Micro-textured Web Deformation via Mated Forming Structures
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing processes for creating micro-textured webs are inefficient, costly, and limited in their ability to produce small-scale textures with high precision, particularly in solid state formation techniques, which struggle to impart micro-textures with open or closed distal ends and location-controlled thinning.
Innovation Solution
A process involving a pair of mated forming structures with protrusions and voids, where the precursor web is moved through deformation zones to form discrete three-dimensional elements with controlled registration, allowing for the creation of micro-textured webs with high aspect ratios and complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum forming process is used to create textured webs, then the web can be formed with a textured surface, but the process is inefficient due to limited pressure capability and necessary heating step
Solution Approach 1:
The patent replaces the vacuum forming process (which relies on negative pressure and heating) with a solid state mechanical deformation process using a pair of forming members. The forming members apply direct mechanical pressure to deform the precursor web into the desired three-dimensional texture without requiring heating or vacuum conditions, thereby eliminating the inefficiencies of the vacuum forming process while maintaining texture formation capability
Solution Approach 2:
The patent changes the operating parameters from thermal-based (heating and vacuum pressure) to mechanical-based (direct contact pressure and deformation). By using forming members with specific surface geometries that apply controlled mechanical pressure, the process achieves efficient texture formation without the heating and vacuum steps required in conventional vacuum forming
2Manufacturing precision
If hydroforming process is used to create textured webs, then high pressure and high temperature water jets can force the web to conform to the forming structure, but the process is costly and inefficient involving high pressure water jets and subsequent drying steps
Solution Approach 1:
The patent replaces the hydroforming process (which uses high pressure water jets and thermal energy) with a solid state mechanical deformation process. Instead of using water jets to force the web conform, the invention uses a pair of forming members with complementary surface geometries that directly deform the web through mechanical contact, eliminating the need for water jets, heating, and subsequent drying steps
Solution Approach 2:
The patent extracts and removes the water jet delivery system, heating system, and drying system from the process. By using self-contained forming members with built-in surface geometries, the invention eliminates the complex external systems (water delivery, thermal control, dewatering) required in hydroforming, resulting in a simpler and more efficient process
3Manufacturing precision
If embossing process is used to create textured webs, then the substrate can be mechanically worked to conform to the pattern on an embossing roll, but heating and cooling steps add cost, inefficiency, and complexity
Solution Approach 1:
The patent replaces the conventional embossing process (which uses heated and cooled embossing rolls) with a solid state deformation process using a pair of forming members. The forming members apply mechanical pressure directly to deform the web into the desired pattern without requiring thermal cycles, thereby eliminating heating and cooling steps while maintaining pattern conformity capability
Solution Approach 2:
Instead of using a single embossing roll that imparts pattern through thermal and mechanical action, the patent uses a pair of forming members where one member has protrusions and the other has corresponding voids. This inverted approach allows the web to be deformed between the members through mechanical pressure alone, eliminating the need for thermal embossing and its associated heating/cooling steps
4Productivity
If conventional solid state formation techniques are used, then low cost and high speed are achieved, but the ability to impart micro-texture with small scale features is limited
Solution Approach 1:
The patent segments the forming members into surfaces with finely spaced protrusions and voids that correspond to the desired micro-texture pattern. By creating forming members with high-resolution surface geometries (small feature sizes), the process can impart micro-textures with tight spacing while maintaining the speed of solid state deformation processing
Solution Approach 2:
The patent changes the geometric parameters of the forming members to include small-scale protrusions and voids (e.g., feature sizes in the range of micrometers to sub-millimeters). This parameter change enables the forming members to impart micro-textures with high resolution while the solid state deformation mechanism maintains high manufacturing speed
5Reliability
If forming structures with large distances between forming elements are used, then the process is simple and durable, but the ability to create small scale texture is reduced
Solution Approach 1:
The patent segments the forming member surfaces into arrays of closely spaced protrusions and voids. This segmentation allows the creation of micro-textures with small feature sizes while the overall forming member structure remains simple and durable. The key is that the forming members themselves are simple components with repeating patterns, not complex assemblies
Solution Approach 2:
The patent changes the spacing parameter between forming elements from large distances to small distances (micro-scale spacing). This parameter change enables fine micro-texture creation while the forming members remain simple, rigid structures that are durable and cost-effective to manufacture
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
Enables the production of micro-textured webs with tightly-spaced, discrete three-dimensional elements and controlled features, providing improved softness, fluid handling, and visual properties, while maintaining high speed and low cost, and allowing for multiple deformations with precise registration.
Implementation Method 1
a process for deforming a precursor web to create a micro-textured web
Data Source
AI summary
Processes for making micro-textured webs are disclosed. The present process includes the steps of providing a precursor web; providing a first pair of mated forming members including a first forming member and a second forming member forming a first deformation zone therebetween; moving the precursor web through the first deformation zone forming a first plurality of structures; providing a second pair of mated forming members including a third forming member and a fourth forming member forming a second deformation zone therebetween; moving the precursor web through the second deformation zone forming a second plurality of structures, and wherein the first plurality of structures is different than the second plurality of structures.