Method and Apparatus for Making an Apertured Web

Abstract

A method for making apertures in a web comprising providing a precursor web material; providing a pair of counter-rotating, intermeshing rollers, wherein a first roller comprises circumferentially-extending ridges and grooves, and a second roller comprises teeth being tapered from a base and a tip, the teeth being joined to the second roller at the base, the base of the tooth having a cross-sectional length dimension greater than a cross-sectional width dimension; and moving the web material through a nip of the counter-rotating, intermeshing rollers; wherein apertures are formed in the precursor web material as the teeth on one of the rollers intermesh with grooves on the other of the rollers.

What is claimed is: 
     
         1 . A method for making apertures in a web, said method comprising,
 a. providing a precursor web material;   b. providing a pair of counter-rotating, intermeshing rolls comprising:
 i. a generally cylindrical first roll, said first roll having a surface, a circumference, and a first axis, said first roll comprising a plurality of circumferentially-extending ridges and grooves; and 
 ii. a generally cylindrical second roll, said second roll having a surface, a circumference, and a second axis, said second roll comprising teeth being tapered from a base and a tip, said teeth being joined to said second roll at said base, said base of said tooth having a cross-sectional length dimension greater than a cross-sectional width dimension wherein the teeth on the second roll are arranged in circumferentially extending rows comprising at least a first row of teeth and an adjacent row of teeth separated by a groove therebetween, and the spaced apart teeth in the first row are staggered relative to the teeth in the adjacent row wherein the teeth in the adjacent row at least partially align with the spaces between the teeth in the first row when viewed looking in the direction of the axis of the second roll; and 
   c. moving said web material through a nip of said counter-rotating, intermeshing rolls;   d. wherein apertures are formed in said precursor web material as said teeth on said second roll intermesh with grooves on the first roll.   
     
     
         2 . The method of  claim 1 , wherein said web material is selected from the group consisting of a polymer film, a nonwoven web, and laminates thereof.