Segmented Anvil Embossing for Absorbent Articles
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Solution Overview
Problem
Traditional rotary embossing systems for absorbent articles face challenges in creating deep channel embossments without damaging the backsheet, achieving uniform embossment depth, and ensuring proper adhesive application and release paper attachment due to the backsheet's irregular surface.
Innovation Solution
A method involving a segmented anvil member and non-contact adhesive application, where the absorbent core is embossed before attaching the backsheet, allowing for deeper embossments and uniform depth, and adhesive is applied using a non-contact die means to ensure proper attachment of the release paper.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the backsheet is attached to the absorbent core prior to embossment, then the backsheet provides structural support, but the embossment depth is limited and the backsheet may be damaged
Solution Approach 1:
The embossment process is performed before the backsheet is attached to the absorbent core. This preliminary action allows the embossing dies to create deep channel embossments without the backsheet being present to restrict depth or suffer damage. The backsheet is subsequently attached to the already-embossed absorbent core, ensuring both deep embossment and backsheet integrity.
2Manufacturing precision
If traditional rotary embossing rolls and anvil rolls are used, then the embossing process is continuous, but uniform embossment depth cannot be achieved especially at closed ends
Solution Approach 1:
The anvil roll is divided into multiple segmented sections that can be independently adjusted vertically. This segmentation allows each section to be precisely positioned to maintain uniform embossment depth across the entire embossment region, including closed ends. The independent adjustment capability ensures consistent pressure distribution and eliminates the depth variation problems associated with traditional continuous anvil rolls.
3Reliability
If adhesive is applied to the release paper first and then contacted with the backsheet, then the adhesive holds the release paper, but adhesive stringing and poor transfer occur due to valleys in the backsheet
Solution Approach 1:
The traditional mechanical contact method of adhesive application is replaced with a non-contact die means. This substitution eliminates the problem of adhesive stringing caused by contact with the uneven backsheet surface. The non-contact die means deposits adhesive precisely without being affected by the valleys and irregularities in the backsheet, ensuring clean transfer and reliable attachment.
4Reliability
If deep channel embossments are formed, then improved fit and fluid barrier performance are achieved, but the backsheet surface becomes irregular causing adhesive application problems
Solution Approach 1:
The deep channel embossments are formed in the absorbent core before the backsheet is attached. This preliminary embossment creates the desired fluid barrier and fit characteristics without compromising subsequent adhesive application. The backsheet is then attached to the embossed surface, and the non-contact die means applies adhesive effectively despite the irregular surface created by the embossments.
Data Source
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AI summary
A method for embossing an absorbent article using a segmented anvil and attaching a release paper to a backsheet having depressed regions.