Crimping Roller Recess Layout for Adjustable Web Draw Resistance
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Solution Overview
Problem
Existing crimping processes for webs, such as paper or tobacco webs, are inefficient and lack a reliable method to create crimped segments with adjustable draw resistance, often using rollers with grooves and ridges that result in inconsistent crimping patterns.
Innovation Solution
A crimping apparatus with rollers featuring circumferential protrusions and recesses that form parallel, interrupted crimping lines with aligned interruptions, allowing for consistent crimping patterns and adjustable draw resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rollers with grooves and ridges are used for crimping, then crimping lines are formed on the web, but the crimping pattern is inconsistent and unreliable
Solution Approach 1:
The roller surface is segmented into multiple circumferential protrusions separated by grooves, with each protrusion containing recesses that define interruption zones. This segmentation creates consistent, repeatable crimping patterns across the web width and length, resolving the inconsistency issue of prior art rollers.
Solution Approach 2:
Each protrusion on the roller has a specific local structure with recesses positioned at defined locations along the interruption lines. This local quality variation allows precise control over where crimping is applied and where interruptions occur, ensuring uniformity and reliability of the crimping pattern throughout the web.
2Adaptability or versatility
If interruption zones are created on the roller, then draw resistance can be adjusted, but the device structure becomes more complex
Solution Approach 1:
The invention merges multiple functions into the roller structure: circumferential protrusions for creating crimping lines, grooves for spacing, and recesses for defining interruption zones. This integration achieves draw resistance adjustment capability without requiring separate adjustment mechanisms, maintaining relative structural simplicity while providing versatility.
3Area of stationary object
If multiple interruption lines are replicated on the roller, then coverage of the web width is improved, but manufacturing complexity increases
Solution Approach 1:
Multiple interruption lines are replicated at regular angular intervals around the roller circumference. This periodic arrangement ensures uniform coverage across the web width while simplifying manufacturing, as the same pattern can be repeatedly formed at standard intervals rather than requiring custom positioning for each line.
Data Source
Figure 1~1A
Figure 2
Figure 3
AI summary
An apparatus (100) for crimping a flat web (N) extending along a longitudinal direction (L), said apparatus (100) comprising a first and a second roller (200, 300) rotatable about a first and a second axis of rotation (X1, X2) parallel to each other, respectively, and wherein at least one of said first and second rollers (200, 300) is a crimping roller comprising a plurality of circumferential protrusions positioned in sequence along the corresponding axis of rotation (X1, X2) and separated by respective grooves, said protrusions having respective peripheral edges lying on a peripheral surface, each protrusion having at least one respective recess defining an interruption (I) with reduced or no crimping on the web (N), wherein the recesses of the protrusions are distributed along at least one interruption line (F) lying along said peripheral surface and extending parallel to the axis of rotation (X1, X2) of the crimping roller (200, 300) so that said interruptions (I) are mutually aligned to define at least one interruption zone (Z) on the web (N) having reduced or no crimping perpendicular to the longitudinal direction (L) of the web (N).