Single-Stack Multi-Ply Lamination for Stronger Ply Bonding
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Solution Overview
Problem
The manufacture of multi-ply paper products with three or more plies requires multiple lamination stacks, increasing financial and spatial investment, and affects attributes like strength, stretch, caliper, absorbency, and aesthetics.
Innovation Solution
A method for manufacturing multi-ply paper products using a single lamination stack by controlling process variables such as anilox roll speed, adhesive solids content, and applicator gap width to form adhesive bonds between at least three cellulosic fibrous plies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple lamination stacks are used to manufacture multi-ply paper products with three or more plies, then the number of plies in the final product is increased, but the financial investment and facility footprint required are increased
Solution Approach 1:
The patent combines multiple lamination functions into a single lamination stack by configuring multiple adhesive applicators and doctor blades within one stack, allowing three or more plies to be bonded simultaneously without requiring multiple separate stacks
Solution Approach 2:
The single lamination stack is designed to perform multiple lamination functions - bonding multiple plies together through different adhesive applicators and doctor blades configured within the same stack, making the equipment multi-functional
2Quantity of substance
If multiple lamination stacks are used to manufacture multi-ply paper products, then three or more plies can be formed, but the facility footprint required is increased
Solution Approach 1:
Multiple lamination operations that would traditionally require separate stacks are merged into a single compact lamination stack, reducing the horizontal space required in the facility while maintaining the capability to bond three or more plies
3Quantity of substance
If traditional multi-stack lamination is used, then multiple plies can be bonded, but ply bonding quality is compromised
Solution Approach 1:
Each adhesive applicator and doctor blade is independently configured with specific gap settings and adhesive application rates tailored to the particular ply being bonded, ensuring optimal bonding conditions for each interface rather than using uniform settings across all plies
Solution Approach 2:
The system allows independent adjustment of adhesive solids content, applicator gap width, and anilox roll speed for each adhesive application zone, enabling optimization of bonding parameters for different ply combinations and adhesive types
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 results in improved ply bonding between the plies, enhancing attributes like plybond, caliper, and absorbency while reducing equipment needs.
Implementation Method 1
transferring an adhesive having a solids content of from about 6% to about 10% from an anilox roll to the adhesive applicator roll
Implementation Method 2
transferring the adhesive from the adhesive applicator roll to a first surface of the second ply at the first nip, whereby some portion of the adhesive remains on the first surface of the second ply and some portion of the adhesive is driven though the width of the second ply to the second surface of the second ply and forms a first adhesive bond between the first ply and the second ply
Data Source
AI summary
Disclosed herein are methods for manufacturing multi-ply paper products, such as napkins, towels, tissues, and wipers are disclosed. More particularly, methods of manufacturing a multi-ply paper product having at least three plies by controlling a combination of process variables, including at least anilox speed, adhesive solids, and adhesive applicator roll nip gap. Multi-ply paper products having at least three cellulosic fibrous plies with improved ply bonding between the first, second, and third plies are also disclosed.