Paper Cushioning Embossing Wetting Applicator
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Solution Overview
Problem
Existing methods for producing paper-based cushioning materials face challenges in creating effective shock absorption without tearing, especially with recycled paper, due to the stress and thinning of paper during embossing, which requires additional laborious wetting processes.
Innovation Solution
A method involving the wetting of paper with a liquid, preferably using an applicator for full-surface or patterned application, followed by passing it through embossing means with alternating elevations and cavities, allowing for embossing of high bulges without tearing, and optionally using heat to enhance penetration and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the paper is embossed with high bulges to provide sufficient cushioning, then the cushioning capability is improved, but the paper is stretched and thinned causing tearing
Solution Approach 1:
The patent applies preliminary wetting to the paper before embossing to soften the fiber structure and increase tensile strength. This preliminary action prepares the paper to withstand the subsequent embossing process without tearing, resolving the contradiction between achieving high cushioning bulges and maintaining paper integrity.
Solution Approach 2:
The patent changes the physical-chemical state of the paper by wetting it with water or steam, which softens the fiber structure and increases tensile strength. This parameter change allows the paper to undergo significant deformation during embossing without tearing, enabling high cushioning capability while maintaining reliability.
2Strength
If the paper is wetted with water to soften fiber structure and increase tensile strength, then the paper can withstand embossing stress, but an additional manual wetting step is required
Solution Approach 1:
The patent combines the wetting step with the embossing process by integrating a liquid application device into the embossing press system. This merging of operations eliminates the need for separate manual wetting steps, reducing device complexity while maintaining the tensile strength benefits of wetting.
Solution Approach 2:
The embossing press system performs the wetting function itself through an integrated liquid application device, making the system self-sufficient. The press applies liquid to the paper automatically during the embossing process, eliminating the need for external manual intervention and simplifying the overall process.
3Object-generated harmful factors
If recycled paper with undefined fiber lengths is used, then environmental friendliness is improved, but the individual fibers do not yield to tensile stress and the paper tends to tear
Solution Approach 1:
The patent changes the physical state of recycled paper fibers by wetting them with liquid, which softens the fiber structure and increases flexibility. This parameter change allows recycled paper with undefined fiber lengths to yield to tensile stress during embossing without tearing, maintaining both environmental friendliness and structural integrity.
Solution Approach 2:
The patent applies preliminary wetting to recycled paper before embossing to prepare the fiber structure. This preliminary action softens the rigid recycled fibers, enabling them to withstand the embossing process and form high bulges without tearing, thus preserving the environmental benefits of using recycled material.
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 method simplifies the wetting process, enhances the cushioning material's stability and absorption capabilities, and allows for automated and uniform application, reducing the risk of tearing and improving the material's performance as a shock-absorbing filler.
Implementation Method 1
This can be countered by wetting the paper with water. This softens the fiber structure, allowing for greater tensile strength without tearing.
Implementation Method 2
optionally using heat to enhance penetration and stability
Data Source
Figure 1~2
Figure 3
AI summary
It is already known to use paper products instead of blister foil, which are embossed on both sides to create a three-dimensional structure, allowing them to be used as filling and cushioning material. However, even with short-fiber paper, it is problematic that it tears during the embossing process. With paper with longer fibers, especially recycled paper, the cohesion is insufficient. It is therefore also known to wet the paper with water. However, this is a cumbersome step. The invention aims to significantly simplify this step. This is achieved by using an applicator to apply the water. Like ink, the water can be applied to the paper to keep it sufficiently moist for the embossing process.It is also possible to use ink to apply a flat print, which also ensures sufficient wetting, but at the same time creates an optical effect.