Multilayer Web Deformation via Single Nip Forming
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Solution Overview
Problem
Existing methods for deforming laminate webs to create absorbent articles often require multiple unit steps, leading to potential weakening of the web structure, tearing, and overlapping of features, which can compromise skin health and comfort in absorbent products.
Innovation Solution
A method and apparatus for deforming a multilayer web in a single nip, allowing for the formation of distinct structures in different regions of the web, including apertures and tufts, using a combination of patterned rolls and forming elements to create features simultaneously across multiple layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple unit steps are used to deform laminate webs to create different structures, then diverse structural features can be formed, but the web structure weakens and may tear during the manufacturing process
Solution Approach 1:
The patent combines multiple deformation operations into a single unit step process. The forming structure includes multiple forming members that can simultaneously create different structural features (apertures, tufts, three-dimensional deformations) in different regions of the web during one passing, eliminating the need for multiple sequential unit steps and preventing web weakening and tearing.
Solution Approach 2:
The forming structure is divided into multiple independent forming members, each capable of creating specific structural features. This segmentation allows diverse structural features to be formed simultaneously without requiring multiple unit steps, as each forming member operates independently within the same unit step process.
2Adaptability or versatility
If multiple unit steps are used to form structures in a web, then different structural features can be created, but features from different unit steps may overlap and misalign
Solution Approach 1:
The patent merges multiple structure formation operations into a single unit step, where multiple forming members operate simultaneously on the web. This eliminates the timing and positioning errors that occur when structures are formed in sequential steps, ensuring precise alignment and preventing feature overlap.
Solution Approach 2:
The patent utilizes three-dimensional deformations that extend through the web thickness (z-dimension), allowing forming members to create features at different depths and orientations. This dimensional approach enables diverse structural features to be formed simultaneously without interfering with each other's alignment in the planar dimensions.
3Productivity
If a single unit operation is used to deform web, then manufacturing efficiency improves, but it is difficult to form both localized and through-web structures simultaneously
Solution Approach 1:
The forming structure is segmented into multiple independent forming members, each capable of creating specific types of deformations. This segmentation allows the single unit operation to simultaneously form both localized surface features and through-web structures, as each forming member can be configured for different deformation depths and patterns.
Solution Approach 2:
The forming structure is designed as a universal system that can create multiple types of structural features (apertures, tufts, three-dimensional deformations) in a single unit step. The forming members can be configured to produce both localized and through-web structures, providing multi-functionality that maintains manufacturing efficiency while achieving diverse structure formation capabilities.
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 approach enables the creation of absorbent articles with enhanced properties like improved softness and fluid handling, reducing the risk of feature misalignment and overlap, thereby improving skin health and comfort while simplifying the manufacturing process.
Implementation Method 1
The first and second forming members are intermeshed to incrementally stretch the precursor web to form the plurality of apertures and the plurality of three-dimensional features
Implementation Method 2
Each of the first and second forming members can comprise a plurality of ridges and grooves
Data Source
AI summary
Methods for deforming a multilayer web are disclosed. Steps of the method include: supplying a first layer of a precursor web; supplying a second layer of the precursor web onto at least the first area of the first layer; forming a plurality of first features and a plurality of second features in the precursor web. The plurality of first features are apertures formed in a first area of the precursor web, and the plurality of second features are formed in a second area of the precursor web in a positive and/or negative Z-direction. The plurality of first features and the plurality of second features are formed simultaneously.