Heated Embossing Roll Assembly with Auxiliary Joining
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Solution Overview
Problem
The existing embossing and lamination assemblies with heated rolls face issues such as unreliable gluing at startup speeds below 150-200 m/min due to glue evaporation before transfer, and risk of damage to rubber rolls from heat exposure, especially during machine stops.
Innovation Solution
The embossing and lamination assembly incorporates heating means for the steel embossing rolls and an auxiliary joining device that activates at lower speeds to ensure proper gluing, along with independent motorizations and movable components to protect rubber rolls from heat damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the steel embossing roll is heated to improve embossing effect and lamination quality, then the embossing quality and bond strength are improved, but the glue evaporates before transfer at startup speeds below 150-200 m/min
Solution Approach 1:
The heating of the steel embossing roll is activated before the paper enters the embossing zone, ensuring the roll reaches the required temperature (typically 100-200°C) in advance. This preliminary heating allows the glue to be applied and transferred effectively even at startup speeds below 150-200 m/min, preventing evaporation issues while maintaining embossing quality
Solution Approach 2:
The system dynamically adjusts the heating temperature and speed parameters to match the operational conditions. At startup speeds below 150-200 m/min, the heating means maintains a temperature that prevents glue evaporation, while at higher speeds the temperature is optimized for embossing quality. This parameter adaptation resolves the contradiction between embossing quality and gluing reliability across different operating speeds
2Manufacturing precision
If the steel embossing roll is heated to enhance embossing effect, then the final embossed effect on plies is improved, but the rubber embossing counter rolls and other rolls face heat damage risk
Solution Approach 1:
A cooling means is introduced as an intermediary element between the heated steel embossing roll and the rubber embossing counter roll. The cooling means (such as cooling channels or cooling rollers) removes excess heat from the rubber roll surface, protecting it from thermal damage while allowing the steel roll to maintain the high temperature needed for quality embossing
Solution Approach 2:
The heating is localized to the steel embossing roll surface where it is needed for embossing, while the rubber rolls are equipped with localized cooling systems. This creates different thermal zones: the steel roll maintains high temperature for embossing, while the rubber rolls are kept at lower temperatures to prevent heat damage, thus resolving the contradiction between embossing quality and roll protection
3Manufacturing precision
If the heating means is added to the steel embossing roll to improve embossing quality, then the embossing effect is enhanced, but the device complexity and cost increase
Solution Approach 1:
The heating means is integrated directly into the steel embossing roll structure, combining the heating function with the existing roll component. This merging approach avoids adding separate complex heating systems and reduces overall device complexity while still achieving the desired embossing quality enhancement
Solution Approach 2:
The steel embossing roll is designed to be self-heating through embedded heating elements that are activated when needed, eliminating the need for external complex heating systems. The roll serves its own heating requirement through a simple integrated system, reducing device complexity while maintaining embossing quality
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 solution enhances the reliability of gluing at startup speeds and protects the rubber rolls from heat damage, improving the overall efficiency and durability of the embossing and lamination process.
Implementation Method 1
heating means (50) associated with the upper steel embossing roll (21) and/or the lower steel embossing roll (31), configured to bring the surface of the steel roll wrapped by the paper plies (11A, 11B) to a temperature between about 90°C and 200°C
Implementation Method 2
the glue applicator roll, the so-called cliché roll, is wetted by the screened roll, the so-called anilox roll, to deliver the glue to the paper ply, but the glue evaporates before it can be transferred to the paper
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
An embossing and lamination assembly with heated rolls comprises two pairs of steel/rubber rolls between which respectively a first paper ply (11A) and a second paper ply (11B) are fed, in which an upper steel embossing roll (21) is coupled with an upper rubber embossing counter roll (22) and a lower steel embossing roll (31) is coupled with a lower rubber embossing counter roll (32), as well as comprises a glue-distributing assembly (40), provided with an anilox roll (42) and a glue applicator roll (41), placed in contact on a side of said upper steel embossing roll (21), and a coupling roll (13), placed in contact on the opposite side of said upper steel embossing roll (21), and comprises heating means (50) associated with at least one of said upper steel embossing roll (21) and said lower steel embossing roll (31), as well as comprises an auxiliary joining device of the plies (60) of the two paper plies (11A, 11B) adapted to be selectively activated and deactivated depending on the driving speed of the embossing and lamination assembly. A related hot embossing and lamination method also forms part of the invention.