Web Deformation Using Nested Rolls for Compact Multi-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 a web 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 deformation methods are used, then simple web structures are formed, but the web lacks dual or multiple properties in specific portions
Solution Approach 1:
The patent employs nested rolls where smaller rolls are positioned within the nip of larger rolls. This allows multiple deformation steps to occur in a compact configuration, enabling the web to acquire multiple properties (softness, fluid handling, absorbency) without requiring a large sequence of separate deformation apparatuses.
Solution Approach 2:
The patent introduces cross-machine direction (CD) deformations in addition to machine direction (MD) deformations. By deforming the web in multiple directions and creating three-dimensional structures like tufts and pockets, the web gains enhanced properties including improved softness, fluid handling, and absorbency capacity.
2Adaptability or versatility
If multiple deformation steps are applied to create complex structures, then web properties are enhanced, but control over deformation registration is lost
Solution Approach 1:
The patent employs registration marks printed on the web and corresponding detection mechanisms that monitor the web position before and during deformation. This feedback system allows the apparatus to maintain precise alignment and registration control even as the web undergoes multiple deformation steps, ensuring that deformations are applied at the correct locations.
Solution Approach 2:
The patent divides the deformation process into discrete steps, each performed by a separate nip or deformation zone. This segmentation allows for independent control of each deformation step while maintaining overall registration accuracy through the use of registration marks and controlled web tension between steps.
3Adaptability or versatility
If multiple deformation apparatuses are used to create complex web structures, then web properties are enhanced, but manufacturing floor space increases
Solution Approach 1:
The patent uses nested rolls where smaller deformation rolls are positioned within the nip of larger rolls. This configuration allows multiple deformation functions to be integrated into a single compact apparatus, significantly reducing the manufacturing floor space required compared to using separate deformation machines in sequence.
Solution Approach 2:
The patent combines multiple deformation nips and rolling elements into a single integrated apparatus. By merging several deformation functions into one machine, the system achieves enhanced web properties without requiring multiple separate apparatuses, thus minimizing the manufacturing footprint.
4Productivity
If features are closely spaced to maximize web functionality, then web efficiency is improved, but deformation control becomes more difficult
Solution Approach 1:
The patent employs a compliant web material that can be deformed into closely spaced three-dimensional features such as tufts, pockets, and channels. The flexibility of the web allows it to conform to the deformation elements while maintaining structural integrity, enabling high feature density without compromising deformation control.
Solution Approach 2:
The patent varies deformation parameters such as nip pressure, roll speed, and forming element geometry to achieve closely spaced features. By optimizing these parameters, the system can create high-density deformations while maintaining precise control over feature spacing and dimensions.
Data Source
AI summary
Methods and apparatuses for deforming a web are disclosed. In one embodiment, the method involves feeding a web into a nip that is formed between at least two intermeshing rolls. The 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.