Embosser Ply Stiffening Before Winding to Prevent Glue Contamination
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Solution Overview
Problem
Existing systems for stiffening paper coils to prevent deformation and tearing during core extraction in tissue paper production result in machine contamination and frequent line stoppages due to the scattering of glue on rewinding machinery.
Innovation Solution
An embosser system with dispensers positioned before the winding process to apply a stiffening substance, such as glue, between paper plies to form a multi-layer ply, ensuring the substance is applied only to the initial coils, preventing contamination and allowing continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a stiffening substance is dispensed on the paper by nozzles in the rewinding machine, then the innermost coils are reinforced and remain compact during core extraction, but the rewinding machine becomes contaminated with glue requiring periodic stoppages for cleaning
Solution Approach 1:
The dispensing function is extracted from the rewinding machine and integrated into the embosser system. The embosser now includes dispensers that apply stiffening substance to the paper plies before they enter the winding section, separating the coating operation from the winding operation and eliminating glue contamination of the rewinding machine.
Solution Approach 2:
The embosser acts as an intermediary device between the paper supply and the rewinding machine. By integrating the dispensing system into the embosser, the stiffening substance is applied through the embosser's dispensers rather than through nozzles in the rewinding machine, preventing direct contamination of the winding rollers.
2Productivity
If the stiffening substance is applied before winding, then the machine remains clean and operation can continue without stoppages, but the application timing and positioning must be precisely controlled
Solution Approach 1:
The dispensing system is merged with the embosser structure, combining the coating function with the existing embossing mechanism. This integration allows the stiffening substance to be applied in synchronization with the embossing operation, utilizing the same mechanical timing and positioning systems already present in the embosser.
Solution Approach 2:
The stiffening substance is applied in advance during the embossing stage, before the paper enters the winding section. This preliminary application ensures the innermost coils are reinforced before they are wound around the core, allowing continuous operation without subsequent stoppages for cleaning.
3Strength
If multiple plies are joined to form a multi-layer ply, then the structural support is improved, but the complexity of the embossing system increases with multiple rollers and coordination
Solution Approach 1:
The embosser system is designed to handle multiple plies simultaneously, with each embossing unit capable of processing one or more plies. The dispensers are configured to apply stiffening substance to the appropriate plies in the multi-layer structure, allowing the system to reinforce the innermost coils of multi-ply rolls without requiring separate processing lines.
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 embosser system effectively stiffens the inner coils of paper rolls, reducing deformations and tears while maintaining machine cleanliness and minimizing line stoppages.
Implementation Method 1
a substance which stiffens the paper on it, between one coil and another of a log being wound
Data Source
AI summary
Provided is an embosser that contains a first embossing unit configured to emboss a first ply (P) of tissue paper wound between a first upper roller and a first lower roller; and a second embossing unit configured to emboss a second ply (P′) of tissue paper wound between a second upper roller and a second lower roller. The first lower roller and the second upper roller are at least close defining a coupling zone (C) of the plies (P) and (P′). The embosser further contains at least one dispenser placed upstream of the coupling zone (C) and configured to dispense a predetermined amount of a stiffening substance on a predetermined area A of the embossed ply (P) or (P′). Also provided are a converting line for processing tissue paper and a process to stiffen a ply of tissue paper to be coil-winded around a core to be extracted.