A system for producing a multiple layer material (49), comprising first and second corrugation rolls (14, 15) for providing a corrugated profile (16) having a plurality of crests (47), wherein the system further comprises first and second press rolls (21, 22) for applying a material sheet (19, 20) to crests (47) of the corrugated profile (16), and a plurality of heating members (28) arranged between the press rolls (21, 22) for welding the material sheet (19, 20) to the crests (47) of the corrugated profile (16) to form the multiple layer material (49). A guiding plate (48) is arranged between the corrugation 10 rolls (14, 15) and the heating members (28). The guiding plate (16) is arranged with a profile engaging side (50) having a plurality of crests (52) corresponding to the crests (47) of the corrugated profile (16). A cooling arrangement is provided for cooling the guiding plate (48). A method for producing the multiple layer material (49) is also disclosed.

A thermoplastic bag may include a sidewall that may have a plurality of first and second ribs formed therein. The first ribs may be longer in length but shorter in height than the second ribs. The second ribs may be arranged in discrete networks that appear superimposed over the first ribs. The second ribs may normally remain in a bent-over configuration. When a force is applied, the second ribs may expand the area of the sidewall so that the bag may easily accommodate large objects. To produce the bag, a thermoplastic web may be directed between opposing first and second rollers. One of the rollers may include ridges that may have first and second segments of differing heights that correspond to the differing heights of the first and second ribs. The formation of the first ribs may increase the width of the web.

A thermoplastic bag may include a sidewall that may have a plurality of first and second ribs formed therein. The first ribs may be longer in length but shorter in height than the second ribs. The second ribs may be arranged in discrete networks that appear superimposed over the first ribs. The second ribs may normally remain in a bent-over configuration. When a force is applied, the second ribs may expand the area of the sidewall so that the bag may easily accommodate large objects. To produce the bag, a thermoplastic web may be directed between opposing first and second rollers. One of the rollers may include ridges that may have first and second segments of differing heights that correspond to the differing heights of the first and second ribs. The formation of the first ribs may increase the width of the web.

A method and apparatus for pleating or otherwise shaping a web are described herein. The method and apparatus may have numerous applications. In some embodiments, the method and apparatus are used in the formation, filling, and sealing of unit dose packages for consumer products. A method and apparatus for forming sealing two moving webs together, which webs have portions that are non-planar are also described herein.

A method and apparatus for pleating or otherwise shaping a web are described herein. The method and apparatus may have numerous applications. In some embodiments, the method and apparatus are used in the formation, filling, and sealing of unit dose packages for consumer products. A method and apparatus for forming sealing two moving webs together, which webs have portions that are non-planar are also described herein.

An apparatus is provided for producing longitudinally corrugated product. The apparatus includes a guide roll for guiding a web of medium material, wherein at least a portion of the guide roll is adapted to be arranged at an angle relative to another portion of the guide roll. The apparatus further includes a plurality of flute forming bars oriented generally along a longitudinal axis of the web to define a first corrugating labyrinth effective to longitudinally corrugate the web to an intermediate geometry. The apparatus further includes a pair of corrugating rollers that cooperate to define, at a nip therebetween, a second corrugating labyrinth effective to longitudinally corrugate the web to a substantially final geometry. The apparatus further includes a web travel pathway for the web that follows a path around a portion of the guide roll, through the first corrugating labyrinth, and through the second corrugating labyrinth.

A method of forming a continuous sheet of pleated, hook-form, fastener product includes training a substrate about a pressure roll having an outer surface defining circumferential grooves. As the substrate approaches a nip between the pressure roll and a mold roll calendered with the pressure roll, a portion of the substrate is disposed within a corresponding one of the grooves between the pressure roll and a stationary horn extending into the groove whereby a longitudinally-extending pleat is formed in the substrate. The pleated substrate is then passed through the nip where resin regions are laminated to a side of the substrate opposed to the pleat.

An apparatus is provided for producing longitudinally corrugated product. The apparatus includes a guide roll for guiding a web of medium material, wherein at least a portion of the guide roll is adapted to be arranged at an angle relative to another portion of the guide roll. The apparatus further includes a plurality of flute forming bars oriented generally along a longitudinal axis of the web to define a first corrugating labyrinth effective to longitudinally corrugate the web to an intermediate geometry. The apparatus further includes a pair of corrugating rollers that cooperate to define, at a nip therebetween, a second corrugating labyrinth effective to longitudinally corrugate the web to a substantially final geometry. The apparatus further includes a web travel pathway for the web that follows a path around a portion of the guide roll, through the first corrugating labyrinth, and through the second corrugating labyrinth.

An apparatus is provided for producing longitudinally corrugated product. The apparatus includes a guide roll for guiding a web of medium material, wherein at least a portion of the guide roll is adapted to be arranged at an angle relative to another portion of the guide roll. The apparatus further includes a plurality of flute forming bars oriented generally along a longitudinal axis of the web to define a first corrugating labyrinth effective to longitudinally corrugate the web to an intermediate geometry. The apparatus further includes a pair of corrugating rollers that cooperate to define, at a nip therebetween, a second corrugating labyrinth effective to longitudinally corrugate the web to a substantially final geometry. The apparatus further includes a web travel pathway for the web that follows a path around a portion of the guide roll, through the first corrugating labyrinth, and through the second corrugating labyrinth.

A method of forming a continuous sheet of pleated, hook-form, fastener product includes training a substrate about a pressure roll having an outer surface defining circumferential grooves. As the substrate approaches a nip between the pressure roll and a mold roll calendered with the pressure roll, a portion of the substrate is disposed within a corresponding one of the grooves between the pressure roll and a stationary horn extending into the groove whereby a longitudinally-extending pleat is formed in the substrate. The pleated substrate is then passed through the nip where resin regions are laminated to a side of the substrate opposed to the pleat.