Progressive Tissue Embossing Assembly for Deeper 3D Patterns
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Solution Overview
Problem
Existing embossing technologies for tissue paper, such as steel/rubber, steel/steel, and steel/paper processes, are limited in their ability to achieve high levels of penetration and thickness, particularly in the steel/rubber process, which restricts the three-dimensional effects and overall quality of the embossed product.
Innovation Solution
A progressive embossing assembly with three stages: initial steel/rubber embossing followed by a steel/steel embossing stage, allowing for increased penetration and thickness by incorporating an intermediate steel/steel stage, ensuring synchronized embossing of continuous strips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If steel/rubber embossing process is used, then the embossing can be applied to tissue paper, but the penetration level and thickness are limited
Solution Approach 1:
The embossing process is divided into multiple sequential stages: first steel/rubber embossing, then steel/steel embossing. Each stage performs a specific function - the first stage creates initial embossing with controlled penetration, while the second stage achieves deeper penetration and greater thickness. This segmentation allows the system to overcome the penetration limitations of single-stage processes.
Solution Approach 2:
The steel/rubber embossing stage performs preliminary embossing on the tissue paper before the final steel/steel embossing stage. This preliminary action prepares the paper surface and creates initial relief structures, which then serve as the basis for the deeper embossing in the subsequent stage, achieving cumulative penetration效果.
2Manufacturing precision
If steel/steel embossing is used, then higher penetration and thickness can be achieved, but the process complexity increases
Solution Approach 1:
The patent merges two different embossing technologies (steel/rubber and steel/steel) into a single integrated process line. The steel/rubber embossing unit and steel/steel embossing unit are combined sequentially, allowing the system to leverage the advantages of both methods - the controlled embossing of steel/rubber and the high penetration of steel/steel - while managing complexity through integration.
Solution Approach 2:
The embossing process maintains continuous action throughout both stages without interruption. The tissue paper continuously passes through the steel/rubber embossing stage and then immediately through the steel/steel embossing stage, ensuring that the useful action of embossing is sustained and cumulative, maximizing penetration and thickness efficiency.
3Shape
If multiple embossing stages are added to increase penetration, then the three-dimensional effects improve, but the device complexity and synchronization requirements increase
Solution Approach 1:
The patent incorporates synchronization mechanisms that monitor and adjust the operation of multiple embossing stages. By implementing feedback control, the system ensures that each embossing stage operates in precise coordination with the others, maintaining consistent paper feed rate and embossing timing, which is critical for achieving uniform three-dimensional effects across the entire paper surface.
Solution Approach 2:
The embossing stages are designed to operate at compatible speeds and pressures, creating equipotential working conditions throughout the process line. This ensures that each stage can perform its function optimally without creating bottlenecks or synchronization issues, as all stages operate under matched operational parameters.
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 assembly achieves higher thickness and more significant three-dimensional effects in tissue paper, enhancing the quality and appearance of the final product through improved synchronism and progressive embossing stages.
Implementation Method 1
the pressure between them causes the engraving (4) to be pressed against the surface of the tissue paper (1A) forcing it against the rubberized surface of the roll (3), consequently, the embossing (4) is transferred to the tissue paper (1A) by a process of deformation of the contact points/elements
Implementation Method 2
the third stage of progressive embossing (12) is formed by the same steel rollers (2), both are synchronized, where the engravings (4) are male and female, between which the continuous strips of tissue paper (1A) and (1N) pass simultaneously
Data Source
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AI summary
Comprising an integrated module (5) to generate a progressive embossing (on the same embossing elements) of at least two continuous strips of paper, traditionally known as "tissue paper" which, after being juxtaposed, form a continuous strip of bulky and soft paper for the manufacture of toilet paper.