Embossing Process with Discrete and Linear Elements

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Solution Overview

Problem

Deep-nested embossing processes often result in webs that lose strength and softness, and can tear or appear rough and stiff, detracting from the product's aesthetic appeal.

Innovation Solution

An apparatus and method involving a first embossing member with discrete embossing elements and a second embossing member with linear embossing elements, where the patterns are coordinated to nest together to a depth of greater than 0.01 mm, enhancing the embossed web's strength, softness, and aesthetics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If deep-nested embossing is performed to enhance web bulk and aesthetic appearance, then the web exhibits improved thickness and quilted appearance, but the web loses strength and softness, and can tear or appear rough and stiff

Engineering Contradiction:

Improvequilted appearance and thicknessVSAvoidweb strength and softness

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The embossing elements are designed with varying depths, where the distal ends of opposing embossing elements are positioned at different depths from the roll surfaces. This creates localized variation in embossing intensity, providing sufficient depth for aesthetic appearance while avoiding excessive compression that would damage web strength and softness.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The embossing process applies compression to a degree that achieves the desired quilted appearance and thickness enhancement, but deliberately limits the compression depth to prevent excessive action that would cause web tearing, stiffness, or loss of softness. The differential depth positioning ensures partial embossing action at critical locations.

Inventive Principle:

Principle #16Partial or excessive action

2Shape

If embossing elements are positioned to achieve deep nesting for enhanced aesthetic appearance, then the quilted pattern is improved, but the web may tear or appear rough and stiff

Engineering Contradiction:

Improveaesthetic pattern and quilted appearanceVSAvoidweb tearing and roughness

Core Design Contradiction:

ShapeVSObject-affected harmful factors

Solution Approach 1:

By positioning distal ends of opposing embossing elements at different depths, the design creates localized zones of varying embossing intensity. This prevents uniform deep compression across all embossing sites, thereby avoiding web tearing and rough appearance while maintaining aesthetic quilted patterns in appropriate areas.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The differential depth positioning of embossing elements serves as a preventive measure, cushioning against the harmful effects of excessive compression before they occur. This design inherently protects the web from tearing and stiffness by ensuring that no single embossing site undergoes excessive nesting depth.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Stability of the object's composition

If nested embossing is performed to maintain web bulk throughout converting and packaging, then the quilted appearance is preserved, but the embossing process may still cause web damage

Engineering Contradiction:

Improvebulk maintenance throughout processingVSAvoidweb integrity during embossing

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The varying depth positioning of embossing elements creates a pattern where some locations provide bulk support while others minimize compression. This local differentiation maintains overall web bulk stability throughout converting and packaging operations while preserving web integrity by avoiding excessive compression at any single point.

Inventive Principle:

Principle #3Local quality

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 provides a deep-nested embossed product with improved strength, softness, and aesthetics, reducing web damage and enhancing the embossing process's reliability, resulting in a more aesthetically pleasing and durable product.

Implementation Method 1

Embossing elements on the rolls compress and/or deform the web

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

The embossed regions of the plies may produce an aesthetic pattern and provide a means for joining and maintaining the plies in face-to-face contacting relationship

Methodology Applied

Scientific EffectMechanical interlocking: Mechanical Fastener

Data Source

PatentUS7435316B2Embossing process including discrete and linear embossing elements

Publication Date: 2008.10.14 PROCTER & GAMBLE CO

AI summary

An apparatus for producing a deep-nested embossed product including a first embossing member and a second embossing member. The first embossing member has a plurality of discrete embossing elements disposed in a first non-random pattern. The second embossing member has a plurality of second embossing elements including at least one linear embossing element. The second embossing elements are disposed in a second non-random pattern such the first non-random pattern and the second non-random pattern nest together to a depth of greater than about 0.01 mm.