Apparatus for making polymeric web exhibiting a soft and silky tactile impression

1. A method for making a polymeric web exhibiting a soft and silky tactile impression on at least one side thereof, the method comprising the steps of:

A. providing a forming drum comprising at least one vacuum chamber;

B. providing a forming structure, the forming structure being moveable upon the forming drum and comprising:

1) a plurality of forming structure interconnecting members that define a plurality of forming structure apertures, said forming structure apertures permitting fluid communication between opposing first and second surfaces of said forming structure;

2) a plurality of protrusions extending from said first surface of said forming structure; wherein said protrusions have an amplitude measured from said first surface of said forming structure to a distal end of said protrusion and are generally columnar forms having a substantially uniform circular cross-section along the amplitude, said protrusions having an average height of at least 50 microns and an average diameter between about 50 and 142 microns;

wherein said protrusions comprise a protrusion sidewall, wherein said protrusion sidewall is generally straight; and

wherein said protrusions have a center-to-center spacing of between about 100 microns and about 250 microns;

C. extruding a precursor web directly onto the forming structure;

D. moving the forming structure adjacent the vacuum chamber; and

E. applying vacuum at a sufficient level to induce a sufficient partial pressure to conform the precursor web to the forming structure, thereby forming the polymeric web exhibiting a soft and silky tactile impression on at least one side thereof, the polymeric web comprising hair-like fibrils having closed distal ends and an average aspect ratio of at least about 0.5.

2. The method of claim 1 , wherein the protrusions have an average diameter between about 50 microns and about 127 microns.

3. The method of claim 1 , wherein the protrusions have an average height of at least 50 microns and an average aspect ratio of at least 1.

4. The method of claim 1 , wherein the protrusions have an average height of at least 75 microns and an average aspect ratio of at least 1.5.

5. The method of claim 1 , wherein the protrusions have an average height of at least 100 microns and an average aspect ratio of at least 1.5.

6. The method of claim 1 , wherein the protrusions have an average height of at least 150 microns and an average aspect ratio of at least 2.

7. The method of claim 1 , wherein the forming structure first surface defines a first surface area and the forming structure comprises at least about 1550 protrusions per square centimeter of first surface area.

8. The method of claim 1 , wherein the forming structure first surface defines a first surface area and the forming structure comprises at least about 2325 protrusions per square centimeter of first surface area.

9. The method of claim 1 , wherein the forming structure first surface defines a first surface area and the forming structure comprises at least about 3100 protrusions per square centimeter of first surface area.

10. The method of claim 1 , wherein the forming structure first surface defines a first surface area and the forming structure comprises at least about 3875 protrusions per square centimeter of first surface area.

11. The method of claim 1 , wherein the forming structure is a cylindrical shaped rotatable drum.

12. The method of claim 1 , wherein the precursor web is a polymer film comprising a particulate filler.

13. The method of claim 1 , wherein the precursor web is a polymer film comprising a surfactant.

14. The method of claim 1 , wherein the precursor web is a co-extruded laminate.

15. A method for making a polymeric web exhibiting a soft and silky tactile impression on at least one side thereof, the method comprising the steps of:

A. providing a forming drum comprising at least one vacuum chamber;

B. providing a forming structure, the forming structure being moveable upon the forming drum and comprising:

1) a plurality of forming structure interconnecting members that define a plurality of forming structure apertures, said forming structure apertures permitting fluid communication between opposing first and second surfaces of said forming structure;

2) a plurality of protrusions extending from said first surface of said forming structure; wherein said protrusions have an amplitude measured from said first surface of said forming structure to a distal end of said protrusion and are generally columnar forms having a substantially uniform circular cross-section along the amplitude, said protrusions having an average height of at least 50 microns and an average diameter between about 50 and 142 microns;

wherein said protrusions comprise a protrusion sidewall, wherein said protrusion sidewall is generally straight; and

wherein said protrusions have a center-to-center spacing of between about 100 microns and about 250 microns;

C. extruding a precursor web directly onto the forming structure;

D. moving the forming structure adjacent the vacuum chamber;

E. applying vacuum at a sufficient level to induce a sufficient partial pressure to conform the precursor web to the forming structure,

F. providing a source of heat; and

G. annealing the precursor web by heating the precursor web;

thereby forming the polymeric web exhibiting a soft and silky tactile impression on at least one side thereof, the polymeric web comprising hair-like fibrils having closed distal ends and an average aspect ratio of at least about 0.5.

16. The method of claim 15 , wherein the protrusions have an average diameter between about 50 microns and about 127 microns.

17. The method of claim 15 , wherein the protrusions have an average height of at least 50 microns and an average aspect ratio of at least 1.

18. The method of claim 15 , wherein the forming structure first surface defines a first surface area and the forming structure comprises at least about 1550 protrusions per square centimeter of first surface area.

19. The method of claim 15 , wherein the precursor web is a polymer film comprising a surfactant.

20. The method of claim 15 , wherein the precursor web is a co-extruded laminate.