Breathable Web Welding Protrusions and Peeling Roller
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing elastic webs for disposable absorbent sanitary products do not adequately address the need for improved breathability in the waist regions, which affects the comfort and performance of these products.
Innovation Solution
A method and apparatus using an ultrasonic or thermo-mechanical welding process with an anvil roller and sonotrode or heated welding roller to create a breathable composite web by forming welding points with protrusions and a peeling roller to remove thin membranes, resulting in through-holes and enhanced breathability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding points are formed to join layers together, then structural integrity is improved, but breathability deteriorates
Solution Approach 1:
The welding protrusions are designed with central through-holes that extend through the entire thickness of the web. This allows the welding points to maintain structural integrity by joining the layers while simultaneously providing breathability through the porous structure of the welding points themselves, directly resolving the contradiction between strength and breathability.
Solution Approach 2:
The welding element is divided into multiple discrete protrusions distributed across its surface, each forming an individual welding point with a through-hole. This segmentation allows the web to have both welded areas for strength and open areas for breathability, preventing the complete blockage of air flow that would occur with continuous welding.
2Strength
If a continuous elastic film is applied between non-woven layers, then adhesion and comfort are improved, but breathability deteriorates
Solution Approach 1:
The elastic film is transformed from a continuous impermeable layer to a porous structure through the formation of through-holes at each welding point. The protrusions penetrate the elastic film and create channels for air flow, allowing the film to maintain its adhesive function while enabling breathability through its modified porous structure.
Solution Approach 2:
The web becomes a composite structure consisting of non-woven layers and an elastic film with integrated porous welding points. This composite design combines the adhesive properties of the elastic film with the breathability provided by the through-holes in the welding protrusions, achieving both adhesion and comfort without sacrificing breathability.
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 achieves improved breathability by creating through-holes and porous areas within the web, enhancing airflow and comfort in disposable absorbent sanitary products.
Implementation Method 1
WO 2017/037617 A1 discloses a method for producing a breathable web, comprising: feeding a web on the surface of an anvil roller rotatable about its axis and having a plurality of welding protrusions cooperating with a welding element, welding said web at a plurality of welding spots on head surfaces of said welding protrusions
Implementation Method 2
A method and apparatus using an ultrasonic or thermo-mechanical welding process with an anvil roller and sonotrode or heated welding roller to create a breathable composite web
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
A method for producing a breathable web (W), comprising: - feeding a web (W) on the surface of an anvil roller (16) rotatable about its axis (A) and having a plurality of welding protrusions (20) cooperating with a welding element (18), - welding said web (W) at a plurality of welding spots (44) on head surfaces (22) of said welding protrusions (20) and forming respective annular welding seams (46) at said welding spots (44), about respective welding projections (20), and respective thin membranes (48) located within said annular welding seams (46) and adjacent to the head surfaces (22) of said welding protrusions (20), and - removing said thin membranes (48) after said welding by means of a peeling roller (36) having an outer surface tangent to said head surfaces (22) of said welding protrusions (20).