Wet Lamination Roller Setup for Holed Paperboard Adhesive Containment
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Solution Overview
Problem
Wet lamination of substrates with going-through holes is associated with adhesive leakage onto lamination rollers, causing equipment pollution and integrity issues in packaging containers.
Innovation Solution
Adjust the distance between the nip and support rollers to accommodate the thickness of the bulk and barrier layers, using an elastomeric nip roller with a Shore hardness of at least 90 ShA and a metal support roller, ensuring the adhesive is contained within the nip, reducing adhesive leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If wet lamination is used to laminate barrier film to bulk layer with going-through holes, then lamination quality is improved, but adhesive leakage onto rollers occurs causing equipment pollution
Solution Approach 1:
The patent changes the physical parameter of the nip roller by specifying its Shore hardness must be at least 90 ShA, making it significantly harder than conventional rollers. This parameter change prevents the roller from deforming and filling the going-through holes in the bulk layer, thereby containing the adhesive within the nip area and preventing leakage onto the roller surface while maintaining effective lamination bonding
2Ease of manufacture
If conventional soft nip roller is used, then adhesive application is effective, but adhesive leaks through going-through holes onto the roller
Solution Approach 1:
The patent fundamentally changes the hardness parameter of the nip roller from soft (conventional) to very hard (Shore hardness ≥ 90 ShA). This parameter change enables the roller to maintain its shape under pressure and prevent adhesive from leaking through the going-through holes in the bulk layer, while still providing sufficient pressure for effective adhesive application and lamination bonding
3Device complexity
If roller distance is not adjusted for material thickness, then lamination process is simple, but adhesive containment fails causing leakage
Solution Approach 1:
The patent introduces dynamic adjustability to the nip roller distance from the support roller, allowing the gap to be adjusted according to the combined thickness of the bulk layer and barrier film. This dynamic adjustment ensures proper adhesive containment for different material combinations while maintaining a relatively simple overall process structure
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
Prevents adhesive leakage and equipment pollution by optimizing roller alignment and material composition, maintaining lamination quality and equipment cleanliness.
Implementation Method 1
The outer circumferential surface of the nip roller is in an elastomeric material having a Shore hardness of at least 90 ShA
Implementation Method 2
coating the barrier film or sheet with a wet adhesive, feeding the coated barrier to a nip formed between a nip roller and a support roller and feeding the bulk layer to said nip, thereby allowing the bulk layer to adhere to the barrier film or sheet by means of the adhesive
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
A method and wet lamination station for lamination of a barrier film or sheet (6) to a bulk layer (5) of paper or paperboard or other cellulose-based material, said bulk layer (5) being provided with going-through holes (3).