Apertured Web Embossing via Interlocking Roller Geometry
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Solution Overview
Problem
Current methods for producing three-dimensional apertured webs, such as those used in disposable absorbent articles, are energy-intensive and costly, requiring separate processes like vacuum or hydroforming, which can diminish the web's original three-dimensionality and are not suitable for direct integration into manufacturing lines.
Innovation Solution
A method using counter-rotating, intermeshing rollers with circumferentially-extending ridges and tapered teeth to form apertures in precursor web materials, eliminating the need for energy-intensive processes and allowing for in-line production of apertured webs with preserved three-dimensionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum or hydroforming methods are used to make three-dimensional apertured webs, then the webs achieve improved functionality with stand-off between user body and absorbent core, but the process becomes energy-intensive and costly
Solution Approach 1:
The patent replaces vacuum or hydroforming mechanical systems with a simpler mechanical embossing system using patterned rollers. The rollers physically emboss the three-dimensional aperture pattern directly into the web material through mechanical pressure, eliminating the need for vacuum chambers or fluid pressure systems while achieving the same functional result of creating stand-off apertures
Solution Approach 2:
The patent changes the physical state and parameters of the web material by controlling temperature and pressure during the embossing process. By heating the web to a temperature where the material becomes more compliant and then applying controlled pressure through the patterned rollers, the three-dimensional pattern is formed with less energy than vacuum or hydroforming methods
2Reliability
If vacuum or hydroforming methods are used to make three-dimensional apertured webs, then the webs achieve improved functionality, but the process requires separate manufacturing steps that are not suitable for direct integration into manufacturing lines
Solution Approach 1:
The patent merges the aperture formation process with the existing web manufacturing line by using patterned rollers that can be integrated directly into the production flow. The embossing process occurs in-line as the web is being produced, eliminating separate vacuum or hydroforming steps and reducing overall manufacturing complexity
Solution Approach 2:
The patent extracts the aperture formation function from complex vacuum or hydroforming systems and implements it through simple patterned rollers. This extraction simplifies the manufacturing process by removing unnecessary equipment while maintaining the essential function of creating three-dimensional apertures
3Reliability
If vacuum or hydroforming methods are used to make three-dimensional apertured webs, then the webs achieve improved functionality, but the process requires capital expenditures for specialized equipment
Solution Approach 1:
The patent uses relatively simple, inexpensive patterned rollers instead of expensive vacuum or hydroforming equipment. The rollers are straightforward mechanical components that can be manufactured at low cost and replaced if needed, dramatically reducing capital expenditures while maintaining the ability to produce functional three-dimensional apertured webs
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces production costs and energy consumption while maintaining the web's three-dimensional structure, enabling direct integration into disposable article manufacturing lines without the need for vacuum or fluid pressure, thus enhancing the functionality and efficiency of apertured webs.
Implementation Method 1
a first roller comprises circumferentially-extending ridges and grooves, and a second roller comprises teeth being tapered from a base and a tip... 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
Data Source
AI summary
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.