Apertured Web Formation via Staggered Intermeshing Rolls
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Solution Overview
Problem
Existing methods for forming macroscopic apertures in micro-textured webs face challenges in fluid drainage due to trapped fluid in flat areas and the fragility of discrete extended elements, which can become stiff and abrasive when heated, compromising the softness of final products like absorbent articles.
Innovation Solution
A method and apparatus for forming macroscopic apertures in micro-textured webs using intermeshing rolls with specific tooth configurations that create quadrilateral apertures, maintaining the softness and integrity of discrete extended elements by controlling heat-induced damage through a gap clearance mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hot roll is used to create apertures by mechanical deformation, then apertures are formed in the web, but the heat from the hot roll melts parts of the discrete extended elements and imparts permanent deformation, or hardens parts resulting in plastic and abrasive feels
Solution Approach 1:
The web is pre-heated to a temperature below the melting point of the discrete extended elements before entering the nip roll. This preliminary heating softens the web matrix to facilitate aperture formation while preventing damage to the discrete extended elements by avoiding excessive heat exposure during the deformation process
Solution Approach 2:
The invention changes the temperature parameter by using a pre-heating step at controlled temperatures that soften the web without reaching the melting point of the discrete extended elements. This parameter optimization allows mechanical deformation to occur while preserving the integrity and softness of the extended elements
2Object-affected harmful factors
If discrete extended elements are used for micro-texturing, then desirable softness and tactile impression are achieved, but fluid is trapped in valleys among the discrete extended elements, compromising fluid drainage
Solution Approach 1:
The invention transitions from a two-dimensional flat web structure to a three-dimensional structure by forming macro-apertures that extend through the web thickness. This dimensional change creates through-drainage pathways that allow fluid to bypass the valleys between discrete extended elements, enabling both softness retention and improved fluid drainage
3Ease of manufacture
If the web is heated to facilitate mechanical deformation, then apertures can be formed, but the heat hardens parts of the discrete extended elements making them stiff and abrasive
Solution Approach 1:
The invention optimizes the temperature parameter by pre-heating the web to a specific temperature range that provides sufficient softness for mechanical deformation while remaining below the threshold that would harden or damage the discrete extended elements. This precise parameter control enables ease of manufacture while preserving product softness
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
The solution enhances fluid drainage and preserves the softness of the web, providing improved tactile impressions and reducing plastic and abrasive feels, making the web suitable for absorbent articles and other applications.
Implementation Method 1
the teeth urge material out of a plane of the precursor web to form a plurality of permanent three-dimensional macroscopic apertures
Implementation Method 2
The precursor web is heated to a temperature sufficient to soften the precursor web, but below a melting point of the discrete extended elements
Data Source
Figure 1~2
Figure 3
Figure 4A~4B
AI summary
A method for making an aperture web, comprising moving a micro-textured web through a first member comprising male elements and a second member comprising discontinuous female elements, wherein the male elements are arranged in a staggered pattern, and have a shape to form quadrilateral apertures in the micro-textured web. A method for making an aperture web, comprising forming microtextures on a web, and continuously moving the web through a first member comprising male elements and a second member comprising discontinuous female elements, wherein the male elements are arranged in a staggered pattern, and have a shape to form quadrilateral apertures in the micro-textured web.