Embossing and Glue Distribution for Decorative Paper Rolls
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Solution Overview
Problem
Existing methods for producing small-volume paper rolls with decorative motifs either damage the paper plies or require costly calibration and cannot apply motifs effectively, lacking in both aesthetic appeal and cost-effectiveness.
Innovation Solution
A method involving an embossing and lamination assembly where a first paper ply is embossed with markings and glue applied at the embossing roll projections, then coupled with a second smooth or microembossed ply using a marriage roll, allowing for decorative motifs without damaging the paper and using minimal adjustments to existing equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If smooth plies are coupled by ply-bonding with pressure between continuous longitudinal lines, then the volume of paper rolls is reduced, but the appearance of the final product is spoiled due to compressed rings
Solution Approach 1:
The invention applies local quality by using smooth plies only in specific regions where volume reduction is needed, while maintaining embossed plies in other regions to preserve aesthetic appearance. The glue distribution assembly selectively applies adhesive only to specific zones, allowing local coupling without compromising overall product appearance.
2Ease of manufacture
If adhesive material is sprayed continuously with nozzles to couple smooth plies, then coupling is achieved, but thorough and costly calibration of nozzles is required based on paper ply speed
Solution Approach 1:
The invention replaces the complex nozzle-based spray system with a mechanical glue distribution assembly that uses direct contact or close proximity mechanical means to apply adhesive. This substitution eliminates the need for precise nozzle calibration while achieving effective glue distribution on the paper plies.
3Ease of manufacture
If continuous spraying of adhesive material is used to couple smooth plies, then coupling is achieved, but decorative motifs cannot be applied unless printed in advance on the plies
Solution Approach 1:
The invention applies preliminary action by pre-configuring the glue distribution assembly with patterns or zones that correspond to desired decorative motif locations. The adhesive is distributed in advance in specific patterns that will form the decorative elements, eliminating the need for separate printing operations and enabling versatile design applications.
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 method produces aesthetically pleasing paper rolls with small volume, maintaining paper integrity and applying decorative motifs efficiently and cost-effectively, with the ability to use either smooth or microembossed plies.
Implementation Method 1
the projections at greater height of the embossing roll 101 emboss projections on the first paper ply 11' defining a decorative motif having a first height
Implementation Method 2
the glue is applied by the cliché roll 104 on the projections with greater height of the first embossed paper ply 11'
Implementation Method 3
the marriage roll 107 presses the two paper plies against each other to ensure the gluing thereof to form a multilayer paper 11
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method for producing a paper roll (111) with smooth plies joined together with glue comprises the steps of - conveying a first smooth ply (11') between an upper embossing roll (101), provided with projections defining a decorative motif, and a glue distribution roll (104), or cliché roll; - the first ply (11'), when passing between said two rolls, being subjected to indentations (14) and to glue deposits (15) in positions corresponding to the projections of the embossing roll; - conveying a second ply (11") between the upper embossing roll (101) and a coupling roll (107); - performing the final coupling between the first ply (11') and the second ply (11") at the glue deposits (15), thus forming a multilayer paper (11). A relative paper roll with smooth plies joined together with glue comprises a first smooth ply (11') bearing, on an outer side, indentations (14) defining a decorative motif and a second ply (11"), wherein the first ply (11') and the second ply (11") are joined together through glue deposits (15) defining a decorative motif in positions corresponding to the indentations (14).