Process and apparatus for forming a continuous web, particularly polymeric film, and material produced by the process

The present invention provides for a process for transforming a substantially continuous web of substantially planar, deformable material having an indefinite length, a first surface, and a second surface into a formed material. The material has a transofrmation temperature range. The process comprises the following steps:(a) The web of material is provided on a forming structure with the first surface of the web of material proximate a forming surface of the forming structure. The forming surface moves in a direction of the length of the web of material and carries the web of material in that direction.(b) A liquid stream is applied to the second surface of the web of material. The liquid stream has sufficient force and mass flux to cause the web of material to be deformed toward the forming surface, such that the material acquires a substantial three-dimensional conformation.(c) The temperature of the web of material is controlled such that it remains below the transformation temperature range of the material throughout the process.