Deformable Coupling Pressing Roller for Tissue Embossing
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Solution Overview
Problem
The production of tissue or towel paper faces a challenge in maintaining product quality due to decreased nip time, which is addressed by using a system with one deformable and one rigid roller to increase nip time, but this approach is not sufficient to achieve both faster production and improved quality.
Innovation Solution
A pressing roller with a deformable coupling structure formed from shape memory alloys, carbon fiber composites, or nylon, which allows the outer ring to compress and deform radially, increasing nip time and improving embossing efficiency by conforming to the mating roller's surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the nip time is decreased to increase production speed, then productivity improves, but manufacturing precision deteriorates
Solution Approach 1:
The pressing roller employs a deformable roller cover structure that can dynamically adjust its surface profile during operation. The roller cover comprises a deformable coupling structure between the inner ring and outer ring, allowing the outer surface to conform to the mating roller's embossing pattern through elastic deformation, thereby maintaining high-quality embossing even at high production speeds with reduced nip time
Solution Approach 2:
The invention changes the physical state and mechanical properties of the roller cover by using deformable materials with specific elastic moduli. The deformable coupling structure allows the roller cover to change its deformation characteristics based on operating conditions, enabling adequate nip time for quality embossing while maintaining fast production speed
2Manufacturing precision
If a deformable roller and rigid roller system is used to increase nip time, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The roller cover is segmented into distinct functional components: an inner ring providing structural support, a deformable coupling structure enabling elastic deformation, and an outer ring forming the embossing surface. This segmentation allows each component to be optimized independently while working together to achieve high-quality embossing with a relatively simple overall structure
Solution Approach 2:
The invention uses composite construction with the deformable coupling structure made from materials such as shape memory alloys, carbon fiber composites, or nylon, combining the inner rigid ring with the outer elastomeric ring. This composite approach achieves the desired deformability and embossing quality without requiring complex mechanical systems
3Strength
If the deformable coupling structure is made from rigid material, then strength improves, but adaptability deteriorates
Solution Approach 1:
The deformable coupling structure exhibits local quality variations through its rib configuration, where the ribs provide localized structural support while allowing other areas to deform elastically. This enables the structure to maintain overall strength while achieving local adaptability to conform to the mating roller's surface profile
Solution Approach 2:
The invention employs composite materials for the deformable coupling structure, such as carbon fiber composites or shape memory alloys, which inherently combine high strength properties with elastic deformability. This allows the coupling structure to simultaneously achieve both strength and adaptability without requiring separate components
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 deformable coupling structure enhances fatigue resistance and allows for extended use, improving embossing quality and production efficiency by increasing nip time without compromising speed.
Implementation Method 1
The deformable coupling structure may be formed from a shape memory alloy (SMA), a carbon fiber composite, or nylon. The inner ring may be formed from a rigid material and the outer ring may be formed from an elastomeric material or other polymeric material.
Implementation Method 2
The deformable coupling structure may be formed from a shape memory alloy (SMA).
Data Source
AI summary
A pressing roller is provided including an inner core and a roller cover structure where the roller cover structure is divided into segments. Each roller cover segment may have a rigid inner ring, an elastomeric outer ring, and a deformable coupling structure located between the inner ring and the outer ring. The deformable coupling structure may be formed from a shape memory alloy, a carbon fiber composite, or nylon.