Web Deformation via Intermeshing Rolls for Dual-Property Structures
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Solution Overview
Problem
Current methods and apparatuses for deforming webs lack the ability to create structures with dual or multiple properties in specific portions of the web, such as improved softness or fluid handling, and struggle with maintaining control over deformation registration, especially when deforming multiple times, and have limitations in footprint size on the manufacturing floor.
Innovation Solution
The development of apparatuses and methods that use intermeshing rolls to deform webs in a single or multiple nips, allowing for discrete deformations such as apertures and protrusions on both sides of the web, with features that can be intermixed and closely spaced, using configurations like nested rolls to maintain web contact and control deformation alignment across multiple deformation steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional web deformation methods are used, then simple deformations can be formed, but the ability to create structures with dual or multiple properties in specific portions is limited
Solution Approach 1:
The web is divided into multiple deformation zones along its path through the apparatus. Different segments of the web receive different deformation treatments in different zones, enabling creation of structures with dual or multiple properties in specific portions while maintaining manageable complexity through modular zone design
Solution Approach 2:
Different portions of the web are given different deformation properties locally. The apparatus applies specific deformation characteristics to specific zones, creating areas with different properties (e.g., softness, fluid handling) within the same web, thereby achieving adaptability without requiring complete system complexity
2Manufacturing precision
If multiple deformation steps are applied to maintain control over registration, then precise deformation alignment is achieved, but the manufacturing footprint increases
Solution Approach 1:
Multiple deformation zones are nested within a compact apparatus structure. The zones are arranged in a space-efficient configuration where subsequent deformation steps occur in closely spaced or overlapping regions, maintaining precise registration control while minimizing the overall manufacturing footprint through nested arrangement of deformation functions
Solution Approach 2:
The apparatus utilizes multi-dimensional space to arrange deformation zones, transitioning from a simple linear footprint to a three-dimensional configuration. By stacking or arranging zones in vertical or lateral dimensions, the system achieves multiple deformation steps with precise registration control without proportionally increasing the primary manufacturing footprint
3Quantity of substance
If features are closely spaced to increase density, then more deformations per unit area are achieved, but maintaining control over registration becomes more difficult
Solution Approach 1:
The apparatus incorporates feedback mechanisms that monitor web position and deformation status in real-time. This feedback enables dynamic adjustment of deformation parameters to maintain precise registration even when features are closely spaced, allowing high density of deformations per unit area without sacrificing control over alignment
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 creation of web materials with complex structures that provide enhanced properties, such as dual properties in specific web portions, while maintaining precise control over deformation registration and reducing the manufacturing footprint.
Implementation Method 1
The two rolls are configured for deforming a web with at least two sets of deformations that are oriented in different directions relative to the surfaces of the web
Data Source
AI summary
Methods for forming discrete deformations in web materials are disclosed. In some embodiments, the method involves feeding a web into an apparatus having nips that are formed between intermeshing rolls. The apparatus may be in the form of nested or other arrangements of multiple rolls, in which the web is maintained in substantial contact with at least one of the rolls throughout the process, and at least two of the rolls define two or more nips thereon with other rolls. In some embodiments, rolls can be used to expose a different side of the web for a subsequent deformation step. In these or other embodiments, the rolls can be used to transfer the web between rolls in such a manner that it may offset the rolls and/or web so that subsequent deformations are formed at a different cross-machine direction location than prior deformations.