Embossing Roller Surface Heating Using Eddy Current Induction
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Solution Overview
Problem
Existing heating systems for embossing rollers in tissue paper production are energy-intensive, inefficient, and pose safety risks to operators due to the use of recirculating fluids, requiring improved heating techniques that are more efficient, rapid, and safer.
Innovation Solution
An embossing-laminating device using electromagnetic induction to heat the outer surface of embossing rollers, with eddy currents generated to rapidly heat and maintain the working surface of the rollers, and a closed-loop control system to regulate temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If recirculating fluid systems are used to heat embossing rollers, then heating capability is achieved, but energy efficiency deteriorates and operator safety deteriorates
Solution Approach 1:
The patent replaces the mechanical recirculating fluid heating system with an electromagnetic induction heating system. The induction heating device generates eddy currents directly in the embossing roller, converting electromagnetic energy directly into heat within the roller itself, eliminating the need for fluid circulation systems and associated energy losses.
Solution Approach 2:
The patent extracts and removes the recirculating fluid system from the heating process. By using electromagnetic induction, the heating function is achieved without the intermediary fluid circulation infrastructure, thereby eliminating the energy losses associated with pumping, heat transfer through pipes, and fluid recirculation.
2Temperature
If recirculating fluid systems are used to heat embossing rollers, then heating capability is achieved, but operator safety deteriorates
Solution Approach 1:
The patent replaces the mechanical recirculating fluid system with electromagnetic induction heating. This substitution eliminates pressurized hot fluid pipes and components that pose burn risks to operators, while maintaining the necessary heating capability through direct electromagnetic heating of the roller.
3Temperature
If recirculating fluid systems are used to heat embossing rollers, then heating capability is achieved, but heating speed deteriorates
Solution Approach 1:
The patent replaces the indirect fluid-based heating system with direct electromagnetic induction heating. The induction system generates eddy currents within the roller material itself, producing heat directly where needed, which dramatically reduces heating time compared to the slow process of heating fluid and transferring heat through roller walls.
Solution Approach 2:
The embossing roller heats itself through the electromagnetic induction process. The eddy currents generated within the roller material create internal heating, eliminating the need for external heat transfer through fluids or contact with heated surfaces, thereby achieving rapid and efficient heating.
4Temperature
If recirculating fluid systems are used to heat embossing rollers, then heating capability is achieved, but device complexity deteriorates
Solution Approach 1:
The patent extracts and removes the complex recirculating fluid system infrastructure, including pumps, pipes, heat exchangers, and fluid reservoirs. The electromagnetic induction heating system replaces this complexity with a simpler setup consisting primarily of the induction heating device and control system.
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 provides efficient, rapid heating and cooling of embossing rollers, reducing energy waste, downtime, and ensuring operator safety while maintaining consistent product quality.
Implementation Method 1
an electromagnetic induction device (19, 20) externally associated with said first embossing roller (4, 5) to heat prevalently said outer surface (SE) of said first embossing roller (4, 5), wherein said electromagnetic induction device (19, 20) is connected to a generator device (23, 24) to supply said electromagnetic induction device (19, 20) with electromagnetic induction currents adapted to generate an electromagnetic flux directed toward said first embossing roller (4, 5)
Implementation Method 2
the operating frequency of said electromagnetic induction currents is such as to generate eddy currents on said first embossing roller (4, 5) such as to prevalently follow the profile of said outer surface (SE) of said first embossing roller (4, 5)
Data Source
AI summary
An embossing device and a method for embossing, employing an electromagnetic induction device such as to induce an eddy current prevalently on the outer surface of an embossing roller. The eddy currents are such as to prevalently heat the outer surface of the embossing roller.