Discrete and Linear Embossments for Bulk Without Web Damage

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Deep-nested embossing processes often result in webs that lose strength and softness, and can be damaged during the embossing process, leading to aesthetically undesirable patterns and increased roughness.

Innovation Solution

The use of an embossing apparatus with both discrete and linear embossing elements, where discrete embossing elements are non-contiguous and linear embossing elements extend continuously, allowing for intermeshing that enhances web strength, softness, and aesthetics, while reducing damage during the embossing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If deep-nested embossing process is used, then web thickness and bulk are increased, but web strength is reduced and web damage occurs

Engineering Contradiction:

Improveweb bulkVSAvoidweb strength

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The embossing pattern incorporates both raised embossed regions and recessed regions, creating local variations in web density and structure. The raised regions provide bulk while the recessed regions maintain structural integrity and strength, resolving the contradiction between increasing web bulk and maintaining web strength.

Inventive Principle:

Principle #3Local quality

2Volume of moving object

If deep-nested embossing process is used, then web bulk is increased, but web smoothness is reduced and roughness increases

Engineering Contradiction:

Improveweb bulkVSAvoidweb smoothness

Core Design Contradiction:

Volume of moving objectVSShape

Solution Approach 1:

The pattern design creates localized raised regions that provide bulk while recessed regions maintain smoothness. By strategically placing recessed regions between raised embossed areas, the web achieves both increased bulk and maintained smoothness in different locations.

Inventive Principle:

Principle #3Local quality

3Shape

If deep-nested embossing process is used, then aesthetic pattern is created, but web damage and aesthetic defects increase

Engineering Contradiction:

Improveaesthetic patternVSAvoidweb damage

Core Design Contradiction:

ShapeVSObject-affected harmful factors

Solution Approach 1:

The embossing pattern uses localized raised and recessed regions to create aesthetic designs without excessive compression. The recessed regions act as stress relief zones that prevent web damage while the raised regions provide the desired aesthetic pattern.

Inventive Principle:

Principle #3Local quality

4Volume of moving object

If knob-to-knob embossing is used, then web thickness is increased through pillowed regions, but thickness benefit is lost during converting and packaging

Engineering Contradiction:

Improveweb thicknessVSAvoidthickness maintenance

Core Design Contradiction:

Volume of moving objectVSStability of the object's composition

Solution Approach 1:

The embossing pattern is segmented into discrete raised regions and recessed regions, creating a structured pattern that maintains its form. This segmentation provides mechanical support to the raised regions, preventing pillow collapse during converting and packaging operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The recessed regions are pre-formed as structural support elements during the embossing process, before converting and packaging operations. These recessed regions provide preliminary structural reinforcement that maintains the raised regions' thickness benefit throughout subsequent handling.

Inventive Principle:

Principle #10Preliminary action

5Shape

If nested embossing with male and female patterns is used, then web softness and quilted appearance are improved, but web strength is reduced

Engineering Contradiction:

Improvequilted appearanceVSAvoidweb strength

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The nested embossing pattern creates localized raised and recessed regions that provide quilted appearance. The recessed regions serve as structural support zones that maintain web strength while the raised regions provide the soft, quilted aesthetic appearance.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS7785696B2Embossed product including discrete and linear embossments

Publication Date: 2010.08.31 PROCTER & GAMBLE CO

AI summary

A web product including one or more plies, the web product having a first side and a second side, the web product including a plurality of discrete embossments extending from the first side to the second side; and at least one linear embossment extending from the second side to the first side, wherein the web product has an average embossment height of greater than about 650 μm.