Embossed Paper Wrapper Conditioning System

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Solution Overview

Problem

Existing paper conditioning systems face challenges in efficiently transforming plain, un-embossed paper sheets into embossed sheets suitable for creating wrappers for hygiene products, particularly due to issues with pre-embossed paper's brittleness and lower tensile strength.

Innovation Solution

A paper conditioning system comprising a series of stations: a printing station for applying deposits, a drying station for curing the deposits, a wetting station for increasing moisture content, and an embossing station for creating the embossed pattern, which allows for the transformation of plain paper sheets into embossed sheets with improved tensile strength and printability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If pre-embossed paper is used, then embossed pattern is achieved, but tensile strength and brittleness are reduced

Engineering Contradiction:

Improveembossed patternVSAvoidtensile strength

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The patent applies preliminary action by performing embossing on the paper sheet before the printing process. The paper sheet is embossed first to create the desired pattern, then coating and printing are applied subsequently. This sequence allows the embossed pattern to be established early while maintaining the option to apply additional layers and treatments that can restore or enhance tensile strength.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent utilizes parameter changes by controlling the moisture content of the paper sheet during the embossing process. The paper is conditioned to specific moisture levels (typically 3-8% moisture content) to optimize embossing effectiveness while maintaining structural integrity. This parameter control allows achieving the desired embossed pattern without excessive brittleness.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If multiple conditioning steps are added, then printability and tensile strength are improved, but process complexity increases

Engineering Contradiction:

ImproveprintabilityVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the paper conditioning process into distinct functional stations: a conditioning station for moisture control, an embossing station for pattern creation, and a printing station for final processing. Each station performs a specific function with optimized parameters, allowing the complex overall process to be managed through modular, manageable segments.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses parameter changes to optimize each stage of the process. The conditioning station controls moisture content (3-8%), the embossing station controls pressure and temperature parameters, and the printing station optimizes coating thickness and curing conditions. These controlled parameter changes enable high printability while keeping each individual station relatively simple.

Inventive Principle:

Principle #35Parameter changes

3Shape

If paper is embossed first, then pattern is created, but handling robustness is reduced

Engineering Contradiction:

Improveembossed patternVSAvoidhandling robustness

Core Design Contradiction:

ShapeVSEase of operation

Solution Approach 1:

The patent applies preliminary action by embossing the paper sheet before applying coating layers and final printing. This sequence allows the embossed pattern to be established on the base paper, then subsequent coating applications can provide a protective and reinforcing layer that enhances handling robustness while maintaining the embossed pattern.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent utilizes composite materials by combining the embossed paper base with applied coating layers (such as primers, adhesives, or protective coatings). This composite structure maintains the embossed pattern from the base paper while the added coating layers provide enhanced mechanical strength and handling properties, effectively resolving the contradiction between pattern creation and handling robustness.

Inventive Principle:

Principle #40Composite materials

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 system effectively produces embossed paper sheets with enhanced tensile strength and printability, facilitating the creation of robust and accurate wrappers for hygiene products, while reducing the complexity and robustness required for handling pre-embossed paper.

Implementation Method 1

a drying station configured to cure the one or more deposits on the un-embossed paper sheet to provide a coated, un-embossed paper sheet

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 2

a wetting station configured to increase a moisture content of the coated, un-embossed paper sheet and provide a wetted, coated, un-embossed paper sheet

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Data Source

PatentUS20250153453A1Process for forming a wrapper with embossing

Publication Date: 2025.05.15 MAGNERA CORP

AI summary

A paper conditioning system is configured to prepare a plain, un-embossed paper sheet into an embossed paper sheet following a paper conditioning cycle or process. The embossed paper sheet can be used to create a paper wrapper for hygiene products that are worn by persons.