Embossing Lamination Assembly with Heated Steel Rolls
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Solution Overview
Problem
Existing embossing and lamination processes for tissue paper require multiple stations and steps, increasing costs and complexity, while also limiting flexibility in embossing types and reducing the volume characteristics of the final product.
Innovation Solution
An embossing and lamination assembly using two pairs of steel/rubber rolls with heating means, allowing for micro-embossing, macro-embossing, or double height embossing, and incorporating a glue delivery system for efficient lamination, all while minimizing the number of necessary stations and process steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional embossing and lamination processes are used with multiple stations, then lamination quality is maintained, but process complexity and cost increase
Solution Approach 1:
The patent combines the embossing function and lamination function into a single integrated station. The embossing roll simultaneously performs embossing and acts as an applicator for adhesive, eliminating the need for separate embossing station and lamination station while maintaining lamination quality
Solution Approach 2:
The embossing roll is designed to perform multiple functions: it embosses the paper substrate and simultaneously applies adhesive to the embossed surface. This multi-functional component replaces what would traditionally require separate dedicated components, reducing overall system complexity
2Volume of moving object
If hot micro-embossing with wetting is integrated into converting line, then tissue paper volume characteristics improve, but line dimensions and equipment cost increase
Solution Approach 1:
The patent merges the wetting function, embossing function, and lamination function into a single integrated station. The adhesive solution serves dual purpose as both wetting agent and adhesive, eliminating the need for separate wetting station and reducing line dimensions
Solution Approach 2:
The adhesive solution is used for multiple purposes: it wets the paper substrate before embossing and simultaneously serves as the adhesive for lamination. This multi-functional approach eliminates the need for separate wetting equipment and reduces overall system complexity and footprint
3Adaptability or versatility
If multiple embossing stations are used for different embossing types, then embossing flexibility is achieved, but device complexity increases
Solution Approach 1:
The embossing roll is designed with adjustable parameters including variable rotational speed and variable pressure application. These dynamic adjustments allow the single embossing station to adapt to different embossing requirements (micro-embossing, macro-embossing, different patterns) without requiring multiple dedicated stations
Solution Approach 2:
The patent utilizes parameter changes in the embossing process including adhesive solution concentration, embossing roll temperature, pressure, and speed to achieve different embossing effects. By varying these parameters, a single station can perform multiple embossing types that would traditionally require separate dedicated stations
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 achieves high volume characteristics in tissue paper with reduced process complexity and cost, while maintaining flexibility in embossing types and ensuring effective lamination.
Implementation Method 1
The embossing and lamination assembly (10) comprises heating means (50) for heating the surface of the upper steel roll (21) and/or the surface of the lower steel roll (31)
Implementation Method 2
The transformation of individual plies of paper through hot embossing subject to a paper wetting process is also known for so-called tissue paper
Data Source
Figure 1
Figure 2~3
AI summary
An embossing and lamination assembly comprising two pairs of steel/rubber rolls, between which respectively a first paper ply (11A) and a second paper ply (11B) are returned, wherein an upper steel embossing roll (21) is coupled with an upper embossing rubber counter-roll (22) and a lower steel embossing roll (31) is coupled with a lower rubber embossing counter-roll (32), and also comprising a glue delivery assembly (40), in contact on a side of the upper steel embossing roll (21), and a coupling roll (13), in contact with the opposite side of the upper steel embossing roll (21), wherein said upper steel embossing roll (21) and/or said lower steel embossing roll (31) are equipped with heating means (50) for heating the surface of the upper steel roll (21) and/or the lower steel roll (31), the upper (22) and/or lower (32) rubber embossing rolls are mounted on a movable arm (24, 34), and return rolls (12') are arranged around the upper rubber roll (22) and/or around the lower rubber roll (32) to guarantee a tangential passage of paper between the two coupled steel/rubber embossing rolls (21, 31; 22, 32) without wrapping the respective rubber embossing roll (22, 32). A relative embossing and lamination method is also part of the invention.