Angled Projection Embossing Roller Reduces Force
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Solution Overview
Problem
Existing embossing roller arrangements for producing multi-ply tissues require high pressure for effective layer adhesion, which leads to roller damage and reduced service life, as well as increased susceptibility to vibrations.
Innovation Solution
The embossing roller arrangement features a projection with side flanks angled more than 10 degrees, which contacts only the embossing edge of a recess with a smaller gradient angle, reducing the active embossing surface and necessary pressure, and is produced using direct laser structuring to achieve precise flank and gradient angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large effective embossing area is used, then layer adhesion is achieved, but high pressure is required which damages rollers and reduces service life
Solution Approach 1:
The patent applies local quality by concentrating the embossing function from a distributed large-area contact to a localized narrow embossing edge. The recess has a slope with a specific angle of inclination, and the projection has angled side flanks that contact only the embossing edge region, creating highly localized pressure application that achieves layer adhesion without requiring high overall pressing forces
Solution Approach 2:
The patent changes the geometric parameters of the embossing elements by defining specific angle relationships between the recess slope angle and the projection flank angle. The projection's angled side flanks contact the embossing edge at controlled angles, transforming the pressure distribution from broad and diffuse to concentrated and directional, thereby reducing the total force required while maintaining adhesion effectiveness
2Reliability
If high pressure is applied for embossing, then layer adhesion is achieved, but rollers become susceptible to vibration damage
Solution Approach 1:
By localizing the embossing action to a narrow edge contact rather than a broad surface, the patent reduces the total force requirement. This localized contact minimizes the transmission of vibratory forces through the roller structure, making the system more resistant to vibration-induced damage while maintaining effective embossing
3Shape
If traditional embossing methods are used, then layer adhesion is achieved, but material thickening occurs causing slanted stacks
Solution Approach 1:
The patent changes the geometric parameters by controlling the angle relationships between the recess slope and projection flanks. This precise angular configuration allows the projection to contact only the embossing edge without excessive penetration, preventing material pile-up and thickening while maintaining sufficient pressure for layer adhesion, resulting in flat embossed surfaces suitable for high-stack applications
Data Source
Figure 1a~1c
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AI summary
Embossing roller arrangement for producing at least two-ply tissues, such as in particular handkerchiefs and/or napkins and/or kitchen rolls and/or toilet paper, with a pair of rollers rolling against each other, wherein the pair of rollers comprises an embossing roller and a counter roller, and with at least one embossing arrangement formed on the pair of rollers, wherein the embossing arrangement comprises a recess on the counter roller and a projection engaging in the recess on the embossing roller, wherein the recess has an embossing edge surrounding the recess opening and the projection has at least partially angled side flanks with which the projection, when entering the recess, contacts the embossing edge at least partially.