “break” in the rib 1002 occurring where the MD tooth contacted the rib 1002, creating a "stitched" appearance of the ribs 1002.
  • Laminated Film Structure 5 (Structure 5) production parameters included Insertion, MD, and TD RR. Structure 5 was created with the outer film being un-stretched Film 3 described above.
  • the inner film was a 0.5 mil 0.920 density LLDPE white film containing approximately 5% white MB. The white inner film was inserted into the ribbed outer film and the resulting composite structure then MD ring rolled at 190 DOE with a 200 pitch tool, followed immediately by TD ring rolling at 20 DOE with a 40 pitch tool.
  • the composite structure appeared as being two toned, having black ribs 1102 interconnected by silver webs 1104 on the outside with a white inner film 1106.
  • the black ribs 1102 appeared discontinuous, with an apparent "break” in the rib 1102 occurring where the MD tooth contacted the rib 1102, creating a "stitched” appearance in the ribs 1102.
  • the webs 1104 between the ribs 1102 appear to alternate in and out of plane in a zigzag manner in the machine direction.
  • Discontinuously Laminated Film Structure 6 (Structure 6) production parameters included Insertion, and MD RR. Structure 6 is the same as Structure 5 described above except without TD RR.
  • Structure 6 was similar to that of Structure 2 described above, except the webs between the ribs alternate in and out of plane in a strongly visible zigzag manner in the machine direction. Also, the composite film was thicker owing to lack of TD stretching.
  • Structure 7 was the same as Structure 6 described above except with finer MD tool markings on the ribbed outer film, resulting in a tighter pitched stitched appearance.
  • the pitch of the webs between the ribs alternating in and out of plan is finer, resulting in a tighter, more pleasing zigzag pattern. This tighter zigzag pattern appears to enhance and intensify the silver color compared to Structure 7 above.
  • Discontinuously Laminated Film Structure 8 (Structure 8) production parameters included Insertion, 100 Pitch MD, and TD RR.
  • the appearance of Structure 8 was the same as Structure 7 above except that TD RR was applied after the MD RR.
  • the TD RR modulates the amplitude of the in and out of plane zigzag pattern in the webs between the ribs. This pattern results in a slightly less intense silver color compared to Structure 7 above.
  • At least some of the processes that may be employed to create the discontinuously laminated film structures disclosed herein generally involve the bonding of ribbed first film portion to a second un-ribbed film portion so as to define a region of discontinuous lamination between the first film portion and the second film portion.
  • the region of discontinuous lamination comprises both a plurality of regions where the first and second film portions are bonded together, and a plurality of regions where the first and second film portions are not bonded together.
  • an example process 1200 is disclosed that may be used to form, for example, Structures 1 , 4 and 5 disclosed herein.
  • Process 1200 begins at 1202 where a first film is folded, such as by C- folding for example.
  • a second film is folded, such as by C-folding for example.
  • the outer film whether it is the first or second film, is a ribbed precursor film formed by a process such as extrusion.
  • the inner film may have an opaque color, such as black or white, for example, although other colors may be used.
  • the ribbed precursor film may include colors such as black or white, for example, in one or both of the ribs and webs between the ribs.
  • the C-folding process, or other folding process may be omitted.
  • the folded first film and folded second film are then stacked 1206 to form a film stack.
  • the film stack is processed, such as by a cold or hot rolling process.
  • the rolling process may be an MD ring rolling process, although other rolling processes such as TD and/or DD ring rolling could additionally, or alternatively, be employed.
  • one of the C-folded films which could be either the first or second film, is inserted into the other C-folded film, which could be either the first or second film, so as to form a film 'book' configuration.
  • the film book may assume a corrugated appearance, with corrugations that are generally perpendicular to the extruded ribs of the outer layer.
  • the film book is ring rolled.
  • a TD ring rolling process is used.
  • other ring rolling processes may additionally or alternatively be employed.
  • the final TD ring rolling process 1212 is omitted. This variation may be used to form, for example, Structure 6 disclosed herein. In another variation, the TD ring rolling process 1212 immediately follows the MD ring rolling process 1208. This latter variation may be used to form, for example, Structure 8 disclosed herein.
  • Process 1300 begins at 1302 where an inner film is inserted into an outer film to form, for example, a film book.
  • the inner film may be a black film
  • the outer film may be a ribbed precursor film, although different inner and/or outer films could be used.
  • the film book is ring rolled, such as by MD ring rolling for example.
  • the MD ring rolled film book is ring rolled, such as by TD ring rolling for example.
  • the TD ring rolling process may be omitted from process 1300.
  • indicia may include, for example, elements such as colors, dyes, pigments, textures, ribs, corrugations, stars, dots, bars, stitches, discontinuous lines, and combinations of any of the foregoing. Not only are such indicia readily apparent to a user of, for example, an end product in which the discontinuously laminated film structure is employed, but such indicia may be advantageous insofar as they are perceptible by one or more senses of a user.
  • indicia may be present in a particular end product, discontinuously laminated film structure, or precursor film.
  • one type of indicia may convey to a user certain information concerning an attribute of an end product.
  • Another type of indicia may serve a largely cosmetic or aesthetic purpose.
  • the foregoing and/or other types of indicia may be combined, for example, in a single end product.
  • indicia may indicate visually, and/or in a tactile sense, certain attributes of the end product such as, for example, a relative strength of the product.
  • the extruded ribs present in a precursor film enhance the strength of the precursor film.
  • such extruded ribs also provide a visible and tactile indicator, to a user, of the strength of the film and/or the strength of a discontinuously laminated film structure or end product in which that film is employed.
  • the stars or dots present in some of the 'Structures' noted below serve as an indicator of highly localized stress whitening, such as may be obtained with various combinations of ring rolling processes, such as MD and/or TD ring rolling.
  • the highly localized stress whitening which may result from ring rolling in a direction generally orthogonal to a direction of extruded ribs of a film, can serve as an indicator to a consumer as to the strength of the discontinuously laminated film structure, since the localized stress whitening occurs at points where the extruded ribs are worked by the teeth of a roller.
  • indicia such as color intensification in the form of localized stress whitening
  • indicia can be localized and controlled using various combinations of voiding agents, coloring agents such as dyes and pigments, and various stretching processes such as hot and/or cold MD and/or TD ring rolling.
  • voiding agents such as dyes and pigments
  • coloring agents such as dyes and pigments
  • stretching processes such as hot and/or cold MD and/or TD ring rolling.
  • such whitening can be highly localized, if desired, as evidenced by indicia such as the dots and stars disclosed elsewhere herein.
  • stress-sensitive agents such as voiding agents, and coloring agents such as dyes and pigments
  • voiding agents and coloring agents
  • coloring agents such as dyes and pigments
  • indicia within the scope of this disclosure may be largely cosmetic or aesthetic in nature.
  • MD ring rolling of the extruded ribs in a ribbed precursor film provides an interesting visual effect that may have little to do with the strength or integrity of the precursor film or associated discontinuously laminated film structure.
  • indicia convey to a user information concerning a property of a precursor film, discontinuously laminated film structure, and/or end product
  • indicia are example implementations of means for conveying information perceptible by a sense of a user.
  • the indicia disclosed herein are provided solely by way of example, and any other indicia of comparable functionality may alternatively be employed.
  • one or more embodiments of the invention may substantially maintain their color characteristics, notwithstanding temporary or permanent deformation of the film.
  • one or more embodiments of the invention may implement various visual effects, such as coloration, with non-metallic films.
  • one or more embodiments of the invention may implement various visual effects such as coloration without the use of color-generating laminates or films.
  • one or more embodiments of the invention may provide visual effects such as coloration without requiring user manipulation, such as by bending or delamination for example, with regard to the finished film.
  • one or more embodiments of the invention may implement desired visual effects with discontinuously laminated films, and thus do not require intimate contact between films.
  • one or more embodiments of the invention may implement desired visual effects with film structures that include at least one ribbed film.
  • one or more embodiments of the invention may realize a relative increase in strength as a result of MD rolling and/or TD rolling of a ribbed precursor film or a laminated film that includes such a rolled precursor film.
  • the relative strength of the film and/or of a product that employs the film may be visually indicated to a user by indicia such as a color, color intensification such as by imposition of stress or strain, contrasting colors, and/or distribution of the color in the film or product.
  • the incremental stretching processes disclosed herein, such as TD and MD ring rolling for example may be advantageous over conventional continuous-stretch processes that do not produce indicia and the other effects noted herein.
  • one or more of the embodiments disclosed herein may be advantageous inasmuch as they possess, or produce, as applicable, indicia using a continuous process. More conventional processes, such as stamping or embossing, are not well suited to be implemented in a continuous fashion. Rather, only discrete portions of the film can be stamped or embossed.
  • the present invention may be embodied in other specific forms without departing from its spirit or essential characteristics.
  • the illustrated and described implementations involve non-continuous (i.e., discontinuous or partially discontinuous lamination) to provide the light bonds.
  • the lamination may be continuous.
  • films could be co-extruded so that the films have a bond strength that provides for delamination prior to film failure to provide similar benefits to those described above.
  • the described embodiments are to be considered in all respects only as illustrative and not restrictive. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Abstract

Selon un mode de réalisation donné à titre d'exemple, un film stratifié comprend une première partie de film nervurée et extrudée qui comprend de multiples nervures, les nervures consécutives étant séparées par des réseaux qui font partie intégrante des nervures. Le film stratifié comprend aussi une seconde partie de film non nervurée et une région de stratification discontinue entre la première portion de film et la seconde portion de film. La région de stratification discontinue comprend de multiples régions où les première et seconde portions de film sont liées l'une à l'autre, et de multiples régions où les première et seconde portions de film ne sont pas liées l'une à l'autre.
PCT/US2014/028109 2013-03-15 2014-03-14 Structures de films stratifiés de façon discontinue dotées de caractéristiques visuelles améliorées WO2014143924A1 (fr)

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AU2014228052A AU2014228052B2 (en) 2013-03-15 2014-03-14 Discontinuously laminated film structures with improved visual characteristics
CN201480022422.7A CN105121151B (zh) 2013-03-15 2014-03-14 具有改进视觉特征的不连续层压膜结构
CA2903883A CA2903883C (fr) 2013-03-15 2014-03-14 Structures de films stratifies de facon discontinue dotees de caracteristiques visuelles ameliorees
HK16100266.9A HK1212299A1 (en) 2013-03-15 2016-01-12 Discontinuously laminated film structures with improved visual characteristics

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US20110117307A1 (en) * 2009-11-16 2011-05-19 The Glad Products Company Discontinuously Laminated Film
US20120134606A1 (en) * 2008-10-20 2012-05-31 Borchardt Michael G Non-Continuously Laminated Multi-Layered Bags With Ribbed Patterns And Methods of Forming The Same
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CN105121151A (zh) 2015-12-02
HK1212299A1 (en) 2016-06-10
CA2903883A1 (fr) 2014-09-18
AU2014228052B2 (en) 2017-09-28
AU2014228052A1 (en) 2015-09-17
CN105121151B (zh) 2017-06-27

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