DE102004001327A1 - Laser perforation of continuous strip, e.g. for cigarette or coffee filters, involves a circular multiplexer feeding light guides to on-line perforating unit - Google Patents

Abstract

Continuous strip (1) is fed to a perforating unit (69) where double lines of accurately positioned holes are produced at rates up to 2,000,000 holes/sec by laser light guided sequentially through up to 200 hollow fiber light guides (13). Laser beams (3) are split by circular multiplexers (2), e.g. rotating beam splitters, and supply light to light guides fitted round the periphery : An independent claim is also included for the equipment needed for this process involving a beam splitter using a rotating mirror or multi-facetted polygon. Focussing (20) and positioning of the beams is mechanized according to the results measured by downstream monitoring sensors (68), checking hole size and porosity.

Description

The Invention describes and includes methods and apparatus for Laser perforation moved up to 600 m / min and up to 2000 mm wide webs, wherein the generated laser rows or rows of holes arranged substantially parallel to the transport direction of the web are.

Under moving webs are in the context of this invention in particular Paper or otherwise refined tracks to understand such. B. Cigarette, mouthpiece coating and coffee filter papers, filter wrap papers called plug wraps, Security papers, holographic printed, foil pressed, coated or metallized paper or packaging or even certain Plastic sheets such as BOPP, LDPE, HDPE, spin nonwovens, etc. at least in the area of the perforations a certain degree of gas or water permeability exhibit.

These Materials are for various finishing processes in the format of 400-2000 mm as big rolls, or also called Jumbo rolls, in lengths up to 25,000 meters and Roll diameters up to 1500 mm unrolled and rolled up.

Therefore are in this invention with broad webs material widths of at least 200 mm, which is for tipping paper transferable to at least 3 bobs is to look at.

in the Similarly, the laser perforation is called offline perforation and is clearly different from the online laser perforation to cigarette manufacturing or filter attachment machines or else From packaging machines. The ones with the human eye normally not visible, or if desired Visible, perforations are very strong with focusable single laser beams precise in the hole size and hole position produced. Due to the physical conditions and thermal Properties and associated absorptions of the preferred used webs come CO2 power lasers in the wave range from 10.4 to 10.8 μm.

• • Materialflächengewichte: 16–100 g/m²
• • Materialbahndicken: 30–80 μm
• • Materialbedruckungen: unterschiedlichster Art und Positionen – meist außerhalb der Perforationsbereiche
• • Bahnbreiten: 400–2000 mm
• • Bahngeschwindigkeiten: bis zu 600 m/min
• • statische Porositätsmessung: Luftdurchsatzmeßsysteme, z. B. Borgwaldt oder Sodimat
• • physikalische Messeinheit der Gasdurchlässigkeit, hier als Porosität genannt für diese Meßsysteme: Coresta Units – ml/min/cm
• • Porositätsbereiche: 80–4000 C. U.
• • Porositätsvariationen: < 3% bei Porositätsbereichen von > 400 C. U.
• • Lochgrößen: 60–300 μm, als Mikro- oder Makrolöcher
• • Lochdichten: 5–40 Löcher pro cm in Bahnlaufrichtung
• • Lochformen: optimal rund bis leicht oval, ohne Außengrad
• • Porosität pro Perforationsloch: 8–80 C. U.
• • Anzahl der Laserlochreihen pro Bobienenseite und Bobiene: 2–6 auf jeder Seite – somit 4–12 für jede einzelne Bobiene
• • minimale Abstände zwischen zwei nebeneinander liegenden Lochreihen: 1.0 mm
• • Lochreihen- oder Lochreihengruppenabstand untereinander: 10–40 mm
• • Anzahl der Einzellochreihen über die Bahnbreite verteilt: 8–120 und mehr
• • Positionierung jeder Laserlochreihe über die Bahnbreite: +/–0.1 mm
• • Lochanzahl für alle Lochreihen zusammen: 100.000–2.000.000 Löcher pro Sekunde
• • Kinetische Energie pro erzeugtes Laserloch – je nach Materialart: 2.0–4.0 mJ
• • Zeitfenster des Laserstrahles pro Perforationsloch: 20–50 μs
• • CO-2 Laser 10.6 μm Wellenlänge und optische Leistungen von 500–4000 Watt
• • CW- oder Puls-Betrieb bis 10.000 Hz, einstellbares Impuls-Pausen-Verhältnis
• • Schwankungen der optischen Laserleistung: 2–4% max.
• • Lasermoden: TEM00 Grundmode oder höhere Moden
• • Strahlqualitätsfaktor: M = 0.6–1.0 mrad
• • Energiedichten bei Fokussierungen des Hauptstrahles in Größenordnungen von 100–200 μm: 1 – 10·10E8 Watt/cm²
• • Durchmesser des zugeführten Laserstrahles: 8–12 mm
• • sehr präzise und gleich bleibende Materialbahnführung im Fokusbereich mit Bahnschwankungen < 100 μm
• • Rotation von Drehspiegeln oder anderen optischen Elementen: 10.004–50.000 U/min

For this, the essential facts and requirements of the offline laser perforation for the initially mentioned webs can be summarized as follows:

• • Stock weights: 16-100 g / m ²
• • Material web thicknesses: 30-80 μm
• • Material printings: various types and positions - usually outside of the perforation areas
• • Web widths: 400-2000 mm
• • Web speeds: up to 600 m / min
• • static porosity measurement: air flow measuring systems, eg. B. Borgwaldt or Sodimat
• • physical measuring unit of the gas permeability, here called porosity for these measuring systems: Coresta units - ml / min / cm
• • Porosity ranges: 80-4000 CU
• Porosity variations: <3% for porosity ranges of> 400 CU
• • Hole sizes: 60-300 μm, as micro or macro holes
• • Hole densities: 5-40 holes per cm in web direction
• • Hole shapes: optimally round to slightly oval, without outer grade
• • Porosity per hole: 8-80 CU
• • Number of rows of laser holes per baton side and bobies: 2-6 on each side - thus 4-12 for each individual bobies
• • minimum distances between two adjacent rows of holes: 1.0 mm
• • Pitch or row spacing between each other: 10-40 mm
• • Number of single-hole rows distributed across the web width: 8-120 and more
• • Positioning of each laser hole row over the web width: +/- 0.1 mm
• • Number of holes for all rows of holes together: 100,000-2,000,000 holes per second
• • Kinetic energy per generated laser hole - depending on the material type: 2.0-4.0 mJ
• • Time window of the laser beam per perforation hole: 20-50 μs
• • CO-2 laser 10.6 μm wavelength and optical powers of 500-4000 watts
• • CW or pulse operation up to 10,000 Hz, adjustable pulse-pause ratio
• • Optical power fluctuations: 2-4% max.
• • Laser modes: TEM00 basic mode or higher modes
• • Beam quality factor: M = 0.6-1.0 mrad
• • Energy densities for focusing of the main beam in the order of 100-200 μm: 1 - 10 · 10E8 Watt / cm ²
• • Diameter of the supplied laser beam: 8-12 mm
• • very precise and constant material web guidance in the focus area with web fluctuations <100 μm
• • Rotation of rotating mirrors or other optical elements: 10,004-50,000 rpm

Under this physical-technical background and the high product requirements The following invention of the offline laser perforation can be seen and are their advantageous solutions Developed.

The state of the art for deflecting, Redirecting, passing on and pulsing CO2 laser beams is described in a large number of international and national patents, so that at this point the industrial property rights are given, which are directly or indirectly related to the perforation of the webs from the above-mentioned fields of application stand.

In the patents DE 29.18.283 C2 . DE 195.11.393 A1 . FR 21.30.698 and US 41.18.619 Basic methods and devices are specified and described in detail, with which laser beams by rotating mirrors, polygons or diffractive optical elements also called DOE's, deflected at an angle mostly below 90 degrees and / or doubled on continuous paper webs are used for perforation. These methods and device techniques are in the years thereafter for many offline laser perforating machines, as multiple Bobienenperforationsanlagen with up to four simultaneously processed Bobienen, Bobienenlängen up to 4000 meters, up to 32 Einzelstrahlkanälen, web widths up to 400 mm, web speeds up to 600 m / min and hole sequences up to 500,000 L / sec. successfully converted.

From the patents on online perforation to cigarette manufacturing or filter tying machines, e.g. B. the US 5,404,889 . US 5,746,229 . JP 100.34.365 A . US 6,229,115 . US 6,064,032 . US 200,100,38,068 . US 200,301,31,856 and US 200,201,580.50 Technologically very high-quality solutions for laser beam deflection and deflection with oscillating mirrors and special optical graduation elements are described in detail. These relate exclusively to a maximum of two Bobienen- or two Bobienenstreifen, the laser perforation often enters through the tipping papers through the filter to lower the nicotine and pollutant levels of cigarettes produced immediately afterwards.

In further patents of PCT WO-99/58006 and EP 0,624,424 B1 Also described are ON-LINE laser perforation methods and devices which incorporate special optical elements, e.g. As acousto-optical transducers, Prismenstrahlumlenkungen with special paper web guide use to perforate a maximum of two Bobienenstreifen just before the production of cigarettes.

A very interesting method and apparatus for OFF-LINE laser perforation of wide tipping paper webs is described in PCT WO-98/39135 and US Pat EP 0909606 specified. Up to 40 individual beam channels are generated over the web width with mechanically very elaborate laser beam guides fixed at 90 degrees to the direction of web travel, and entire production rolls are arranged with automated bobbin changing devices, also with online porosity devices directly after the perforation, and thus perforation-technologically improved.

For such highly automated Breitbahnperforationsanlagen comparable online Porositätsmesseinrichtungen including in the DE 102.51.610.3 described.

to further supplement and in the direct context of this invention are also current publications like: standardized and flexible beam guidance systems for laser material processing, Dieter Frank, GMS Frank Optic Products 2002; flexible hollow waveguide for new ones Laser applications, Prof. Dr. med. Klaus Behler 2002; flexible hollow-core waveguides for CO2 laser, potential and limitation as beam guiding system for material processing, Prof. dr. Behler 2003; Silica Waveguides from Polymicro Products; high-power laser fibers, CeramOptec GmbH 2003; Lincoln laser high-speed scanner Laser products; a new slab laser concept allows improved beam properties, Keming Du, EdgeWave GmbH 2003; Trumpf Laser the path of the laser beam from the laser device to the workpiece 2003; Rofin Baasel Lasertech GmbH press release Perfolite and high-end Perfolas, 2001-2003; Micro Laser Technology GmbH, products of the MLP-10 and MLP-50, cited.

As from the cited Fonts can be seen are with the previous methods and devices usually perforate two bob strips online as well as with the offline laser perforations up to a maximum of 4 bobbins and 32 single beam channels at 90 degrees to the web running mechanically very complex, optical beamlines and focusing, so as to position each individual laser line of perforation to achieve the continuous material web.

The Breitbahnperforationsverfahren from PCT WO-98/39135 and EP 0909606 allows the perforation of up to 20 simultaneously produced Bobienen, where it is easy to see that the number of mechanically very complex guided individual beam channels is limited to 40.

With respect to the prior art and the cited patents, a first consideration regarding the limited optical beam channels and the resulting laser perforation lines per bobbin side shows the following image;
With 32 single-jet channels and 4 simultaneously perforated bobbins, 4 laser-hole lines per bob-side are possible.

For the mentioned Breitbahnperforationsverfahren with up to 20 simultaneously processed Bobienen and 40 optical single rays is only one Laser hole line per Bobienenseite generated.

One Another essential aspect is the limitation of the hole sequences at 100,000 to about 400,000 holes per second, the fed, optical beam power of a laser beam of currently about 2000 Watt at Offline and approx. 300 Watt at Online Laser Perforation Systems with high rotating polygonal or rotating mirrors to see otherwise the individual energies for each generated laser hole in the web is no longer sufficient. This leaves Easily determine according to the given listing.

there It should be noted that the web speeds in the offline Laser perforation in the range up to 600 m / min and at the online perforations move at the cigarette machines at about 160 m / min.

Furthermore, it is known from the patents, the practical procedures and from the laser perforation systems on the market that an automated and completely automatic adjustment of the laser line positioning and focusing on the material web is completely impossible because, on the one hand, the individual optical beam channels are not motor-adjustable and / or none geometric perforation and optical porosity detection after the perforation section, such. B. in the DE 102.51.610.3 described, is present. And this for systems with a maximum of 32 or even 40 individual laser lines.

Therefore is easy to see that a manual adjustment of the geometries all single jet channels extraordinarily laboriously, time-consuming and subsequently a later check during the running perforation almost entirely impossible is, so that deviations in the laser line position as well as in the hole quality individual rows of holes and associated porosity deviation, z. B. triggered by Dirt on the laser heads, influences the suction air and contamination of the guide rollers on the focusing, low web edge offset and the same more, only to the end the produced Bobiene and to the standstill of the machine recognizable are.

Also are in practice the ones with changes of Loch qualities associated porosity deviations while The current perforation can not be compensated directly, because almost exclusively all processes the optical laser power as a beam source very much Keep constant, but after beam splitting and focusing no impact possibilities the change the intensity the single beam channels consist.

Consequently are hole quality and Perforationsprofilkontrollen and the subsequent control loop to trend updates for the Perforation system simultaneously not possible, what with the high automation gad the production equipment is disadvantageous is. This applies in particular for an automated and fast setup and adjusting the perforation heads over the Web width in terms of positioning and initial porosity, as this u. a. for motorized lower and upper knife positioning of slitter winder systems is known.

In conclusion, be yet mentioned that almost all offline laser perforation methods and systems available on the market Bobiene for Bobiene ennoble, which means in practice, that after each bobien cut of 3000 or 4000 meters in length the machine is stopped, the bobbies exchanged and then the machine is put back into production.

This Start-stop operation not only reduces the overall efficiency of the Plant but generated by the acceleration and braking phases also a not inconsiderable percentage of scrap material in the Magnitude from 4-8%.

Therefore is easy to see that at very high web speeds up to 600 m / min and upgraded Laser and perforation services the stop phases for replacement the finished and to prepare the new Bobienen be up to 5 minutes can, what causes, that with 3000 meters long Bobienen the idle time between 30-50% amounts to can.

Therefore the invention has the object, all the disadvantages indicated the prior art methods and devices and to provide technical new solutions with which a much higher Number of laser beam channels, and up to 120 individual channels and web widths up to 2000 mm, possible are the geometries and also the focusing of all laser lines automated and by means of optical online porosity measuring device is adjustable.

And in the other whole production roles without stops with z. B. 20 bobbins in the web width of 1000 mm and z. At 18,000 production meters so a total of 120 bobbins perforation- and porosity-controlled, without any scrap material, can be finished with high efficiency.

For this In the following description of the invention, various design solutions are cited and explains their process and device details.

The inventive method and device for laser perforation of wide webs triggers the precedent Task by the main features of claims 1-21.

After that are basically available three possible solutions whose first conception is based on that of a highly rotating Mirror element a pulsed or non-pulsed laser main beam in a full 360 degree angle on a high number of optical entrance channels with coupled fibers and within a certain time window the laser energy feeds the individual fibers, which in principle an optical CO2 high performance laser multiplexer represents.

The Ends of all fibers are provided with focusing optics as microperforation heads and can by their flexibility and degree of freedom in an ideal way and with those in the market motor positioning systems, such. B. on slitter used, in the continuous material web, the laser hole lines anywhere and according to the perforation grid, produce.

Consequently are in this variant of the invention in the previous art very complex used, optical deflection and mechanical high quality guide elements completely avoided.

In the second conception are in full circle angle of 360 degrees as well a plurality of individual beam channels arranged in the center itself a highly rotating mirror element or special beam splitter located.

their The task is to use the incident, non-pulsed laser main beam, or four individual laser main beams, on the individual optical channels via a Time window, determined by the time when the laser beam the respective Entrance window sweeps over, couple.

Of the or the four simultaneous laser power beams then follow that optically fixed beam guidance by means of Linear guide units and motorized deflecting mirrors and in vertical Level subsequent Focusing units and micropertortation heads to the material web.

The circular Laserstrahlauffächerung is structurally designed so that their overall diameter is smaller or larger as the web width and the device above or below the continuous web comes to the arrangement. With the geometric adjustment of the deflection mirror all single jet channels across from the center of the beam feed, and the resulting skew adjustment across from the transversely passing material web, the laser perforation lines can be to the desired Create positions. Because the beamlines of each single channel only change in length, stay the focusing or beam divergence properties are not affected in the first instance, so that the previously stated beam quality factor is maintained.

And this taking into account the very close and or more widely positioned Laser hole lines, from z. B. 1.0 mm and 40 mm, depending on Bobienenbreite and screening. By a slight inclination of the overall arrangement across from the web will overlap avoided in the 90 and 180 degree range of the individual channels.

According to the invention is recognized and been confirmed by a variety of investigations and practical tests, that only with a circular arrangement a high number of single optical channels of z. B. 80, 120 or more is possible are, as yet with the Polygonstrahlauffächerungs- and Wellenbogentechnik up to a maximum of 32 single channels with Beam deflections of a laser power beam of less than 90 degrees is practiced.

Consequently can be z. B. at a web width for tipping paper of z. B. 1000 mm and 20 single bobbins, each 3 rows of perforations per Bobbin side, so 6 rows of holes per Bobiene generate. Add is nor that the web widths of the tipping paper caused by the standard widths of gravure printing machines almost without exception 1000 mm, which at different bob beech widths then different number of Schneidbobbienen leads.

Of Furthermore, it is technologically and production-wise a big advantage that with the highly rotating mirror elements or the one used here, special dual or quadruple beam splitter the circular orbiting Laser beams are operated with very high optical powers can, what the elementary prerequisite for the necessary laser energy Per perforation hole of 2.0-4 mJ in the web, which of course a high minimum speed should have, as well as for the Lochfolgefrequenz the individual and all channels of z. B. 2,000,000 holes per second together.

With the use of the new dual or quad laser power beam splitter for high Rotation speeds, it is now possible for the first time, including the relatively high circulation jet sequences and hole sequences of the many-numbered, single optical channels to realize with beam splitters.

In addition, quadruple laser beam outputs z. T. directly available, such as. B. at PRC-CO-2 laser sources, each with 500 watts of optical power, which makes the supply to the inventive device with up to 120 or even more individual optical channels significantly easier and performance achievable.

The third conceptual solution is with an inclined, highly rotating polygon wheel with z. B. 6 facets constructed, a fourfold and non-pulsed laser beam and associated jet fan-out of 4 x 2 x 45 degrees each over the associated one Circular sections of z. B. 4 · 30 individual channels offers a technological and technological first-class solution for the realization of the aforementioned basic requirements. By the Inclination of the polygon surface can be z. B. four laser beams obliquely incident from above to feed without that a gap in horizontal and equal level of the optical single channels necessary is.

Further Process and device advantages of this invention will become apparent from the relatively simple laser beam guidance with conventional, optical CO-2 components, the absolute identity of all individual channels, the compact execution of all Deflection and perforation heads, their mechanical-motor linear units very inexpensive, z. B. in Taiwan or even at Edmund industrial optics, are to be acquired.

Of Another is to emphasize that the technological and mechanical Effort for beam guidance and generating a high number of individual optical channels with the inventive, circular High-power laser multiplexer is significantly lower than this conventional fixed beamlines would be feasible with significantly smaller, single optical channels.

In order to are the technological realization and the investment effort for up to 120 or more single optical channels and wide webs up to 2000 mm practically only become feasible.

Finally, the not to be underestimated, productive advantages of all inventive conceptual solutions are given, which are based on the fact that now by the genus geometric perforation and optical porosity detection, z. B. as in the current DE 102.51.610.3 described, and through the functional feedback, it is possible to automatically and accurately position all the many individual beams and laser hole lines across the web. As well as their porosities and hole qualities of each row of holes or row of holes to capture and on the motor focussing of the inventive devices in certain areas, without deteriorating their hole qualities, adjust, so as to keep these essential product sizes largely constant.

below some calculations, which are exemplified for tipping paper webs, what comparability with the requirements issued at the beginning allowed. As can be seen from the results, this becomes more advantageous Way fulfilled, what practical tests of the first technological industrial designs approved to have.

Leave in the same way further calculation examples with different physical conditions for others Derive material web types from it.

• • bei A = 20 Löcher pro cm perforierter Lochlinie und Bahngeschwindigkeiten von 120 m/min: (120 m/min/60 Sek./min)·100 cm·20 Löcher/cm = 4000 Löcher pro Sekunde pro cm – pro Einzellochreihe
• • bei 120 Einzelkanälen: 120·4000 Löcher/Sekunde = 480.000 Löcher pro Sekunde
• • bei B = 20 Löcher pro cm perforierter Lochlinie und Bahngeschwindigkeiten von 300 m/min: (300 m/min/60 Sek./min)·100 cm·20 Löcher/cm = 10.000 Löcher pro Sekunde pro cm – pro Einzellochreihe
• • bei 120 Einzelkanälen: 120·10.000 Löcher/Sekunde = 1.200.000 Löcher pro Sekunde

For the hole repetition rate of each row of holes and in total for all:

• • at A = 20 holes per cm perforated hole line and web speeds of 120 m / min: (120 m / min / 60 sec./min) .100 cm x 20 holes / cm = 4000 holes per second per cm per single hole row
• • 120 individual channels: 120 x 4000 holes / second = 480,000 holes per second
• At B = 20 holes per cm perforated hole line and web speeds of 300 m / min: (300 m / min / 60 sec./min) .100 cm x 20 holes / cm = 10,000 holes per second per cm per single hole row
• • 120 individual channels: 120 · 10,000 holes / second = 1,200,000 holes per second

• • bei A = 4000 L/Sek/4 = 1000 U/Sek Für s Polygon mit 6 Facetten und vier Laserstrahlen:
• • bei A = 4.000 L/Sek/6/4 = 166.66 U/Sek
• • bei B = 10.000 L/Sek/6/4 = 416.66 U/Sek

For rotation of the beam part or inclined polygon, the following applies:
For the quadruple beam splitter, a rotation of:

• • at A = 4000 L / s / 4 = 1000 U / s For s polygon with 6 facets and four laser beams:
• • at A = 4,000 L / sec / 6/4 = 166.66 U / sec
• • at B = 10,000 L / s / 6/4 = 416.66 U / s

• • bei A = 1000 U/Sek. und 120 Einzelkanälen: 1/1000 Sek./(120/4) = 33.2 μs abzüglich der Zeit für das Ein- und Austauchen des Laserstrahles in die volle optische Öffnungsweite des Eintrittkanals mit ca. 40% = ca. 20 μs
• • bei A = 4000 Löcher/Sek. und 3.5 mJ/Loch = 4000·3.5 mJ·30 = 420 Watt Für geneigte Polygon mit 6 Facetten errechnet sich theoretisch:
• • bei A = 1000 U/Sek. und 120 Einzelkanälen: 1/1000 Sek./(120/4/6) = 200 μs abzüglich der Zeit für das Ein- und Austauchen des Laserstrahles in die volle optische Öffnungsweite des Eintrittkanals mit ca. 40% = ca. 120 μs
• • bei A = 4.000 Löcher/Sek. und 3.5 mJ/Loch = 4000·3.5 mJ·30 = 420 Watt pro Laserleistungsstrahl – bei 4 Strahlen = 1680 gesamte Laserleistung
• • bei B = 10.000 Löcher/Sek. und 3.5 mJ/Loch = 10.000·3.5 mJ·30 = 1050 Watt pro Laserleistungsstrahl – bei 4 Strahlen = 4200 Watt gesamte Laserleistung

Calculation of time and laser energy per fed or split beam:
For the quad beam splitter theoretically calculated:

• • at A = 1000 U / sec. and 120 individual channels: 1/1000 sec./(120/4) = 33.2 μs minus the time for the laser beam to enter and exit the full optical aperture of the inlet channel with approx. 40% = approx. 20 μs
• • at A = 4000 holes / sec. and 3.5 mJ / hole = 4000 · 3.5 mJ · 30 = 420 watts For inclined polygon with 6 facets theoretically calculated:
• • at A = 1000 U / sec. and 120 individual channels: 1/1000 sec./(120/4/6) = 200 μs minus the time for the laser beam to enter and exit the full optical aperture of the inlet channel with approx. 40% = approx. 120 μs
• • at A = 4,000 holes / sec. and 3.5 mJ / hole = 4000 x 3.5 mJ x 30 = 420 watts per laser power beam - at 4 beams = 1680 total laser power
• • at B = 10,000 holes / sec. and 3.5 mJ / hole = 10,000 x 3.5 mJ x 30 = 1050 watts per laser power beam - at 4 beams = 4200 watts total laser power

As from the simple, theoretical calculation examples is, the essential physical quantities move in the initially listed magnitudes, which has been further confirmed in practice.

It are now different ways to advantageously design the teaching of the present invention to further educate and indicate. On the one hand on the one hand in the claims 1-20 described designs, and on the other hand to the following explanations of several embodiments to refer to the invention with reference to the drawings 1-15.

In Connection with the explanation the preferred embodiments The invention and the drawings are also in general preferred embodiments and developments of the teaching explained. This especially for Material webs such as tipping papers as well as packaging webs of any kind and design.

in this connection show the drawings in detail:

1 schematic plan view of the 360 degree device with supply of a laser main beam and rotating mirror for 80 individual optical channels and fiber outcoupling and the underlying material web

2 schematic side view of in 1 shown, inventive device with laser beam supply and single fiber decoupling

3 Side view of the fiber extraction with the perforation head over the material web

4 Top view of the material web with the laser rows of holes behind 1

5 schematic plan view of the 360-degree device, feeding a and orbiting laser main beam and with a beam splitter for 80 single optical channels, linear guides and the underlying material web

6 Side view of the 5 with a laser beam supply, the rotating mirror, single beam deflection and the beam extraction on the material web

7 Side view of the 5 with a laser beam supply, and alternatively a rotating beam splitter, the single beam deflection and beam extraction on the material web

8th schematic plan view of the 360-degree device, supply of four main laser beams and rotating beam splitter for 80 individual optical channels and linear guides and the underlying material web

9 Side view of the 8th with quadruple laser beam supply, and alternatively a rotating inclined polygon, the single beam deflection and beam extraction on the material web

10 Top view of the material web with the laser rows of holes behind 8th

11 Top view of the material web with the laser rows of holes behind 8th and hole row details

12 Top view of the material web with the laser rows of holes behind 8th and further hole row details

13 Overall view of the broad-web laser perforation machine

14 Side view of the wide web laser perforation machine

15 General view of the fiber-coupled perforation section

1 shows the schematic plan view of the 360 degree device as optical CO2 high power laser multiplexer 2 with the feed pipe 3 for the laser main beam and rotating mirror 4 , which from the high-speed engine 9 , as it is offered by different manufacturers, is operated. The revolving laser beam 5 with direction 6 For every 360 full-angle revolutions, the 80 individual channels shown here overlap their optical inlet opening and topped cylindrical lens 10 , The lenses 7 and 8th , whose specifications simultaneously define the first and last optical channel, focus the respectively entering laser beam on the fiber coupling 12 , The decoupling takes place via the fibers 13 , which are preferably designed as CO2 hollow waveguide, and are available in the international market. Below the device 2 is the continuous material web 1 , with the feed direction 14 , drawn.

The diameter and the spatial arrangement of the optical CO2 multiplexer 2 is completely independent of the material web width and only determined by the geometric dimensions and optical element arrangements. In this example, the arrangement succeeds directly over the web 1 , in the 13 z. B. directly on the laser source output.

In continuation of this view shows 2 the side view with the beam feed tube 3 and the laser beam 15 , About the fixed deflection mirror 16 the main beam reaches the focusing lens 17 , which is usually water-cooled due to the high energy density, with a beam diameter of up to about 200 microns diameter on the high-rotating mirror 4 configured, deflected by 90 degrees and in full circle angle with direction of rotation 6 on the cylindrical lenses 10 to the respective fiber input 11 and 12 arrives. The high rotating mirror 4 can be designed as a plane mirror or as a parabolic mirror, and includes in its holder a mechanically precise recess to compensate for the high centrifugal forces.

Further require optical details At this point, no further explanation, as in the beginning mentioned patent specifications in detail are explained.

Each with the laser beam 15 acted upon and preferably CO-2 hollow fiber 13 , with z. B. 50 or 200 microns inner core diameter, the way is 3 executed. After that is at the end of the collimator system 19 and with the motor-adjustable interior optics 20 As a microperforation head, allowing a very fine focusing for hole sizes of 50-200 μm in diameter on the towards 14 continuous material web 1 can take place. These individual units 20 are also referred to as microperforation heads, and are, as described in detail above, distributed over the web width in two rows, motorized and automated positioned and thus produce the respective laser hole rows.

Under 4 with top view of the material web 1 and their feed direction 14 illustrated illustrated. For exact web guidance serve the two guide rollers 22 , It should also be noted that the perforation heads 19 , whose mechanical mounts and motorized transverse adjustments of simplicity are not shown here, since the Perforationsentstehung on the web 1 is illustrated. These can be split in two rows in the Y plane or arranged in two rows in the Y plane. As an example of the rows of holes produced in this procedure and sequence are with 23 . 24 . 25 . 26 . 27 and 28 characterized. The other, not further designated Perforationsköpfe for the rows of holes 24 - 28 are with the under 19 equivalent.

In 5 is the second, exemplary conceptual solution manifested. Again forms the full circle arrangement 2 the starting point with the material web passing underneath 1 and their feed direction 14 , With the high-speed engine 9 powered rotating mirror 4 The laser beam is deflected and exposed with each revolution all shown here 80 Individual channels. In contrast to the first conception solution here are motor-adjustable linear guide units 30 used for each single optical channel, with which by a position shift 32 and skew 33 occurs with respect to the X and Y axis and thus the positions of each individual laser hole row, and this completely independently, are possible in certain distance ranges. One each perforation head 31 is directly in the direction perpendicular to the material web 1 arranged what is in 6 is illustrated.

The first optical channel is as before, with 7 and the circumferential last optical channel with 8th characterized. The generated laser hole lines are subject to the same name 23 - 28 , wherein the necessary spatial offset of the individual perforation heads to closely adjacent rows of laser holes is clearly highlighted.

Basically the full circle arrangement of the high power laser multiplexer and the Single or also Multiple beam redirections, which in the drawing examples not are further specified, constructively chosen so that both their overall diameter be smaller but also bigger can, as the web width. And above or below the material web can be arranged in this way optimal positional shifts and geometries for to get the laser rows of holes.

in the further are the execution options also to understand that high-power laser beam multiplexer it is by multiple individual beam deflections, starting from the beam deflection center and outside the web width, the individual beams optically to the web width again are traced back which ultimately leads to a direct parallel shift in the X-direction compared to the allowed in the Y direction continuous material web.

This has the great advantage that no long displacement paths, as is the case with the oblique adjustment and angle change in the X-axis, and thus provides a direct comparability in the positioning of the perforation rows of holes at arbitrary locations of the material web with extremely short displacement paths , as practiced in the recent offline laser perforation systems for narrow web widths with up to four bobbins becomes.

In addition, it should be mentioned that the entire circle unit 2 The beam distribution has an extremely high mechanical stability and precision, as is known from conventional CO2 power beam guides.

Following and 5 is their side view with their details below 6 illustrated. In the manner already described several times leads from the top supplied and not focused here before laser beam 15 the orbital movement through the rotating mirror 4 and high-speed engine 9 in the direction 6 out. The cylindrical lens 29 and the motor-adjustable linear unit 30 with the deflection mirror 16 guides the rotating laser beam 34 vertically down 35 on the motorized focusing optics 20 to, with the in focus 21 the laser hole line on the material web 1 , with feed direction 14 , arises.

Another variant of the second conceptual solution is in 7 a special beam splitter 36 with beam feed 15 from above, instead of the rotating mirror used. Again, the drive via the high-speed motor 9 , This new, high-rotating CO2 beam splitter 36 has the basic shape of a cube with the beam entrance 38 from below or above and a double or quadruple beam exit 39 on the side edges, with almost identical performance and beam quality features. The variants are not further specified at this point, but also quadruple parabolic mirror are possible in place of the quadruple beam splitter.

As in 6 explained, follow the two or four circumferential single rays 37 the optical radiation pattern with the cylindrical lens 29 , motor 30 shiftable 32 deflecting 16 in the vertical direction 35 to every single perforation head 31 and the adapted motorized focusing optics 20 , In the focus area 21 arise the desired laser hole rows in the web 1 and their feed direction 14 ,

For a better understanding of the rotating quadruple beam splitting after 7 is 8th as a top view of the entire unit 2 specified.

The beam splitter 36 generates the four partial beams 37 . 40 . 41 and 42 simultaneously, so that the optical beam paths with the cylindrical lenses 29 to every 360 degrees of circulation in the direction 6 and time by the factor 4 allow faster exposure to the rotating mirror. This has the advantages already described with regard to the desired high hole repetition frequency for each single optical channel, starting with 7 and ending at 8th ; and the resulting laser hole lines 23 - 28 , The material web 1 is also in this direction 14 transported. For positioning the linear units 30 and the diameter of the entire unit 2 will be on the remarks of the 5 directed.

Another variant of the rotary rotating mirror is in 9 as a side view of the beam rotation with an inclined polygon wheel 43 which is also from the high-speed engine 9 is driven.

The polygon wheel 43 preferably 6 Facets with the z. B. with four simultaneously incident laser beams also four beam deflections over a fan-out range of 4 · 90 degrees to the full angle and to supply all the individual optical channels arise. The obliquely from above, z. B. at an angle of 30 degrees, incident principal ray 44 is preferably with a cooled lens 17 on a very small diameter 46 z. B. in the range of 50-200 microns on the polygon 43 focused, and hits in the defined angular range with each power beam 45 the individual optical channels with their cylindrical lenses 29 at the optical inlet. The beam transmission within each individual optical channel takes place in the manner described several times via deflection mirrors 16 , motorized adjustment 30 , Direction of movement 32 and 35 reaches the motorized focusing optics 20 and the perforation head 31 , The ray incidence 44 from above or below into the overall unit 2 has the same advantage as previously mentioned, that no spatial Aussparrungen in full angle of the unit 2 necessary.

On the Aufflächerungsbereich from Z. B. 4 · 90 Degrees or other constellations to the full angle of 360 degrees Supply of all individual optical channels are then optical laser powers from 4 × 500 Watt or 4 · 1000 Watt can be used, which is no problem with today's CO2 laser sources is feasible. With this solution Even extremely high perforation performance and thus can be achieved connected porosities up to 1000 C.U per hole row group, feed rates the material webs up to 300 m / min hole frequencies up to 2,000,000 holes per Generate second.

Explained afterwards 10 another division of the individual laser rows of holes over the web width, as already in 4 first executed. The material web 1 is over two guide rollers 22 very precise in the direction 14 guided and includes the example of the perforation head 19 generated laser hole series 23 , The perforation heads staggered by others in the Y axis create the laser rows of holes 24 . 47 . 48 . 49 and 50 , This embodiment is z. B. well on packaging webs transferable.

An enlarged view of the laser hole row arrangement on the material web 1 , as in playful for tipping papers, is in 11 specified. Clearly here are the previously mentioned laser hole series 23 - 28 as well as further 51 - 54 to recognize in the cut and distributed over the web width. With 55 . 56 and 57 the designated Bobbie sections are marked. Of course, these are in the feed direction 14 the material web 1 pronounced rows of laser holes and in this example selected groups of two per buffy side.

In the further enlargement of the 12 This arrangement is found again, with additional gold strips 61 and the later cut edges 62 every single bobbie, in clipping with 55 and 56 named, reflected. To illustrate the hole diameter in the range of 50-200 microns they are symbolic with 59 and their distances of the individual holes of each row of holes in the feed direction 14 specified.

With the three final drawings of the 13 - 15 should be an overall view and practical embodiments of the inventive Breitbahnlaserperforationsanlage and their new components are taught.

After that shows 13 the overall view of the wide web laser perforation system with the unwinding 63 , centrally inserted perforation section 69 , the subsequent optical online porosity measuring device 68 and the reeling 64 , The material web 1 rolls as indicated, in direction 14 from. The common laser source 66 leads in this example two main laser beams 3 to the two units of the optical multiplexer 2 , which also here for example and for beam guiding reasons not on the material web 1 but directly after the laser source 66 are positioned. All individual fibers 13 are easy to install way to the motorized focusing optics 20 guided.

The spatial distance between both optical multiplexer units 2 and the perforation section can be up to 5 meters, as z. B. of industrial CO2 power laser systems for welding, joining, cutting, finishing and other material processing is known, which again underlines the other advantages, especially the high flexibility and integration of the laser beam fibers on both crossbars of the perforation section of the inventive versions.

14 gives an impression of the entire Breitbahnlaserperforationsmaschine in the side view. Clearly here are the two guide rollers 22 and the automatically positionable focusing optics 20 to recognize.

Another section shows the final 15 the entire perforation section 69 with the direction 14 to material web inlet 1 , In this view are the two crossbeams with recording of the individual perforation heads 31 , their fiber feed 13 and the two motorized positioning shown enlarged. All further details need no further explanation.

Basically still to add that in all three variants of solutions described here by way of example the supplied Laser power beams in continuous operation, so not pulsed, but also in time and in dependence from the rotations of the beam redirecting or beam splitting components and beam positions triggered in front of the inlet ports of the individual channels, can be pulsed.

To the Conclusion is emphasized that the inventive Teaching through the many embodiments merely explained but not restricted is. Rather lets the teaching of the invention also further process steps and device variants for laser perforation from wide webs, the other or more constructive features exhibit.

Claims (21)

Method for laser perforation of wide webs ( 1 ), such. For cigarettes, tipping or coffee filter papers, filter wrapping papers, so-called plug-wraps, security papers, holographically printed, film-pressed, coated or metallised paper or packaging or also certain plastic webs such as BOPP, LDPE, HDPE or spin nonwovens with visible or invisible laser beams, their rows of holes ( 23 ) substantially parallel to the transport direction ( 14 ) the train ( 1 ) are formed, characterized in that by a trained between 90 to 360 degrees orbital motion of one or more high-power laser beams ( 5 ) all in the outer circle of the optical high-power laser multiplexer circumferentially located optical single channels ( 7 . 8th ) supplied with the supplied, full laser beam power over a specific and the same time window for all individual channels and thus a large number of individual optical channels ( 7 . 8th ) are available with the same optical power and without beam quality losses. A method according to claim 1, characterized in that a powerful laser beam ( 3 ) in the wavelength range of 10.4-10.8 microns centric from the top or bottom in a fast rotating, cubic beam splitter element ( 36 ) occurs, and at two or four side surfaces temporally simultaneously and in approximately the same power division, the partial beams ( 37 . 40 . 41 . 42 . 43 ) without significant losses of divergence or beam quality. A method according to claim 1 and 2, characterized in that the temporally simultaneously from the beam splitter ( 36 ) exiting partial beams by rotation in 360 degrees full angle the circumferential optical single channels ( 7 . 8th ) in the number of 2 to 200 sequentially. A method according to claim 1, characterized in that instead of the special beam splitter ( 36 ) also rotating mirror ( 4 ), Single or quadruple parabolic mirror perform the Strahlumlenk- and rotational movement in the full circle of 360 degrees. Method according to claim 1, characterized in that polygons inclined to the beam deflection and rotational movement ( 43 ), whose degree of inclination and facet arrangement is selected such that up to four simultaneous laser beam feeds ( 37 . 40 . 41 . 42 ) are possible, and this deflected in each case four circular sections of 90 degrees with the circumferential, individual optical channels ( 7 . 8th ) serve. Method according to claim 1 or more of claims 2-5, characterized in that with the full circle arrangement ( 2 ) and direct positioning above or below the material web ( 1 ) with the many star-shaped and motor-driven linear units ( 30 ) and attached deflecting mirrors ( 16 ) in their movement towards and away from the center an oblique adjustment ( 33 ) parallel to the transport direction ( 14 ) arises, with which the laser rows of holes ( 23 - 28 ) can be positioned over the web width in certain areas. Method according to claim 1 or more of claims 2-6, characterized in that by a double-row division and assignment of the individual channels ( 7 . 8th ) both in the star-shaped linear units ( 30 ) as well as in the fiber use ( 13 ) closely adjacent laser hole row positioning ( 23 - 28 ) possible are. Method according to claim 1 or more of claims 2-7, characterized in that all individual optical channels ( 7 . 8th ) a motor focusing ( 20 ) to the web so as to increase the hole sizes ( 59 ) and adjust porosities optimally and automatically. Method according to claim 1 or more of claims 2-8, characterized in that hollow fibers ( 13 ) instead of fixed beam guides the laser power beam at the optical multiplexer ( 2 ), this flexible the perforation section ( 69 ), where it can be positioned motor-driven and in the following each individual channel ( 7 . 8th ) at the end of the hollow fiber a motor collimator ( 19 ) and Fukussiereinheit ( 20 ) to the material web ( 1 ) owns. A method according to claim 1 or more of claims 2-9, characterized in that a beam focusing in front of the high-rotation rotating mirror ( 4 ), Parabolic mirror or inclined polygon wheel ( 43 ) Diameter ranges of 50-500 microns is provided. Method according to claim 1 or more of claims 2-10, characterized in that a plurality of laser partial beams (BIR) circulating simultaneously from the beam splitter ( 37 . 40 . 41 . 42 ) or directly applied main beams through the polygon with high optical power in the range of 500-2000 watts and up to 200 optical single channels ( 7 . 8th ), create hole sequences up to 2,000,000 holes per second and at the same time the required individual energies per perforation hole ( 58 ) in the range of 1.5-4.0 mJ. Method according to claim 1 or more of claims 2-11, characterized in that the hole sequences of each individual optical channel ( 7 . 8th ) by the rotational speed of the Strahlumlenk- or beam splitter element and the number of power sub-beams ( 37 . 40 . 41 . 42 ) are determined. A method according to claim 1 or more of claims 2-12 herein characterized in that the supplied Laser power beams in continuous operation, so not pulsed, but also in time and in dependence from the rotations of the beam redirecting or beam splitting components and beam positions triggered in front of the inlet ports of the individual channels, can be pulsed. Method according to claim 1 or more of claims 2-13, characterized in that an optical multi-sensor unit ( 68 ) in the transport direction ( 14 ) directly behind the perforation section ( 69 ) and their measured values for the hole row positions, hole qualities and porosities of each hole row group on the laser perforation system and their individual channels ( 7 . 8th ) to automatically compensate for such changes occurring. Apparatus for carrying out the method according to claim 1 or more of the claims 2-14 the with one or more lasers and a rotating optical deflector, one or more laser beams emitted by the laser periodically deflects and so on a plurality of individual beam channels for Generation of perforation holes on the surface of the flat sheet material, characterized in that each beam channel is assigned a beam entry element, wherein the beam entry elements in a full circle around the optical Deflection element are positioned around. Device for carrying out the method according to claim 1 or more of claims 2-15, characterized in that in the center of a circular optical high-power laser multiplexer unit ( 2 ) is a high-rotating Strahlumlenkungs- or beam splitter element, which in the full angle of 360 degrees or in circular sections of 4 · 90 degrees or other divisions simultaneously temporally located in the outer circle single optical channels ( 7 . 8th ) served. Device for carrying out the method according to claim 1 or more of claims 2-15, characterized in that for the beam deflection and rotation rotating mirror, single or multiple parabolic mirror ( 4 ) or inclined polygons ( 45 ) are used with 4-40 facets. Device for carrying out the method according to claim 1 or more of claims 2-15, characterized in that the supply of the individual power beams take place obliquely from above or below, so that there is no gap between the outer circle arrangement of the individual optical channels ( 7 . 8th ). Apparatus for carrying out the method according to claim 1 or more of claims 2-15, characterized in that with motor-operated linear units ( 30 ) the laser beam rotating from the center ( 37 ) with one or more deflecting mirrors ( 4 ) or beam splitter ( 36 ) or polygon wheel ( 45 ) and their power beams ( 37 . 40 . 41 . 42 ) of the continuous material web ( 1 ), and by their movement ( 32 ) from the center an oblique offset ( 33 ) is created, which allows any laser hole row positioning over the web width. Device for carrying out the method according to claim 1 or more of claims 2-15, characterized in that at the end of each individual optical channel ( 7 . 8th ) a collimator ( 19 ) and motorized focusing optics ( 20 ), with which the hole sizes ( 59 ) from Z. B. 50-200 microns in diameter and the porosity in running web ( 1 ) are optimized. Apparatus for carrying out the method according to claim 1 or more of claims 2-15, characterized in that the circular optical high-power laser multiplexer unit ( 2 ) with the linear units ( 30 ) is smaller or larger in diameter than the web width and has no gap to the beam feed in the outer circle.