A laminate of thermoplastic film materials exhibiting throughgoing porosity and comprising plies A and B, A having an inner surface A1 partly in contact with B and an outer surface A2, and B having an inner surface BI partly in contact with A and an outer surface B2, A and B consisting of continuous
A laminate of thermoplastic film materials exhibiting throughgoing porosity and comprising plies A and B, A having an inner surface A1 partly in contact with B and an outer surface A2, and B having an inner surface BI partly in contact with A and an outer surface B2, A and B consisting of continuous material except for a multitude of perforations in each ply, whereby essentially no perforation in A corresponds directly to a perforation in B, the lamination between A and B on surfaces A1 and B1 being a) through a coextruded lower melting lamination layer on A and/or B and b) established in such discontinuous manner that there is formed a channel system between A1 and B1 connecting the majority of the perforations in A each with at least one of the perforations in B, and connecting the majority of the perforations in B each with at least one of the perforations in A is provided in addition to a process and apparatus for producing such a laminate.
대표청구항▼
1. A laminate of thermoplastic film materials exhibiting throughgoing porosity and comprising: plies A and B, the ply A having an inner surface A1 partly in contact with the ply B and an outer surface A2, andthe ply B having an inner surface B1 partly in contact with the ply A and an outer surface B
1. A laminate of thermoplastic film materials exhibiting throughgoing porosity and comprising: plies A and B, the ply A having an inner surface A1 partly in contact with the ply B and an outer surface A2, andthe ply B having an inner surface B1 partly in contact with the ply A and an outer surface B2,where the ply A and the ply B comprise continuous material except for a multitude of perforations in each ply, whereby substantially no perforation in the ply A corresponds directly to a perforation in the ply B,where the lamination between the ply A and the ply B on surfaces A1 and B1 being: a) through a coextruded lower melting lamination layer on the ply A and/or the ply B andb) established in such a discontinuous manner that there is formed a channel system between the surfaces A1 and B1 connecting a majority of the perforations in the ply A each with at least one of the perforations in the ply B, and connecting a majority of the perforations in the ply B each with at least one of the perforations in the ply A, andcharacterized in that each channel includes a barrier part having a gap as measured from the surface A1 to the surface B1 limited to about 200 μm or less, where the gap being formed by surface irregularities in the surface A1 and/or the surface B1 and where the surface irregularities comprise protruding thicker bosses and thinner receding portions, where the channels and the barrier parts withstand hydrostatic pressure and dynamic water pressure, but allow passage of vapor and air. 2. The method according to claim 1, wherein the surface A1 and the surface B1 are hydrophobic at least throughout the barrier parts. 3. The laminate according to claim 1, wherein over an area which forms the barrier part, the gap has an average size of no less then 3 μm. 4. The laminate according to claim 1, wherein either the ply A and/or the ply B in themselves are cross laminates, or both comprising oriented material each with a main direction of orientation, the two main directions of orientation crossing each other. 5. The laminate according to claim 1, wherein the surface irregularities in the barrier part are bosses created by impression in the ply A and/or the ply B. 6. The laminate according to claim 1, wherein the surface irregularities in the barrier portion are created by particulate material added to the ply A and/or the ply B. 7. The laminate according to claim 1, wherein the surface irregularities in the barrier part are in the form of meltfractures in the surface A1 and/or the surface B1. 8. The laminate according to claim 1, wherein the surface irregularities are in the form of randomly occurring stretching irregularities. 9. The laminate according to claim 1, wherein the surface irregularities comprising the protruding bosses and receding portions are constituted by segmentally stretched, narrow linearly extended receding portions of the ply A and/or the ply B, thereby creating narrow, linearly extending bosses. 10. The laminate according to claim 1, wherein there is a lamination layer on both the ply A and the ply B, each lamination layer being only present in a pattern comprising a linear array of stripes, the stripes on the ply A crossing the stripes on the ply B to form bonding only at spots where the two arrays intersect. 11. The laminate according to claim 10, wherein the bonding comprises spot-bonding or line-bonding established on and confined to all or some of the protruding bosses. 12. The laminate according to claim 11, wherein a distance between adjacent spot- or line-formed protruding bosses engaged in the bonding is no larger then about 1 mm. 13. The laminate according to claim 9, wherein in the ply with receding portions, the protruding bosses are uniaxially oriented substantially in their longitudinal direction, and the formation of the receding portions has been established by segmental stretching transverse to this direction. 14. The laminate according to claim 13, wherein both the plies A and B have receding portions, where the receding portions in the two plies criss-cross each other. 15. The laminate according to claim 13, wherein a division between the receding portions is no larger than about 0.3 to 0.4 mm. 16. The laminate according to claim 15, wherein a width of the receding portions is between about 0.05 to 0.2 mm. 17. The laminate according to claim 9, wherein the ply A is fluted with flutes defining channels which extend linearly in a longitudinal or a transverse direction, with the bases of the flutes bonded to a substantially flat ply B, whereby the flutes define channels which extend substantially in the longitudinal or the transverse direction of the laminate, a wavelength of the flutes being about 3 mm or less and a height of the flutes being about 0.3 mm or more, whereby the barrier parts of the channel formed connections are at the bases of the flutes where the ply A is bonded to the ply B, and are formed by segmentally stretched narrow, receding portions in the ply B which extend under an angle to the direction of the flutes. 18. The laminate according to claim 17, wherein the channels formed by the receding portions are hydrophobic as achieved by the choice of polymer materials, while at least a part of the channels formed by the flutes are hydrophilic either due to contents of a hydrophilic filling material in these channels or a hydrophilic coat on parts of the surface A1 which form walls of these channels. 19. The laminate according to claim 1, wherein at least one of the plies A or B has been impressed in the form of a pattern of parallel fine linear furrows. 20. The laminate according to claim 19, wherein both the plies A and B have such a pattern of impression on the surfaces which are bonded together, where the two patterns criss-cross each other. 21. The laminate according to claim 19, wherein a division of the pattern is about or lower than 10 μm. 22. The laminate according to claim 1, further comprising: a ply C added on the surface A2 of the ply A,where the ply C similarly being supplied with a big multitude of perforations which are offset relative to the perforations in the ply A and that similarly connecting channels between the two series of perforations are formed at the interphase, each such connection comprising a barrier part. 23. The laminate according to claim 22, further comprising: a ply D added on the surface B2 of the ply B,where the ply D similarly being supplied with a big multitude of perforations which are offset relative to the perforations in the ply B and that similarly connecting channels between the two series of perforations are formed at the interphase, each such connection comprising a barrier part. 24. The laminate according to claim 1, wherein the surfaces A1 and B1 comprise polyethylene at least where they form the barrier part of the connections. 25. The laminate according to claim 1, wherein a size of the holes formed by the perforations is about 0.1 to 0.4 mm and a distance between neighboring holes in one and the same ply is about 0.5 to 5 mm. 26. The laminate according to claim 1, wherein the perforations are surrounded by material which is substantially unoriented and thicker than the immediately adjacent material, achieved by perforating with local melting. 27. The laminate according to claim 14, wherein the perforations in the two piles A and B form a regular pattern, and the directions of the criss crossing arrays of receding portions have been coordinated with this pattern in such way that substantially no single thin portion in the ply B leads from any perforation in the ply A to any perforation in the ply B. 28. The laminate according to claim 27, wherein the receding portions in both the plies A and B are bent towards the surface of the laminate which also is a surface of the ply B, this bent shape preferably being a stabilized shape. 29. The laminate according to claim 14, wherein each of the plies A and B comprises a regular pattern of parallel linear regions, which are without receding portions, and have a width at least 10 times an average width of the receding portions. 30. A process for forming a laminate of thermoplastic films exhibiting throughgoing porosity, in which a ply A having a surface A1 is brought into contact with a ply B having a surface B1, with the surface A1 is in contact with the surface B1, and the ply A is laminated to the ply B comprising the steps of: perforating the ply A and the ply B,registering the ply A and the ply B in such a manner that substantially no perforation in the ply A corresponds to a perforation in the ply B,heating and partially melting a co-extruded lower melting lamination layer on the ply A and/or the ply B, while the surface A1 and the surface B1 are in contact to form a lamination between the plies A and B, where the lamination between the ply A and the ply B is established in a discontinuous manner such that a channel system is formed between the surface A1 and the surface B1 connecting a majority of the perforations in the ply A each with at least one of the perforations in the ply B via channels and such that a majority of the perforations in the ply B is connected with at least one of the perforations in the ply A via the channels, andproviding the surface A1 and/or the surface B1 with surface irregularities forming protruding thicker bosses and adjacent thinner receding portions whereby at least, in a barrier part of the laminate, there is formed a gap between the surface A1 and the surface B1 which is limited to about 200 μm or less. 31. The process according to claim 30, wherein both the surfaces A1 and B1 are provided with surface irregularities forming protruding bosses and adjacent receding portions. 32. The process according to claim 30, wherein one of the plies A or B is provided with such surface irregularities forming protruding bosses and adjacent receding portions and the other ply has no such surface irregularities. 33. The process according to claim 30, wherein the gap is formed by the adhesion of the surface A1 to the surface B1 by at least some of the bosses forming the surface irregularities, whereby the receding material adjacent to the bosses is not adhered to the opposite surface and forms part of the channel system. 34. The process according to claim 30, wherein surface A1 and surface B1 are hydrophobic at least throughout the barrier part and comprise polyethylene. 35. The process according to claim 30, wherein the plies A and B are perforated together and then mutually displaced in a longitudinal or transverse direction to form the channel system and are laminated together, all in line. 36. The process according to claim 30, wherein either the plies A and/or B in themselves are cross laminates, or both comprise oriented material each with a main direction of orientation, the two main directions of orientation crossing each other. 37. The process according to claim 30, wherein the perforation is carried out by use of needles or needle like items mounted on a roller. 38. The process according to claim 37, wherein the needles or needle like items are heated to perform the perforation under local melting of the film material. 39. The process according to claim 38, wherein perforation is carried out by using serrations on blades mounted around the circumference of a heated roller. 40. The process according to claim 39, wherein the serrations have a cross section of about 0.2 mm by 0.2 mm. 41. The process according to claim 30, further comprising the step of: forming the bosses in the ply A and/or the ply B by forming spotwise impressions in the ply A or the ply B as the case may be using pressure between rollers with patterned surfaces such as to make one side of the ply recede and make the other side protrude in the spots. 42. The process according to claim 30, wherein the surface irregularities in the surfaces A1 and/or B1 are created in the coextrusion process by creating pronounced melt fracture. 43. The process according to claim 30, wherein the surface irregularities in the surface A1 and/or B1 are created in the coextrusion process by addition to the lamination layer of a suitable particulate material. 44. The process according to claim 30, wherein the orientation is carried out in the plies A and/or B under conditions to make this orientation spontaneously occur spotwise or linewise, thereby creating the bosses and the receding portions, or if they already are formed in the coextrusion process, making the surface irregularities deeper. 45. The process according to claim 30, wherein the receding portions in the plies A and/or B are produced by segmental stretching, between intermeshing grooved rollers, to make the bosses and the receding portions extend linearly. 46. The process according to claim 45, further comprising the step of: prior or subsequently to the segmental stretching, stretching the ply in solid state to give at least the bosses a main direction of orientation substantially parallel with their longitudinal direction. 47. The process according to claim 45, wherein the segmental stretching is carried out by means of grooved rollers which have circular cogs to make the bosses and receding portions extend in the machine direction. 48. The process according to claim 45, wherein the segmental stretching is carried out by means of grooved rollers which have axially extending cogs to make the bosses and receding portions extend perpendicularly to the machine direction. 49. The process according to claim 45, wherein the segmental stretching is carried out by means of helically extending cogs to form the bosses and receding portions under an angle lower than 90° to the machine direction. 50. The process according to claim 47, wherein the crests of each cog has two edges of a sharpness adapted so that each cog forms two receding portions in the ply. 51. The process according to claim 50, wherein the crest has a concave shape when viewed in cross-section. 52. The process according to claim 47, wherein each ply A and B is extruded in the form of a tubular film, after solidification is segmentally stretched in form of a lay-flat tubular film to form bosses and receding portions which at least essentially are parallel with the machine direction, subsequently is helically cut to form a new machine direction under an angle to the linearly extending bosses and receding portions, and after these steps the two plies are subjected to the perforation and lamination, thereby the plies are arranged such that the direction of the bosses cross each other. 53. The process according to claim 52, wherein the segmental stretching is carried out with grooved rollers on which there are intervals of missing cogs, to obtain a stretching result in which there occurs a regular pattern of parallel linear regions, which are without receding portions and have a width at least 10 times the average width of the receding portions. 54. The process according to claim 52, wherein the perforations in the two plies A and B are formed in a regular pattern, and the directions of the criss crossing arrays of receding portions are coordinated with this pattern in such way that essentially no single receding portion in the ply B leads from any perforation in the ply A to any perforation in the ply B. 55. The process according to claim 54, where a fluid under pressure, preferably air, is passed through the laminate from the ply A side to the ply B side to bend the receding portions in both plies in the direction of this flow, whereby preferably the fluid has an elevated temperature suitable for stabilization of the bent shape of the receding portions. 56. The process according to claim 42, wherein the lamination layer is on both the plies A and B, each lamination layer being only present in a pattern consisting of a linear array of stripes, the stripes on the ply A crossing the stripes on the ply B to form bonding only at the spots where the two arrays intersect. 57. The process according to claim 30, wherein the ply A is supplied with flutes which extend linearly in the longitudinal or transverse direction, and the bases of the flutes is bonded to a generally flat ply B, whereby the flutes define channels which extend substantially in a longitudinal or a transverse direction of the laminate, a wavelength of the flutes being about 3 mm or less and a height of the flutes being about 0.3 mm or more, whereby the barrier parts of the channel formed connections are at the bases of the flutes where the ply A is bonded to the ply B the gap of this barrier part being formed by segmental stretching of the ply B to form linear receding portions which in the laminate extend under an angle to the direction of the flutes. 58. The laminate according to claim 3, wherein the gap has an average size of no less then 5 μm. 59. The laminate according to claim 3, wherein the gap has an average size of no less then 10 μm. 60. The laminate according to claim 6, wherein the added particulate material is disposed in a coextruded surface layer forming the surface A1 and/or the surface B1. 61. The laminate according to claim 8, wherein the stretching irregularities comprise type occurring in stiff polymers at low stretching ratios and low stretching temperatures. 62. The laminate according to claim 12, wherein the distance is no larger than about 0.5 mm. 63. The laminate according to claim 12, wherein the distance is no larger than about 0.1 to 0.2 mm. 64. The laminate according to claim 15, wherein the division between the receding portions is no larger than about 0.2 mm. 65. The laminate according to claim 19, wherein the ply is oriented in substantially an uniaxial manner substantially parallel with these furrows. 66. The laminate according to claim 25, wherein the size of the holes is about 0.1 to 0.4 mm and the distance between neighboring holes is about 1 to 3 mm. 67. The laminate according to claim 25, the size of the holes is between about 0.2 to 0.3 mm and the distance between neighboring holes is about 0.5 to 5 mm. 68. The laminate according to claim 25, wherein the size of the holes is about 0.2 to 0.3 mm and the distance between neighboring holes is about 1 to 3 mm. 69. The laminate according to claim 28, wherein the bent shape is a stabilized shape. 70. The process according to claim 38, wherein perforation is carried out by using serrations on blades mounted around the circumference of a heated roller.
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