Multicolored Tissue Embossing via Variable Contact Pressure
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Solution Overview
Problem
Existing methods for producing tissue products like kitchen rolls and toilet paper cannot create multicolored decorative elements, as they only allow for all elements to be highlighted in one color or none when using colored glue, failing to achieve high-quality, multicolored designs.
Innovation Solution
A device with a first embossing roller having multiple embossing elevations and assigned application units, allowing for selective application of glue or ink to different embossing heights, enabling the creation of multicolored designs by varying the contact pressure of each application unit to achieve specific color combinations on the tissue products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single application unit is used with one embossing height, then the device complexity is low, but the product cannot achieve multicolored decorative elements
Solution Approach 1:
The embossing roller is segmented into multiple embossing elevations with different heights (first, second, and third embossing heights), and the application system is segmented into multiple application units (first and second application units). Each application unit applies glue or color to specific embossing heights, enabling multicolored decorative elements while maintaining a manageable device structure through systematic segmentation.
Solution Approach 2:
The invention adds a vertical dimension (embossing height) to differentiate decorative elements. By creating embossing elevations at three distinct height levels, the system can apply different colors to different heights, transforming a single-dimension (flat surface) coloring problem into a three-dimension (height-based) coloring solution, enabling complex multicolored designs.
2Manufacturing precision
If upstream printing is used to create designs, then color variety is possible, but the print quality and precision fitting to embossing design is insufficient
Solution Approach 1:
The design is not printed upstream separately and then attempted to match embossing. Instead, the embossing pattern is first created on the roller with precise height variations, and then glue or color is applied directly to these pre-formed embossing elevations. This preliminary formation of the embossing structure ensures perfect alignment and precision fitting between the decorative pattern and the applied color.
Solution Approach 2:
The embossing elevations themselves serve as an intermediary between the design concept and the final colored output. The raised surfaces at different heights act as physical templates that guide the application units, ensuring that color is applied precisely where intended without requiring separate printing systems or complex alignment mechanisms.
3Adaptability or versatility
If all embossing elements are glued in one color, then the application process is simple, but multicolored designs like yellow blossoms and green stems cannot be achieved
Solution Approach 1:
Different contact pressures are applied locally to different application units. The first application unit uses a higher contact pressure to apply color to both second and third embossing heights, while the second application unit uses a lower contact pressure to apply color only to the third embossing height. This local differentiation of contact pressure enables precise control over which embossing elements receive which colors, achieving multicolored designs like yellow blossoms and green stems.
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 the production of high-quality, multicolored tissue products by allowing for the precise application of different colors to various embossing elements, such as yellow blossoms and green stems, using a combination of embossing heights and application units, resulting in enhanced product aesthetics.
Implementation Method 1
the contact pressure of the first application unit is dimensioned such that the first application unit presses the top layer in the area of the second embossing and in the area of the at least one third embossing, and wherein the contact pressure of the second application unit is dimensioned such that the second application unit only wets the top layer in the area of the at least one third embossing
Implementation Method 2
a first embossing roller for embossing an upper layer, wherein the first embossing roller has at least one first embossing elevation with a first embossing height, at least one second embossing elevation with a second embossing height and at least one third embossing elevation with a third embossing height
Data Source
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AI summary
Device for multi-colored gluing of at least two-ply tissue products, comprising a first embossing roller for embossing a top layer, wherein the first embossing roller has at least one first embossing raised area with a first embossing height, at least one second embossing raised area with a second embossing height, and at least one third embossing raised area with a third embossing height, wherein the third embossing height is greater than the second and the second is greater than the first, wherein at least two coating units are assigned to the first embossing roller, wherein the contact pressure of the first coating unit is dimensioned such that the first coating unit wets the top layer in the area of the at least one third embossing raised area, and wherein the contact pressure of the second coating unit is dimensioned such that the second coating unit wets the top layer in the area of the at least one second and in the area of the at least one third embossing raised area, further comprising a second embossing roller for embossing a bottom layer.furthermore, a comprehensive marriage roller for joining the base layer to the top layer.