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Method for constructing a three-dimensional film forming structure for imparting a selectively apertured three-dimensional pattern to a heated plastic material which is either fed in film form from a supply roll or extruded as a melt directly onto the surface of the forming structure and subjected t

Method for constructing a three-dimensional film forming structure for imparting a selectively apertured three-dimensional pattern to a heated plastic material which is either fed in film form from a supply roll or extruded as a melt directly onto the surface of the forming structure and subjected to a fluid pressure differential while in contact with its surface. The completed structure comprises a stacked laminate of initially imperforate planar sheets having continuous patterns of apertures formed therein and at least one initially perforate selectively apertured planar sheet located beneath the uppermost continuously apertured sheet. The apertures formed in the initially perforate selectively apertured sheet coincide with the portions of the plastic web to be apertured. The completed laminate forming structure is preferably tubular in shape so as to facilitate continuous plastic web processing against its outermost surface.

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A method for constructing a three-dimensional forming structure for imparting a substantially continuous three-dimensional pattern of debossments, a predetermined portion of said debossments being apertured at preselected points along the surface of a heated plastic web subjected to a fluid pressure

A method for constructing a three-dimensional forming structure for imparting a substantially continuous three-dimensional pattern of debossments, a predetermined portion of said debossments being apertured at preselected points along the surface of a heated plastic web subjected to a fluid pressure differential while in contact with the surface of said forming structure, said method comprising the steps of: (a) forming at least one continuously apertured planar sheet exhibiting a first substantially continuous pattern of apertures corresponding to the debossments to be imparted to said web; (b) forming a second selectively apertured planar sheet having an overall size and shape generally similar to said continuously apertured planar sheet, said selectively apertured planar sheet exhibiting a second pattern of apertures corresponding to the portions of said web to be debossed and apertured and a third pattern of smaller sized apertures corresponding to those portions of said web to be debossed without aperturing; and (c) superposing said continuously apertured planar sheet on said selectively apertured planar sheet so that at least a portion of said apertures in said second and third patterns in said selectively apertured planar sheet are placed in fluid communication with said apertures in said continuously apertured planar sheet, whereby those portions of said selectively apertured planar sheet exhibiting said third pattern of fluid communicating apertures contact and provide support to said heated plastic web when said web is subjected to said fluid pressure differential, thereby preventing rupture of said web at said points of contact, while those portions of said selectively apertured planar sheet exhibiting said second pattern of fluid communicating apertures provide no support to said heated plastic web when said web is subjected to said fluid pressure differential, thereby permitting rupture of said web in areas coinciding with said second pattern of fluid communicating apertures. A three-dimensional forming structure for imparting a substantially continuous three-dimensional pattern of debossments, a predetermined portion of said debossments being apertured at preselected points along the surface of a heated plastic web subjected to a fluid pressure differential while in contact with the surface of said forming structure, said forming structure comprising: (a) at least one continuously apertured planar sheet exhibiting a first substantially continuous pattern of apertures corresponding to the debossments to be imparted to said web; and (b) a second selectively apertured planar sheet having an overall size and shape generally similar to said continuously apertured planar sheet, said selectively apertured planar sheet exhibiting a second pattern of apertures corresponding to the portions of said web to be debossed and apertured and a third pattern of smaller sized apertures corresponding to those portions of said web to be debossed without aperturing, said continuously apertured planar sheet being superposed on said selectively apertured planar sheet so that at least a portion of said apertures in said second and third patterns in said selectively apertured planar sheet are placed in fluid communication with said apertures in said continuously apertured planar sheet, whereby those portions of said selectively apertured planar sheet exhibiting said third pattern of fluid communicating apertures contact and provide support to said heated plastic web when said web is subjected to said fluid pressure differential, thereby preventing rupture of said web at said points of contact, while those portions of said selectively apertured planar sheet exhibiting said second pattern of fluid communicating apertures provide no support to said heated plastic web when said web is subjected to said fluid pressure differential, thereby permitting rupture of said web in areas corresponding with said second pattern of fluid communicating apertures.