Dual Lamination Embossing Roll for Cleaning Paper
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Solution Overview
Problem
Existing methods for producing toilet paper with decorative embossing on both sides fail to maintain volume while keeping unit weight fixed, leading to issues like adhesive drying, inadequate adhesion, and loss of embossing patterns, especially in mass production and continuous winding processes.
Innovation Solution
A converting machine with a dual lamination unit system, featuring embossing rolls with recesses and tabs, micro embossing rolls, and precise adhesive application to ensure decorative embossing on both sides and effective layer joining, maintaining adhesive freshness and enhancing embossing patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If adhesive is applied to outer layers and layers are joined after embossing, then volume is increased, but adhesive may dry before joining causing embossing to disappear and formation to be lost
Solution Approach 1:
The patent applies preliminary embossing to the outer layers before adhesive application and joining. The embossing rolls create the decorative pattern and structural formation in advance, ensuring that when adhesive is applied and layers are joined, the embossing pattern is already established and will not be lost during the joining process.
Solution Approach 2:
The patent divides the processing into separate sequential steps: first embossing the outer layers independently, then applying adhesive, and finally joining the layers. This segmentation allows each process to be optimized independently, ensuring embossing quality is maintained while achieving reliable adhesive bonding.
2Volume of moving object
If decorative embossing is applied to both outer layers, then volume and absorbing capacity are increased, but adhesion regions on the side of outer layer facing intermediate layer are not wide enough to provide required formation
Solution Approach 1:
The embossing rolls are designed with different surface characteristics: the outer surface provides decorative embossing pattern, while the inner surface that contacts the intermediate layer provides adequate adhesion region width. This local differentiation allows both decorative embossing on both sides and sufficient adhesion areas to coexist.
Solution Approach 2:
The patent addresses the adhesion region width issue by utilizing the radial dimension of the embossing rolls. By designing the rolls with appropriate inner diameter and surface geometry, sufficient adhesion width is provided in the radial direction while maintaining decorative embossing on the outer cylindrical surface.
3Device complexity
If single adhesive unit is used for embossing both sides, then system complexity is reduced, but both outer layers cannot be decorative patterned and volume is decreased
Solution Approach 1:
The patent uses two separate adhesive units, each dedicated to one outer layer. This segmentation allows independent control of adhesive application for each layer, enabling both outer layers to receive decorative embossing while maintaining adequate adhesive coverage for joining to the intermediate layer.
Solution Approach 2:
The patent combines the functions of embossing and adhesive application into integrated units for each side. Each unit performs both embossing and adhesive application simultaneously, which while increasing device complexity, enables double-sided decorative embossing with adequate adhesion.
4Productivity
If end-to-end joining method is used, then continuous production is enabled, but different patterns cannot be applied to two outer layers and decorative embossing application cannot be realized
Solution Approach 1:
The patent uses two independent embossing units with different embossing rolls, each capable of applying different decorative patterns to the respective outer layers. This segmentation maintains continuous production capability while enabling pattern variety on both sides.
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 achieves increased volume, improved dry resistance, enhanced softness, and reduced water absorption duration while minimizing fiber usage and environmental impact, with the ability to maintain continuous production and distinct embossing patterns on both sides.
Implementation Method 1
at least one embossing roll providing embossing to the outer layer of a cleaning paper by means of the recesses and tabs thereof provided on the outer wall
Implementation Method 2
one lamination mechanism provided so as to transfer adhesive to the side of the bottom outer layer facing the intermediate layer
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
Converting machine comprising a first lamination unit (20) and a second lamination unit (30), each lamination unit having an embossing roll (21, 31) for providing embossing to the outer layers (211, 311) of a cleaning paper (40) by means of recesses (212, 312) and tabs (213, 313) on the outer wall (211, 311), and at least one joining roll (23, 33) positioned at a vicinity of the embossing roll (21, 31).