Deformed Web Structures With Nested-Roll Registration Control
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Solution Overview
Problem
Current methods and apparatuses for deforming webs lack the ability to create structures with dual or multiple properties in specific portions of the web, such as improved softness or fluid handling, and struggle with maintaining control over deformation registration, especially when deforming multiple times, and have limitations in footprint size on the manufacturing floor.
Innovation Solution
The development of apparatuses and methods that use intermeshing rolls to deform webs in a single or multiple nips, allowing for discrete deformations such as apertures and protrusions on both sides of the web, with features that can be intermixed and closely spaced, using configurations like nested rolls to maintain web contact and control deformation alignment across multiple deformation steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional web deformation methods are used, then the web can be deformed with basic structures, but the web cannot achieve dual or multiple properties (such as improved softness and fluid handling) in specific portions
Solution Approach 1:
The patent applies local quality by creating different deformation features (apertures, protrusions, depressions) in specific portions of the web to provide localized dual or multiple properties. The deformation apparatus forms different types of features in different regions of the web, allowing each portion to have tailored properties such as improved softness in one area and fluid handling in another area.
Solution Approach 2:
The patent segments the deformation process into multiple steps using a series of deformation rolls, each capable of forming different types of features. The web passes through multiple nips between rolls, with each nip creating specific deformation patterns. This segmentation allows precise control over where and what type of deformations are formed, enabling dual or multiple properties in specific web portions.
2Manufacturing precision
If the web is deformed multiple times to create complex structures, then the web can achieve enhanced properties, but control over the registration of deformations becomes difficult
Solution Approach 1:
The patent employs a nested roll configuration where multiple deformation rolls are arranged in a compact nested arrangement. The rolls are positioned such that they share common axes or are closely spaced, creating multiple nips in a limited space. This nesting allows the web to pass through multiple deformation zones while maintaining precise registration control, as each roll's deformation is registered relative to the others through their geometric relationships.
Solution Approach 2:
The patent merges multiple deformation functions into a single integrated apparatus. Multiple rolls with different deformation capabilities are combined in one apparatus, allowing the web to receive multiple deformations in sequence. The rolls are synchronized and positioned to work together, combining their individual deformation functions to create complex web structures with precise registration control.
3Manufacturing precision
If multiple rolls are used to deform the web multiple times, then tighter spacing and controlled registration can be achieved, but the apparatus footprint on the manufacturing floor increases
Solution Approach 1:
The nested roll arrangement places multiple rolls in a compact configuration where they share space efficiently. Rolls are positioned with their axes close together or in overlapping arrangements, allowing multiple deformation nips to occur in a small footprint area. This nesting dramatically reduces the apparatus's floor space requirement while maintaining the ability to perform multiple deformations with tight spacing and precise registration control.
Data Source
AI summary
Deformed web materials are disclosed. The web materials have discrete deformations formed therein. The deformations may be features in the form of portions of a web with apertures therein, protrusions, depressed areas, and combinations thereof. These features may extend out from the surface on one side of the web, or from both of the surfaces of the web. Different features may be intermixed with one another.