Embossed Web Forming via Static Gas Pressure Plenum
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing web embossing processes are inefficient due to the need for heating and cooling steps, limited pressure capabilities, and difficulty in imparting small-scale texture, often resulting in uniform thickness and slow production speeds.
Innovation Solution
A process involving a static gas pressure plenum and a forming structure with discrete apertures or depressions, allowing for the creation of embossed webs with discrete extended elements without heating, at ambient temperature, and enabling high-speed production with three-dimensional structures and varying thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional embossing processes are used, then texture can be imparted to the web, but heating and cooling steps are required which increase process time and energy consumption
Solution Approach 1:
The patent replaces the thermal field-based embossing process with a mechanical field-based process. Instead of heating the web to emboss it and then cooling to set the texture, the invention uses a mechanical pressing mechanism that directly deforms the web material into the embossing pattern at ambient temperature, eliminating the heating and cooling cycles
Solution Approach 2:
The invention changes the fundamental parameters of the embossing process from thermal (temperature-based) to mechanical (pressure-based). By using a pressing mechanism that applies controlled mechanical force, the web is deformed directly without requiring temperature changes, thereby reducing process time and energy consumption while maintaining the desired texture
2Manufacturing precision
If conventional embossing processes are used, then texture can be imparted to the web, but heating and cooling steps are required which increase energy consumption
Solution Approach 1:
The patent replaces the thermal field-based embossing process with a mechanical field-based process. Instead of heating the web to emboss it and then cooling to set the texture, the invention uses a mechanical pressing mechanism that directly deforms the web material into the embossing pattern at ambient temperature, eliminating the heating and cooling cycles
Solution Approach 2:
The invention converts the typically harmful effect of mechanical deformation (which requires thermal setting) into a beneficial direct-deformation process. By using a pressing mechanism with controlled mechanical force, the web is deformed directly without requiring temperature changes, thereby reducing process time and energy consumption while maintaining the desired texture
3Ease of operation
If vacuum forming process is used, then soft and silky tactile impression can be achieved, but limited pressure capability requires significant heating to soften or melt the precursor film
Solution Approach 1:
The patent replaces the thermal field-based embossing process with a mechanical field-based process. Instead of heating the web to emboss it and then cooling to set the texture, the invention uses a mechanical pressing mechanism that directly deforms the web material into the embossing pattern at ambient temperature, eliminating the heating and cooling cycles
Solution Approach 2:
The invention performs the embossing deformation as a preliminary action before any thermal processing. By applying mechanical pressure to deform the web into the desired pattern while the web is still in its original state, the process eliminates the need for subsequent heating to soften the material, thereby reducing energy consumption and process time
4Ease of operation
If hydroforming process is used, then soft and silky polymeric webs can be produced, but high pressure and high temperature water jets are required which increase cost and inefficiency
Solution Approach 1:
The patent replaces the thermal field-based embossing process with a mechanical field-based process. Instead of heating the web to emboss it and then cooling to set the texture, the invention uses a mechanical pressing mechanism that directly deforms the web material into the embossing pattern at ambient temperature, eliminating the heating and cooling cycles
Solution Approach 2:
The invention extracts and eliminates the complex hydroforming system components (high pressure water jets, temperature control systems, dewatering equipment) from the process. By using a simplified mechanical pressing mechanism, the patent removes the need for these complex systems while achieving the same soft and silky tactile impression
5Manufacturing precision
If conventional embossing processes are used, then texture can be imparted to the web, but relatively large dwell times are required which result in slow production speeds
Solution Approach 1:
The patent replaces the thermal field-based embossing process with a mechanical field-based process. Instead of heating the web to emboss it and then cooling to set the texture, the invention uses a mechanical pressing mechanism that directly deforms the web material into the embossing pattern at ambient temperature, eliminating the heating and cooling cycles
Solution Approach 2:
The invention implements continuous embossing action without interruption for heating or cooling cycles. The mechanical pressing mechanism continuously deforms the web material as it passes through the embossing zone, eliminating dwell times and enabling high-speed production while maintaining consistent texture 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
This process efficiently produces embossed webs with small-scale texture and three-dimensional discrete elements, reducing energy consumption and production time, while allowing for high-speed processing and varying thickness, thus overcoming the limitations of traditional methods.
Implementation Method 1
applying pressure from the static gas pressure plenum against the precursor web opposite the forming structure thereby creating a differential pressure across the precursor web sufficient to force the precursor web into the apertures of the forming structure
Data Source
AI summary
A process for making an embossed web. A precursor web is provided between a forming structure and a static pressure plenum. The forming structure has a plurality of discrete apertures or depressions. Pressure is provided by the static pressure plenum against the precursor web and the forming structure to force the precursor web into the apertures or depressions of forming structure to form the embossed web. The resulting embossed web has a plurality of discrete extended elements.