Interchangeable Embossing Rollers for Tip-to-Tip and Nested Configurations
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Paper converting industries require flexible machines that can quickly switch between tip-to-tip and nested embossing technologies to produce multi-ply web materials, as existing machines are not easily adaptable for changing production techniques or small batch demands.
Innovation Solution
An embossing machine with interchangeable rollers and a lamination system that allows for easy switching between tip-to-tip and nested embossing configurations, using a third embossing roller to facilitate production of multi-ply materials with either technique without mechanical intervention, and a transfer device for efficient roller replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dedicated embossing machines are used for tip-to-tip or nested technology, then production precision and reliability are improved, but adaptability deteriorates
Solution Approach 1:
The embossing machine is designed with multiple embossing rollers (first, second, and third embossing rollers) that can be selectively positioned and activated. The machine can operate in tip-to-tip mode using the first and third embossing rollers, or in nested mode using the first and second embossing rollers, making a single machine universal for both production techniques.
Solution Approach 2:
The machine employs dynamically reconfigurable roller positioning where the second embossing roller can be moved between an operative position (for nested technology) and a retracted position (for tip-to-tip technology). This dynamic adjustment allows the machine to adapt its configuration based on the required production mode.
2Ease of operation
If machine reconfiguration is simplified for quick switching, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The second embossing roller is mounted on a movable support structure that allows it to be positioned into or out of the embossing nip. This dynamic positioning mechanism, while adding some structural elements, provides a straightforward and quick method for switching between production modes without requiring complex disassembly or reconfiguration procedures.
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
Enables rapid and flexible production of various embossed materials by allowing easy changeovers between embossing configurations, reducing operational complexity and increasing efficiency in responding to market demands for different product types.
Implementation Method 1
a first embossing roller provided with first embossing protuberances; a first pressure roller forming with the first embossing roller a first embossing nip configured for receiving and embossing a first ply
Implementation Method 2
the originally smooth material is subjected to a permanent deformation resulting in the formation of embossed protrusions
Implementation Method 3
a lamination roller co-acting with the first embossing roller and configured for laminating the first ply and the second ply between the lamination roller and the first embossing protuberances
Data Source
Figure 1~1C
Figure 2
Figure 3
AI summary
The embossing device (1) comprises three embossing rollers (5, 7, 9), each co-acting with a pressure roller (11, 15, 19), to emboss a plurality of paper plies (V1, V2, V3). Two em- bossing rollers can be easily interchanged to switch from a nested configuration to a tip- to-tip configuration, or to switch from one type of patter to another. A lamination roller and a glue dispenser are arranged around one of the embossing rollers.