Web Deformation Apparatus for Absorbent Articles

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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 process and apparatus that allow for simultaneous deformation of a web's layers in specific areas using a single unit operation, enabling the formation of distinct features such as apertures and tufts across the web, including through the entire z-dimension, to enhance absorbency and breathability while maintaining structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple unit steps are used to deform the web to create different structures, then functional requirements for different regions can be met, but the web structure is weakened and tearing occurs

Engineering Contradiction:

Improvefunctional requirements for different regionsVSAvoidweb structure strength

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The patent combines multiple deformation operations into a single unit step by using a forming device with multiple forming elements that simultaneously create different structures (apertures, tufts, embossments) in different regions of the web during one pass, eliminating the need for multiple sequential steps and preventing web weakening

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The forming device is segmented into multiple independent forming elements, each capable of creating specific structures in predetermined regions. This segmentation allows different functional requirements to be met simultaneously without requiring multiple unit steps, as each forming element operates independently within the same unit step

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If multiple unit steps are used to form structures in the web, then different functional regions can be created, but features from different steps overlap and compromise skin health

Engineering Contradiction:

Improvedifferent functional regionsVSAvoidfeature placement precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

By merging multiple deformation operations into a single unit step, the patent ensures that all structures are formed simultaneously in their predetermined positions without the risk of overlapping from sequential operations. The forming device coordinates multiple forming elements to create precisely positioned features in one pass

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The forming device is configured with forming elements positioned to create structures in predetermined regions before the web proceeds to subsequent processing. This preliminary positioning of multiple structures in a single unit step prevents later overlapping and ensures precise feature placement

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If multiple unit steps are used for structure formation, then complex functional requirements can be met, but the process complexity increases

Engineering Contradiction:

Improvecomplex functional requirementsVSAvoidprocess complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges multiple deformation operations that would traditionally require separate unit steps into a single integrated forming device. This consolidation meets complex functional requirements through one unit step, thereby reducing process complexity while maintaining the capability to create diverse structures

Inventive Principle:

Principle #5Merging (Combining)

4Stability of the object's composition

If structures are formed through the entire web in z-dimension, then uniform deformation is achieved, but regions requiring different structures cannot be addressed

Engineering Contradiction:

Improveuniform deformationVSAvoiddifferent structures in different regions

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The forming device incorporates different types of forming elements (for apertures, tufts, embossments) positioned to act on specific predetermined regions of the web. Each forming element creates the appropriate local structure in its designated region, allowing uniform deformation where needed while providing region-specific structures where functional requirements demand

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS11213434B2Method for deforming a web

Publication Date: 2022.01.04 PROCTER & GAMBLE CO

AI summary

A process for deforming a web is disclosed. The steps include forming a plurality of microscopic aberrations in a first layer and/or second layer of a precursor web. The microscopic aberrations comprising sidewalls and an aperture disposed at a distal end of the sidewalls. The first layer extends laterally outboard more than the second layer. The precursor web is advanced to a forming unit. The plurality of macroscopic features is simultaneously formed in the precursor web, including first and second features; the first features are disposed in an area of overlap between the first and second layer; the second features are disposed in an area laterally outboard of the second layer; the microscopic aberrations extend in a first direction from the precursor web; the first and second features extend in a second direction from the precursor web; and wherein the first direction is opposite the second direction.