Heatable Embossing Rolls for Tissue Ply Bonding
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Solution Overview
Problem
Existing tissue paper manufacturing processes struggle to produce products with sufficient thickness, softness, and tensile strength while maintaining good absorption capacity.
Innovation Solution
An apparatus with synchronized heatable embossing rolls and a marrying roll is used to emboss and ply-bond tissue paper plies, employing heat-embossing to create nested or tip-to-tip bonding structures, and an adhesive supplying unit for precise adhesive application, allowing for high-speed production with increased strength and absorption capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional embossing and bonding processes are used, then production speed can be maintained, but the tensile strength and absorption capacity of the tissue paper product are insufficient
Solution Approach 1:
The embossing operation is performed in advance of the bonding operation. The heatable embossing roll creates embossed patterns on the tissue paper web before it reaches the bonding section, allowing the paper fibers to be pre-shaped and pre-heated. This preliminary embossing action enhances the subsequent bonding strength without requiring additional processing time, thereby maintaining high production speed while improving tensile strength
Solution Approach 2:
The patent combines the embossing function with the heatable roll that will later be used for bonding. The same heatable embossing roll serves dual purposes: creating the embossed pattern and providing the heat necessary for subsequent bonding. This merging of functions eliminates the need for separate embossing and heating sections, maintaining production speed while enhancing bond strength through the embossed structure
2Strength
If adhesive bonding is used to combine plies, then bonding strength is improved, but the absorption capacity of the tissue paper product decreases
Solution Approach 1:
The patent replaces chemical adhesive bonding with mechanical bonding through embossing. The heatable embossing roll creates embossed patterns that mechanically interlock with the counter roll, forming bonds through physical interlocking rather than chemical adhesion. This mechanical bonding mechanism maintains porosity and does not require adhesive materials, thereby preserving the absorption capacity of the tissue paper while achieving sufficient bonding strength
Solution Approach 2:
The embossing process creates a porous, three-dimensional structure on the tissue paper surface. This porous embossed structure allows for mechanical interlocking during bonding while maintaining the overall porosity and void spaces necessary for fluid absorption. The embossed pattern provides bonding strength through physical interlocking without filling the pores with adhesive, thus preserving absorption capacity
3Quantity of substance
If multiple plies are combined with mechanical bonding, then absorption capacity is maintained, but the bonding strength and softness are insufficient
Solution Approach 1:
The patent changes the temperature parameter by using a heatable embossing roll. The heat applied during embossing softens the paper fibers, allowing them to deform and interlock more effectively with the counter roll. This thermal parameter change enhances the bonding strength of the mechanical embossing process while maintaining the porous structure necessary for absorption capacity
Solution Approach 2:
The patent creates a composite structure through the embossed pattern, where the raised and recessed areas of the embossed web interlock with the counter roll to form a composite bonded structure. This composite embossed-bonded structure achieves both bonding strength and porosity, combining the benefits of mechanical bonding with enhanced structural integrity
4Shape
If embossing is performed to increase thickness and softness, then product quality is improved, but the production speed decreases
Solution Approach 1:
The heatable embossing roll serves multiple functions simultaneously: it creates the embossed pattern for thickness and softness, provides the heat necessary for subsequent bonding, and prepares the fiber structure for better interlocking. This multi-functionality eliminates the need for separate embossing and heating sections, allowing the embossing operation to proceed at high speed without compromising product quality
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 method results in tissue paper products with enhanced tensile strength, absorption capacity, and maintained softness, with strength increases of 5-25% and absorption capacity gains of 15%, while processing speeds reach up to 700 m/min without compromising product quality.
Implementation Method 1
a first heatable embossing roll, a second heatable embossing roll... configured to emboss a first ply between the first heatable embossing roll and the first counter roll
Data Source
AI summary
This disclosure relates to an apparatus for manufacturing a tissue paper product, such as toilet paper or household towel. The apparatus comprises an embossing unit comprising a first counter roll, a first heatable embossing roll, a second counter roll, and a second heatable embossing roll, and a marrying roll. The apparatus is configured to emboss a first ply between the first heatable embossing roll and the first counter roll, to emboss a second ply between the second heatable embossing roll and the second counter roll, and to ply-bond the first ply and the second ply between the first heatable embossing roll and the marrying roll.