Micro-textured Web Forming via Mated Roller Engagement
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Solution Overview
Problem
Existing methods for creating micro-textured webs are inefficient, costly, and limited in their ability to produce small-scale textures with high precision, often requiring high pressure, temperature, and complex processes that result in slow manufacturing speeds and durable but inflexible tooling.
Innovation Solution
An apparatus using a pair of mated forming structures with voids and protrusions, allowing for the creation of micro-textured webs with closely-spaced discrete three-dimensional elements by engaging the voids with protrusions at a controlled spacing, enabling high-speed production of webs with precise micro-textures without the need for heating or high pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If vacuum forming process is used to create textured web surface, then the web can be formed to conform to the texture of the forming structure, but the process is limited by the amount of pressure that can be exerted and requires heating steps which reduce efficiency
Solution Approach 1:
The patent replaces the vacuum forming mechanical system with a hydroforming system that uses high pressure water jets to deform the web. This substitution eliminates the need for heating steps and vacuum pressure limitations, allowing direct mechanical deformation at room temperature and significantly improving manufacturing efficiency
Solution Approach 2:
The patent changes the pressure parameter from vacuum pressure (limited) to high pressure water jet (unlimited), and changes the temperature parameter from heated state to room temperature. These parameter changes enable the web to be deformed without heating while achieving the desired surface texture, thereby improving productivity
2Ease of operation
If hydroforming process is used to create soft and silky polymeric webs, then the desired feel can be achieved, but the process is costly and inefficient due to high pressure and high temperature water jets and subsequent drying steps
Solution Approach 1:
The patent extracts and eliminates the drying steps (dewatering steps) from the hydroforming process. By using a forming structure that allows water to drain away during the forming process itself, the web is left with the desired texture without requiring subsequent drying operations, thereby reducing process complexity and cost
Solution Approach 2:
The patent makes the forming process continuous by integrating the water drainage function into the forming structure itself. The water jets deform the web while water simultaneously drains through the forming structure, eliminating the need for separate drying steps and maintaining continuous productive action throughout the process
3Temperature
If embossing process with compliant material is used to enable embossing at relatively low temperatures, then temperature requirements are reduced, but high pressure and deformations result in equipment wear and reduced lifetime
Solution Approach 1:
The patent uses a sacrificial layer that is consumed during the embossing process. This layer absorbs the high pressure and deformation stresses, protecting the expensive forming structures from wear. The sacrificial layer can be easily replaced, while the main forming structures maintain their integrity and longevity
Solution Approach 2:
The patent introduces a sacrificial layer as an intermediary between the water jets and the forming structures. This intermediary layer receives the high pressure and deformation forces, preventing direct contact between the water jets and the expensive forming structures, thereby protecting equipment and extending lifetime
4Productivity
If solid state processes with two mated rigid structures are used, then low cost, high speed, and durable tooling are achieved, but it is difficult to impart small scale texture to precursor webs
Solution Approach 1:
The patent uses hydraulic water jets instead of mechanical contact between rigid structures to impart texture. The water jets can be focused to very small dimensions and can create micro-scale textures on the web without requiring correspondingly small mechanical features in the forming structures, thereby achieving high manufacturing precision while maintaining high speed production
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 apparatus enables the production of micro-textured webs with high aspect ratio three-dimensional elements and controlled thinning, providing improved softness, fluid handling, and visual properties while maintaining control over deformation registration, thus overcoming the limitations of prior art in terms of cost, speed, and precision.
Implementation Method 1
high pressure and high temperature water jets force the precursor web to conform to the texture of the forming structure
Implementation Method 2
high pressure and high temperature water jets force the precursor web to conform to the texture of the forming structure
Implementation Method 3
a vacuum forces the precursor web to conform to the texture of the forming structure
Implementation Method 4
moving the web through a deformation zone of the mated forming structures, wherein the voids of the first forming structure engage with the protrusions of the second forming structure at an engagement position
Data Source
Figure 1~2
Figure 3
Figure 4A~4B
AI summary
Apparatus for making micro-textured webs. The apparatus comprises a pair of mated forming structures having a first forming structure (102), a second forming structure (103), and a deformation zone (130); wherein at least the first forming structure (102) comprises voids (30,38), and wherein at least the second forming structure comprises protrusions (20,26) wherein at least one protrusion has center-to-center spacings of less than about 800 microns with at least three of its adjacent protrusions. The voids (30,38) of the first forming structure (102) are engagable with the protrusions (20,26) of the second forming structure (103) at an engagement position to form a micro - textured web (60). In another embodiment, the apparatus comprises a pair of counter- rotating rollers wherein the first roller comprises grooves having a length, wherein the length of the grooves are oriented at an angle different from the machine direction.