Cellulose Wadding Assembly Installation Without Marking
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Solution Overview
Problem
Existing installations for manufacturing cellulose wadding products often result in sheet marking during the assembly process, especially when transitioning between embossed and non-embossed production modes, leading to irregularities and loss of mechanical properties.
Innovation Solution
An installation featuring a first embossing group with a rigid cylinder and a deformable coating, a matching cylinder, and an additional blending cylinder that allows for the assembly of cellulose wadding strips without marking, enabling easy switching between production modes while maintaining product smoothness and mechanical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a rigid cylinder with embossing protuberances and a deformable coating cylinder are used for embossing, then the sheet can be embossed with desired pattern, but the sheet surface is marked during assembly between rigid cylinders
Solution Approach 1:
The assembly function is segmented from the embossing function. The sheet passes through the embossing group (rigid cylinder with protuberances and deformable coating cylinder) separately from the assembly zone (between matching cylinder and rigid cylinder). This segmentation allows embossing without assembly marking, as the sheet is not pressed against rigid cylinders during the embossing phase.
Solution Approach 2:
The deformable coating cylinder acts as an intermediary that transfers the embossing pattern from the rigid cylinder to the sheet without causing marking. During embossing, the deformable coating contacts the sheet while the rigid cylinder provides the pattern. During assembly, the matching cylinder (with deformable coating) contacts the sheet against the rigid cylinder, preventing direct rigid-to-rigid contact that causes marking.
2Adaptability or versatility
If the deformable coating cylinder is separated from the rigid cylinder, then the sheet can pass without embossing, but the sheet is still marked during passage between rigid cylinders
Solution Approach 1:
The installation is segmented into distinct functional zones: the embossing group and the assembly zone. When embossing is not required, the deformable coating cylinder can be separated from the rigid cylinder in the embossing group, allowing smooth sheet passage. The assembly zone between the matching cylinder and rigid cylinder is positioned such that the sheet path does not cause marking even when no embossing occurs.
Solution Approach 2:
The system dynamically adapts between embossed and non-embossed modes by separating or contacting the deformable coating cylinder with the rigid cylinder. The matching cylinder's position is also adjustable to optimize the assembly path. This dynamic configuration allows versatility in production modes while maintaining the no-marking property through proper geometric arrangement.
3Strength
If strong pressure is applied between smooth cylinders and wheels for mechanical binding, then the plies can be bound without adhesive, but the pressure causes irregular rendering and wheel imprinting
Solution Approach 1:
The matching cylinder is equipped with a deformable coating (flexible shell) that replaces the hard wheels used in conventional mechanical binding. This flexible coating distributes the pressure evenly across the sheet surface, achieving strong mechanical binding between plies without causing localized wheel imprints or irregular rendering. The deformable material conforms to the sheet surface, ensuring uniform pressure distribution.
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
The solution prevents sheet marking, ensures consistent smoothness, and allows for seamless mode switching without altering the sheet's path, resulting in a perfectly symmetrical and non-deformed product with preserved mechanical properties.
Implementation Method 1
The pressure exerted by the deformable cylinder on the fold causes a more or less pronounced deformation of the latter which follows the relief of the engraved cylinder
Implementation Method 2
the pressure exerted by the deformable cylinder on the fold causes a more or less pronounced deformation of the latter
Data Source
Figure 1~5
AI summary
Assembly installation for at least two strips (10, 20) of cellulose wadding with or without marking of said strips, comprising a first embossing unit with a rigid cylinder (5A1) provided with embossing protrusions and a cylinder (5C1) with a deformable coating that can be placed against the rigid cylinder (5A1) for embossing a first strip (10) of cellulose wadding by passing the first strip (10) between the rigid cylinder (5A1) and the cylinder with a deformable coating (5C1), as well as a joining cylinder (5M), which can be applied against the rigid cylinder (5A1) so as to join the first strip (10) to a second strip (20), the two strips being guided between the joining cylinder (5M) and the rigid cylinder (5A1) of the first embossing unit,characterized in that it comprises an additional bonding cylinder (5M2) that can be placed against the bonding cylinder (5M) so as to allow the joining of two cellulose wadding strips by passing between the bonding cylinder (5M) and the additional bonding cylinder (5M2), the joining being without marking when the first strip passes around the first rigid cylinder (5A1) without the deformable-coated cylinder (5C1) bearing against the rigid cylinder (5A1).