Embossing-Laminating Unit With Phased Protuberances
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Solution Overview
Problem
Existing embossing-laminating units often cause damage to the embossing patterns during the lamination process, leading to partial compression and alteration of the embossed design in multi-ply web materials.
Innovation Solution
An embossing-laminating unit with a laminating roller having protuberances phased with the embossing rollers, which applies pressure in the valleys between the embossing protuberances, reducing the compression effect on the embossed patterns and maintaining the integrity of the embossing design during lamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a laminating roller with a flat surface is used to bond plies, then lamination bonding is achieved, but the embossing pattern is compressed and damaged
Solution Approach 1:
Instead of pressing the laminating roller against the embossed surface (conventional approach), the invention inverts the approach by having the laminating roller press against the non-embossed reverse side of the ply. This allows bonding to occur without compressing the embossing pattern, thereby resolving the contradiction between achieving strong bonding and preserving embossing integrity
Solution Approach 2:
The invention segments the lamination process into two distinct zones: an embossing zone where the embossing roller creates the pattern, and a lamination zone where the laminating roller bonds the plies on the reverse side. This spatial segmentation allows both embossing and lamination to occur without interfering with each other, maintaining embossing quality while achieving strong bonding
2Productivity
If a hard laminating roller is used to apply lamination pressure, then bonding efficiency is improved, but embossing compression increases
Solution Approach 1:
The invention inverts the lamination approach by applying pressure to the reverse side of the ply rather than the embossed side. This allows the use of a hard laminating roller for efficient bonding without the roller directly contacting and compressing the embossed surface, thereby maintaining both bonding efficiency and embossing quality
Solution Approach 2:
The reverse side of the ply acts as an intermediary surface for applying lamination pressure. By using this intermediate surface rather than the embossed surface directly, the invention enables effective pressure application for bonding while protecting the embossed motifs from compression damage
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
This configuration minimizes the damage to the embossing patterns, allowing for better processing and maintaining the original embossing design without substantial alteration, resulting in a higher quality multi-ply web material.
Implementation Method 1
The paper ply or plies passed in the nip between the embossing roller and the pressure roller are subjected to a permanent deformation, which entails the formation of a raised embossing pattern on the ply
Implementation Method 2
a second pressure roller, cooperating with said second embossing roller to emboss a second ply of web material
Implementation Method 3
The laminating roller is provided with protuberances in phase with at least some of the first protuberances of the first embossing roller in order to generate a laminating effect in correspondence of areas of the first ply embossed by the first embossing roller
Data Source
Figure 1A~1C
Figure 2~4
AI summary
The embossing - laminating unit (1), comprises: a first embossing roller (3) provided with a series of first embossing protuberances (3P); a first pressure roller (5), cooperating with said first embossing roller to emboss a first ply (V1) of web material; a second embossing roller (9) provided with a series of second embossing protuberances (9P); a second pressure roller (11), cooperating with said second embossing roller to emboss a second ply (V2) of web material; a glue applicator (7), cooperating with said first embossing roller (3); a laminating roller (15), cooperating with said second embossing roller (9); The laminating roller is provided with protuberances (15P) in phase with at least some of the first protuberances of the first embossing roller in order to generate a laminating effect in correspondence of areas of the first ply embossed by the first embossing roller.