Emboss Roller Segmentation for Uniform Fiber Density
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Solution Overview
Problem
Existing emboss rollers for surface sheets in absorbent articles create uneven fiber density due to gear-shaped projections and recesses, leading to reduced fiber density and shape stability, especially when unwoven cloth is processed, resulting in skin troubles and poor shape retention.
Innovation Solution
An emboss roller apparatus with a first and second roll set, featuring projecting and recessed portions with smooth reference surfaces, allowing for uniform fiber density and stable embossing by distributing tensile stress in two stages, preventing excessive fiber pulling and maintaining shape integrity during fluid absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If gear-shaped projections and recesses are used on emboss rollers, then embossing function is achieved, but fiber density becomes uneven and shape stability deteriorates
Solution Approach 1:
The embossing roller surface is segmented into distinct functional zones: projecting portions (for compression), recessed portions (for embossing), and smooth reference surfaces (for stress distribution). This segmentation allows each zone to perform its specific function independently, preventing the gear-shaped continuous pattern from causing uniform fiber density issues while maintaining effective embossing capability.
Solution Approach 2:
Different surface regions of the emboss roller are given different local qualities: the projecting portions have compressive geometry, the recessed portions have embossing geometry, and the smooth reference surfaces have stress-distributing geometry. This local differentiation ensures that each area contributes specifically to the overall goal of achieving uniform fiber density while maintaining shape stability.
2Shape
If gear-shaped meshed rolls are used for shaping, then projecting-and-recessed shape is formed, but tensile stress concentrates causing fiber pulling and reduced shape retention
Solution Approach 1:
The smooth reference surfaces are positioned beforehand to cushion and distribute tensile stresses before they can concentrate at the gear mesh points. This preemptive stress distribution prevents excessive fiber pulling during the embossing process, thereby maintaining shape retention and preventing the emboss pattern from collapsing during subsequent handling or fluid absorption.
3Shape
If conventional embossing method is used, then emboss pattern is created, but skin contact area increases causing skin troubles
Solution Approach 1:
The emboss pattern is segmented into projecting portions that rise from the surface and recessed portions that create voids. This segmentation reduces the actual contact area between the surface sheet and skin, minimizing skin troubles while maintaining the embossing function for fluid management and comfort.
Data Source
AI summary
An emboss roller is provided that can give projecting-and-recess embosses to a surface sheet while uniform fiber density is realized through in an emboss roller which has a first emboss roll and a second roll formed as a set and gives projecting-and-recessed embosses by passing a surface sheet between these emboss rolls, and on the surface of the first emboss roll, a projecting portion projecting outward from a reference surface with the reference surface as a boundary and a recess portion recessed from the reference surface are provided, and the smooth reference surface is present in the periphery of the projecting portion and the recess portion, and on the surface of the second emboss roll, a projecting portion projecting outward from the reference surface with the reference surface as a boundary and meshed with the recess portion of the first emboss roll and a recess position recessed from the reference surface and meshed with the projecting portion of the first emboss roll are provided, and the smooth reference surface is present in the periphery of the projecting portion and the recess portion.