GB2569421A - Printing and embossing apparatus and a method of use - Google Patents

Printing and embossing apparatus and a method of use Download PDF

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Publication number
GB2569421A
GB2569421A GB1814904.7A GB201814904A GB2569421A GB 2569421 A GB2569421 A GB 2569421A GB 201814904 A GB201814904 A GB 201814904A GB 2569421 A GB2569421 A GB 2569421A
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GB
United Kingdom
Prior art keywords
web
embossment
printing
printed
embossing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB1814904.7A
Other versions
GB201814904D0 (en
Inventor
Collinson Steven
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Emerson and Renwick Ltd
Original Assignee
Emerson and Renwick Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from GBGB1715044.2A external-priority patent/GB201715044D0/en
Priority claimed from GBGB1807359.3A external-priority patent/GB201807359D0/en
Application filed by Emerson and Renwick Ltd filed Critical Emerson and Renwick Ltd
Publication of GB201814904D0 publication Critical patent/GB201814904D0/en
Publication of GB2569421A publication Critical patent/GB2569421A/en
Withdrawn legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
    • B41J3/00—Typewriters or selective printing or marking mechanisms characterised by the purpose for which they are constructed
    • B41J3/38—Typewriters or selective printing or marking mechanisms characterised by the purpose for which they are constructed for embossing, e.g. for making matrices for stereotypes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F13/00—Common details of rotary presses or machines
    • B41F13/02—Conveying or guiding webs through presses or machines
    • B41F13/025—Registering devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F19/00—Apparatus or machines for carrying out printing operations combined with other operations
    • B41F19/02—Apparatus or machines for carrying out printing operations combined with other operations with embossing
    • B41F19/06—Printing and embossing between a negative and a positive forme after inking and wiping the negative forme; Printing from an ink band treated with colour or "gold"
    • B41F19/062—Presses of the rotary type
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F33/00—Indicating, counting, warning, control or safety devices
    • B41F33/0081—Devices for scanning register marks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
    • B41J11/00—Devices or arrangements  of selective printing mechanisms, e.g. ink-jet printers or thermal printers, for supporting or handling copy material in sheet or web form
    • B41J11/008—Controlling printhead for accurately positioning print image on printing material, e.g. with the intention to control the width of margins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
    • B41J11/00—Devices or arrangements  of selective printing mechanisms, e.g. ink-jet printers or thermal printers, for supporting or handling copy material in sheet or web form
    • B41J11/0095—Detecting means for copy material, e.g. for detecting or sensing presence of copy material or its leading or trailing end
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
    • B41J11/00—Devices or arrangements  of selective printing mechanisms, e.g. ink-jet printers or thermal printers, for supporting or handling copy material in sheet or web form
    • B41J11/36—Blanking or long feeds; Feeding to a particular line, e.g. by rotation of platen or feed roller
    • B41J11/42—Controlling printing material conveyance for accurate alignment of the printing material with the printhead; Print registering
    • B41J11/46—Controlling printing material conveyance for accurate alignment of the printing material with the printhead; Print registering by marks or formations on the paper being fed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
    • B41J15/00—Devices or arrangements of selective printing mechanisms, e.g. ink-jet printers or thermal printers, specially adapted for supporting or handling copy material in continuous form, e.g. webs
    • B41J15/04—Supporting, feeding, or guiding devices; Mountings for web rolls or spindles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
    • B41J29/00—Details of, or accessories for, typewriters or selective printing mechanisms not otherwise provided for
    • B41J29/38—Drives, motors, controls or automatic cut-off devices for the entire printing mechanism
    • B41J29/393—Devices for controlling or analysing the entire machine ; Controlling or analysing mechanical parameters involving printing of test patterns
    • B41J2029/3935—Devices for controlling or analysing the entire machine ; Controlling or analysing mechanical parameters involving printing of test patterns by means of printed test patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
    • B41J3/00—Typewriters or selective printing or marking mechanisms characterised by the purpose for which they are constructed
    • B41J3/407—Typewriters or selective printing or marking mechanisms characterised by the purpose for which they are constructed for marking on special material
    • B41J3/4078—Printing on textile

Abstract

Printing and embossing apparatus for printing and embossing a web of material, for example to form wallpaper, comprising a digital printing means 106, embossing means 104, and sensing means 120 for sending the position of the printed image on the substrate relative to a registration mark or means, which may or may not have been embossed, characterised in that the digital printing means is arranged to be able to adjust the size and/or position of the image printed onto the web of material based on the data from the sensing means. This provides a feedback loop for the alignment of the printing and the embossing in order to stop errors from accumulating over time, which is of particular use where an entire roll of the material is being printed. The embossing and printing might take place as part of the same apparatus (figure 2), i.e. ‘online’, or separately, i.e. ‘offline’, as shown in figure 5. Also claimed is a method for the same.

Description

Printing and Embossing Apparatus and a Method of Use
This invention relates to printing and embossing apparatus and to a method of use of the same.
Although the following description refers almost exclusively to printing and embossing apparatus for the printing and embossment of a web material in the form of wallpaper, it will be appreciated by persons skilled in the art that the printing and embossing apparatus could be. used to print and emboss any material, such as textile fabric, board material, foil, plastic film, non-woven material, leather and/or the like, for use in any application.
Conventionally, the printing and embossment of an elongate web of .material, such as wallpaper, uses an in-line apparatus, where the printing and embossing steps are combined into a single item of apparatus, or an off-line apparatus where the printing and embossing steps are undertaken on separate items of apparatus. An example of a conventional in-line rotary printing and embossment apparatus 2 is shown in figure 1. The apparatus 2 comprises a printing section. 4 for printing a repeat pattern or image on an elongate web of paper material 6, a pair of embossment rollers or embossment nip 8 located downstream of the printing section 4 for embossing a repeated pattern in alignment with the repeated printed image, and first and second pairs of tension rollers or nips 10, 12 located either side of the printing section 4 for adjusting the tension of the web as it passes through the apparatus 2. The rotation of die roller pairs forming the embossment nip 8 and tension nips 10, 12 are each independently driven by motors 14, 16, 18 respectively.
A registration sensor 20 is generally provided between the second tension nip 12 and the embossment nip 8 to detect registration of the repeated printed image with one or more registration marks prior to the web entering the embossment nip 8. However, a registration sensor can be provided downstream of the embossment nip in some cases. Correct registration of the printed image with the embossment roller is essential in aligning the repeated printed image with the repeated| embossment pattern to be embossed on the web. The registration sensor 20 communicates with a computer 22, which in turn controls a. drive controller 24 for( adjusting one or more operational parameters of the second tension nip 12 and thej embossment nip 8 respectively. In order to get the repeated printed image on thej web to match the repeated embossed pattern on the web, the web tension betweenj the first tension nip 10 and the second tension nip 12 is generally kept constant,i and the web tension between the second tension nip 12 and the embossment nip 8 is adjusted. This allows the position of the web relative to the printing section and the embossment section to be adjusted in a longitudinal direction. Adjustment of the web tension is typically achieved by adjusting, the .toller speed and/or the angular position of the rollers forming nips 8,12.
Thus, error adjustment in the adjustment of the repeated printed image and the repeated embossed pattern is in the longitudinal direction £X’ of the web only (i.e. in the direction of travel of the web 6 through, the apparatus 2) The error adjustment does not allow for adjustment of the alignment of the repeated printed image with the repeated embossed pattern in the. web width or lateral direction to the direction £X’. Certain apparatus processing conditions, such as heat, tension, moisture and/or tire like, can cause changes in the width dimension of the web as it passes through the apparatus. As such, the repeated printed image may be out of | alignment with the embossed pattern in a lateral direction of the web material. In order to adjust for errors in the width or lateral direction of the web material, such as for example as a result of web shrinkage, this requires re-engraving of the j embossing rollers and/or the printing rollers, which, is both time consuming and expensive.j
It ...is. ...therefore... an... aim ...of ...the... pre sent., invention to provide printing and embossing[ apparatus which overcomes the abovementioned problem.j
It is a further aim of the present invention to provide a method of printing and embossing a web of material which overcomes the abovementioned problem.
.According to a first aspect of the present invention there is provided printing and embossing apparatus for printing and embossing a web of material, said apparatus comprising printing means for printing at least, one image on a web of material in use, embossment means for embossing at least, one pattern on the web of material in use, and sensing means for sensing a position of the at least one printed image on the web of material relative, to registration means provided on or associated with the web of material and/or relative to a pattern or mark embossed on tire web of material to provide registration data, characterised in that the printing means includes or consists of digital printing means, and said digital printing means is arranged so as to be able to adjust, the size and/or position of the image being printed or to be printed on the web of material by the digital printing means in response to the registration data sent from said sensing means.
Thus, the present invention uses digital printing means to allow the position of an image being printed on the web material to be adjusted in order to achieve alignment or registration between the printed image and the. embossed pattern rather than having to adjust, or solely adjust, the tension of the web material and/or the speed of the embossment rollers to achieve alignment between the printed image and the embossed pattern on the web. In particular, use of the. digital printing means for achieving correct alignment or registration of the printed image and the embossed pattern allows alignment/registration in a longitudinal direction and/or lateral direction of the web material as it passes through the apparatus in use. This allows a significantly greater level of accuracy in aligning the printed image with the embossed pattern on the web material in use and avoids the need .for .re-e.niTravinv..the..nrintine' means or the embossment means. In addition, it allows a more stable tension of the web material to be produced during the printing and embossing process.
Preferably the registration data is data relating to the position of the registration means formed by printing or embossing relative to the position of the at least one printed image. For example.
The present invention allows registration data and/or one or more signals generated by the sensing means to be fed directly or indirectly into or used by the digital printing means rather than by the embossment means and/or tensioning means as in the prior art.
It is to be noted that registration or alignment of the embossed mark or pattern with the printed registration means can include coincidence or substantial coincidence of the embossed registration means with the printed registration means (i.e. one mark being placed directly over and overlapping with another mark), or it can include registration or positioning of the marks in a particular or pre-requited manner wherein the marks do not coincide. For example, the embossed mark may need to be a pre-determined spaced distance away from the printed registration mark, such as 20mm apart. Alternatively the embossed and printed marks may need to be provided in a ctoss (+) relative to each other rather than in complete alignment.
In one embodiment the at least one image to be printed on the web of material by the digital printing means includes one or more printed registration means or marks. The sensing- means are arranged to sense whether these registration means or marks are in alignment with one or more marks or patterns embossed on the web of material. For example, during an initial start-up phase of the apparatus, the digital printing means may only print one or more registration means or marks to allow alignment of the material web with the embossment means prior to printing one or more further images onto the material web. This saves on digital ink during alignment of the web of material with the digital pnnbng ineans and the embossment means. Once the sensing means senses correct alignment of the one or more registration means or marks and the embossment means, the digital printing means can then print the at least one further image on the material web.
In one embodiment the embossment means embosses one or more registration marks or patterns on the web of material. The sensing means can be arranged to sense whether these registration marks or patterns are in alignment, with one or more printed registration means or marks. Alternatively, the sensing means is arranged to sense the position of the one or more embossed registration marks or patterns and use this position data to instruct the digital printing means to print the at least one .image in-register with the embossed pattern and/or embossed registration marks or patterns.
In one embodiment the at least one image to be printed on the web of material by the digital printing means includes at least one image and at least one registration means or mark.
In one embodiment the at least one pattern to be embossed on the web of material by the embossment means includes at least one pattern and at least one registration mark or pattern.
JL
Preferably the at least one image, further image and/or registration means or mark to be printed by the digital printing means is a repeated image and/or mark that includes at least two or more copies of the same image and/or mark for printing on the web material in use.
Preferably the at least one embossed pattern and/or registration mark or pattern to be embossed on the web material is a repeated pattern that includes at least two or more copies of the same pattern for embossing on the web material in use.
Preferably tire at least one image to be printed can. include any or any combination of one or more shapes, marks, lines, pictures, numerals, letters, symbols, pattern, abstract pattern and/or the like.
Preferably the at least one embossed pattern can include any or any combination of one or more embossed shapes, lines, pictures, numerals, letters, symbols, abstract pattern, pattern and/or the like.
Preferably an atm of the apparatus is to allow exact or substantially exact alignment between the embossed pattern and the digitally printed imag;e on the web material in use, irrespective of the order in which the embossed pattern and digitally printed image are appEed to the web material.
In one embodiment the apparatus includes tensioning means for applying a tension to the web of material as it passes through the apparatus in use.
In one embodiment the tensioning means includes one or more rollers, nips, nip rollers and/or the Eke.
Preferably the tensioning means or nip includes at least one pair of opposing rohers.
In one embodiment the tension of the web of material, created by the tensioning means or otherwise, into the embossment means is arranged to be constant or substantially constant in use.
In one embodiment the sensing means does not feed any registration data or one or more signals to the embossing means and/or tensioning means in use. Preferably the sensing means only feeds registration data or one or more signals to the digital printing means in use.
Preferably the apparatus is an in-line apparatus.
In one embodiment an in-line apparatus is defined as one where the components of the. apparatus are Enked together and the web of material is able to flow from one component to another. For example, the embossment means, the digital printing means and sensing means are all linked together such that the web of material follows a path of movement via the same as it passes through the apparatus.
Preferably the apparatus is a single in-line apparatus.
In one embodiment the apparatus is an off-line apparatus. This is preferably the case where the embossment process is to take place before the digital printing process. For example, the embossment means can be provided in a first apparatus or machine to undertake the embossment process or embossing at least one pattern on the web of material. The web of material can then be moved to digital printing means, provided as a second separate apparatus or machine to the first apparatus, to undertake the printing of at least one image on the web of material.
Preferably the digital printing means adjusts the size and/or position of the image on the material web by scaling the at least one image to be printed.
Preferably the digital printing means can adjust the size, and/or position of the image on the material web in a longitudinal direction of the web material (i.e. in a direction parallel or substantially parallel to a longitudinal axis of the web material or in a direction of travel of the web material through the apparatus in use) and/or in a lateral direction of the web material (i.e. in a direction transverse, perpendicular or substantially perpendicular to a longitudinal axis of the web material or to the direction of travel of the web material through the apparatus in use).
I 1 In one embodiment, the embossment, means are provided downstream of thej digital printing means (i.e. the embossment process of embossing at least one1 pattern and/or registration mark or pattern on the web of material takes place afterj the digital printing process of printing at least one image on the web of material).ί
In one embodiment the embossment means are provided upstream of the digital;
printing means in the application (i.e. the embossment process of embossing ati least one pattern and/or registration mark or pattern on the web of material takes;
place before the digital printing process of printing at least one image on the web of material).
Preferably the embossment means includes rotary embossment means.
Preferably the rotary embossment means includes at least one pair of embossment rollers, and preferably a pair of opposing embossment rollers. However, any number of embossment roller pairs could be provided as required.
Preferably an embossment nip is formed in the location where two opposing embossing tollers, farming an embossment roller pair, come into contact with each other.
In one embodiment the embossment means includes stamping embossment means.
Preferably the embossment means, one or both of the embossment, roller pair or nip, the rotary embossment means or the stamping embossment means is provided •with an engraved pattern on the same to form the. embossment pattern to be embossed on the material web in use.
Preferably the web of material includes any or any combination of material that can be embossed in use, paper, laminated material, wall paper, cardboard, board material, textile fabric, foil, plastic film, sheet material, coated material, non-woven material, leather and/or the like.
In one embodiment the web of material is in a continuous form. For example, the web of material is elongate in form, and further preferably is sufficiently elongate in form, such that an image to be printed can be repeated a plurality of times and/or in a repeated manner on the same.
In one embodiment the web of material is in a discrete or non-continuous form. For example, the web material is provided in discrete lengths or pieces with breaks in between the lengths of pieces. The image to be printed, can be printed a single time on each discrete length or piece of web material and/or the image can be printed a plurality of times and/or in a repeated manner on each discrete length or piece of web material.
Preferably the embossment means is any means which allows one or more parts of the surface of the web material to be moved from a flat or planar form to a raised and/or recessed form relative to one or more surrounding areas of said surface part. For example, the embossment means can be any means which allows one or more indentations to be made in the web material.
Preferably the embossment means is any means which results in a physical and/or permanent change in one or mote characteristics of the web material during the embossment process.
Preferably the digital priming means includes any printer which uses a digital data file to provide the image data for the printing process. The digital printing means can be used to print in colour and/or black and white.
Preferably the digital printing means includes at least one digital printer.
In one embodiment the digital printing means consists of a single digital printer only in the apparatus.
Preferably the digital data file used by the digital printing means is provided on or associated with micro-processing means, such as for example a computer, provided in or associated with the digital printing means.
Preferably embossment data or an embossment data file relating to die embossment pattern applied, or to be applied, by the embossment means in use is communicated to or provided in die digital printing means or associated conmuter/inicromrocessfog.,,mean;; The emhossmiau tyna or cnfoossmciu data file allows the image to be printed by the digital printing means to be scaled to match the embossment pattern embossed, or to be embossed, via the embossing means in use.
Preferably the embossment data or embossment data file relating to the embossment pattern includes width and/or length dimensions of the embossment pattern or embossment repeat pattern (i.e, dimensions in a lateral and/or longitudinal direction of the web of material).
Preferably the tensioning means includes any means which allows tension to be applied and/or adjusted with respect to the web of material as it passes through the apparatus in use.
Preferably the tensioning means includes at least one pair of tensioning rollers. However, any number of tensioning .tollers or roller pairs could be provided as requited.
Preferably a tensioning nip is formed in the location where two opposing tensioning rollers forming a tensioning roller pair come into contact with each other.
Preferably at least one tensioning nip and/or tensioning means is provided upstream of the digital printing means in the apparatus.
Preferably at least one tensioning nip and/or tensioning means is provided upstream of the embossing means, and optionally further preferably downstream of the digital printing means or as part of the digital printing means.
Preferably at least, one tensioning nip and/or tensioning means is provided downstream of the embossing means.
In one embodiment there is provided at least a first tensioning nip and/or tensioning means upstream of the digital printing means and at least a second tensioning nip and/or tensioning means upstream of the embossing means and downstream or as part of the digital printing means.
Preferably drive means are provided on or associated with the tensioning means and/or the embossing means for driving movement or rotation of the tensioning means and/or embossing means in use.
Preferably the drive means includes one or more motors.
Preferably the drive means or motor for each tensioning means and/or the embossing means are independent to or separate from each other.
In one embodiment control means are provided on or associated with the drive means or one or more motors for controlling one or more parameters of the drive means or one or more motors in use.
Preferably the one or more parameters controlled by the control means includes any or any combination of the speed of one or more of the embossment means, tensioning means, and/or one or more tollers; adjustment of the tension of the web material moving through the apparatus in use; adjustment of the angular position of the embossment means, tensioning means, and/or one or more rollers with respect to die web material and/or the like.
In one embodiment the sensing means includes any means which allows determination of the position of one or more printed images, registration means and/or registration marks relative to one or more positioning means, registration means and/or embossed marks, means or pattern provided on or associated with the web material in use.
Preferably the sensing means are arranged to detect an error or misalignment of the one or more printed images relative to the one or more positioning means, registration means or embossed means/mark/pattem. The sensing means are arranged to signal or communicate this error or misalignment to the digital printing means in use.
Preferably the sensing means can detect an error or misalignment of one or more printed images relative to one or more positioning means or registration means in a longitudinal direction of the apparatus or a longitudinal axis of the web material and in a lateral or transverse direction of the apparatus or lateral or transverse to the longitudinal axis of the web material.
In one embodiment the sensing means includes at least one longitudinal direction or length sensing means and at least one lateral direction or width sensing means.
Preferably the sensing means includes any or any combination of one or more optical sensors, colour sensors, contact sensors, cameras, image processing means or sensors and,/or the like.
Preferably the sensing means communicates directly or indirectly with the digital J O J -V o printing means.
In one embodiment registration data from the sensing means is communicated to a computer or micro-processing means and said computer or micro-processing means communicates with the digital printing means. It is to be noted that the computer or micro-processing means can form part of the digital printing means or can be separate to the same.
In one embodiment the sensing means are provided upstream of the embossing means. However, the sensing means could be provided downstream of the embossment means solely, or in addition to the sensing means provided upstream o f the emb o s sing means.
In one embodiment the sensing means are provided downstream of die embossment means.
In ©ne embodiment the sensing means are provided dorvnsmum of dw digital printing means or form a part of the digital· printing means in die apparatus. However, the sensing means could be provided upstream of the digital printing means solely, or in addition to the sensing means provided downstream of the digital printing means.
Preferably the positioning means or registration means includes one or more registration marks, one or more parts of the printed and/or embossed design or image and/or the like. The registration marks can include any or any combination of lines, shapes, images and/or the like.
Preferably the registration means includes at least two sets of registration means; at least one set of registration means associated with the printing means and at least one set of registration means associated with the embossment means.
In one embodiment the sensing means detects alignment of the at least two sets of registration means together and any misalignment is fed back into the printing means.
In one embodiment manually detected misalignment of the at least two sets of registration, means can be signalled to the printing means to allow the size and/or the position of the image being printed on the web of material to be adjusted.
Preferably the printing and embossing apparatus provides a closed loop system wherein data being generated by the system is continuously or substantially continuously being fed back into the system to allow further control of the system.
Preferably the apparatus allows for continuous or substantially continuous adjustment of one or more operating parameters, tension, roller speed and/or the like in use.
According to a second aspect of the present invention there is provided method of printing and embossing a pattern on a web of material, said method including the steps of printing at least <ve image -on a web of. m embossing at least one pattern on the web of material using embossment means; sensing a position of the at least one printed image on the web of material relative to registration means provided on or associated with the web of material and/or relative to a pattern or mark embossed on the web of material using sensing means to provide registration data, characterised in that the printing means includes or consists of digital printing means, and said digital printing means is arranged so as to be able to adjust the size and/or position of the image being printed or to be printed on the web of material by the digital printing means in response to the registration data sent from said sensing means.
The method can include a printing process, followed by an embossment process. Alternatively, the method can include an embossment process followed by a printing process.
Embodiments of the present invention, will now be described with reference to the following figures, wherein:
Figure 1 (PRIOR AR!1) is a simplified view of a conventional printing and embossing apparatus;
Figure 2 is a simplified view of in-line printing and embossing apparatus according to an embodiment of the present invention, wherein a digital printing process takes place before an embossment process in the apparatus;
Figure 3 is a simplified view of in-line printing -and embossing apparatus according to an embodiment of the present invention, wherein an embossment process take place before a digital printing process in. the apparatus;
Figure 4 is a variation of the apparatus shown in figure 3; and
Figure 5 is : a simplified view of off-line printing and embossing apparatus
according to an embodiment of the present invention, wherein an embossment
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process.
Referring to figure 2, there is illustrated continuous in-line rotary printing and embossing apparatus 100 for printing and embossing a repeated pattern on a continuous web of material 102 in use. An example of the web of material that the apparatus 100 can be used with is wallpaper.
The apparatus 100 is an in-line apparatus comprising embossment means in the form of at least one embossment nip 104 and digital printing means in the form of a digital printer 106 provided upstream of nip 104 in the apparatus. Tensioning means in the form of a first tension nip 108 is provided upstream of the digital printer 106 and. optionally, a second tension nip 110 is provided between digital printer 106 and the embossment nip 104. Each nip 104, 108, 110 typically comprises 2 opposing rollers forming a roller pair.
The web of material 102 can enter the apparatus 100 via. any suitable means.
Drive means in the form of a motor 112, 114, 116 is provided with each of the first tension nip 108, the second tension nip 110 and the embossment nip 104 for driving rotation of the pair of rollers forming each nip. The motors 112, 114, 116 are each separate to each other and independently controlled.
Control means in the form of a drive controller 118 is provided in association with, the second tension nip 110 and the embossment nip 104 for controlling one or more parameters of the second tension nip 110 and embossment nip 104 in use. For example, the one or more parameters could include the tension of the web between nip 110 and nip 104, speed of the rollers forming the nip 110 and/or nip 104, the angular position of the rollers forming the nip 110 and/or nip 104 and/or the like.
Control means in the form of a drive controller or the same drive controller 118 can be associated with 'the first nip 108 to aiimv ihc corrcci uusioii so be pu;\ ided, adjusted and/or maintained of the web material upstream of the printer 106 or between the first nip 108 and the embossment nip 104 if required.
Registration sensing means 120 are provided between the second tension nip 110 and embossment nip 104 for determining whether the image printed on to the web by digital printer 106 is in registration with. the registration marks provided on the web. If the image being printed is out of registration with the registration marks, the sensing means 120 detects this and signals to a computer 122 provided as part of or associated with the digital printer 106. The computer 122 is then able to scale the image being printed by digital printer 106 to allow adjustment of the printed image on the web in either a longitudinal direction (i.e. in a direction parallel to the direction of travel of the web through the apparatus) and/or a lateral direction (i.e. in a direction transverse to the direction of travel of the web through the apparatus). This allows correct ahgnment of the printed image with the embossed image on the web material in use.
It is to be noted that the registration sensing means could include more than, one sensor and can be positioned at each side of the web material to allow the lateral error to be measured and/or the longitudinal error to be measured. In one example, the registration, sensing means could include a single camera which allows opposing lateral edges of the web material to be monitored simultaneously.
Referring to figure 3, there is illustrated continuous in-line printing and embossing apparatus 200 for embossing and. printing a pattern on a continuous web of material 202 in use.
The apparatus 200 is similar in form to the apparatus shown, in figure 2, but an embossment nip 204 is provided upstream (before) of a digital printer 206 in the apparatus. The embossment nip applies an embossment pattern, to the web, together with embossed registration marks on the web. The digital printer applies a digitally printed image on the web, together with printed registration marks. A tension nip 208 is provided downstream of the digital printer 206 to tension the web of material as it passes through the apparatus. Other tensioning means can. optionally be provided if required but. are not shown in the figure. Drive means in the form of a motor 210, 212 are provided for driving the rotation of the embossment nip 204 and the tension nip 208 respectively.
Registration sensing means in the form of a registration sensor 214 is shown downstream of the digital printer 206 (web-web mode). The sensor 214 is arranged to detects whether the emboss register marks applied to the web 202 via the embossment nip are in alignment with the printed register marks applied by printer 206. Alignment of the registration marks determines whether the repeated embossment pattern and repeated printed images are in alignment together. The alignment data detected by the sensor 214 is fed back to the digital printer 206 via a computer 216 provided as part of or associated with printer 206. The computer 216 is then able to scale the image on the web in a longitudinal direction and/or a lateral direction to ensure correct alignment, of the embossed pattern and the printed image. Thus, die printer 206 is digitally controlled and the position of the ink applied by the printer on the web of material is electronically controlled. The monitoring and alignment is typically a continuous process.
‘The registration sensor 2'14 in one example could be an optical camera or a light reflectance type of sensor.
A slight variation to the apparatus shown in figure 3 is provided in die in-line embossing and printing apparatus 300 shown in figure 4. The same reference numerals are used to show the same features. In this embodiment, a registration sensor 214 is provided upstream of die digital printer 206 (web-printer mode). In this embodiment die sensor 214 detects the position of the embossed registration marks on the web and instructs the digital printer 206 via computer 216 to print the ink for the images so that it keeps in register with the embossed pattern beingapplied to the web.
Figure 5 shows a further embodiment of die present invention in which the printing and embossment apparatus is off-line apparatus 300 and comprises at least two separate items of machinery/appara tus.
In this embodiment, the first apparatus is embossment apparatus 302 including an embossment nip 304 provided between a web unwind feed mechanism 306 located upstream of the nip 304 and a web rewind feed mechanism 308 located downstream of the nio 304. In use, the web of material 3'10 is unwound from mechanism 306 and passes between the embossment nip 304 for an embossment pattern and registration mark to be applied to the web. A motor 309 is provided to drive the movement of the roller pair forming the embossment nip 304. The web 310 is then rewound onto mechanism 308. The rewound reel is then transferred to the second apparatus in the form of digital print apparatus 312.
The web of material on the rewound reel is unwound from the same by unwind mechanism 314 in the second apparatus. The web then passes through tensioning means in the form of a tension nip 316, past digital printer 318 to allow a digital image and digital registration marks to be applied to the embossed web, before passing through a further tension nip 320. Motors 322 and 324 are provided to drive rotation of the tension nips 316 and 32.0 respectively. The number and position of tension nips could be varied in the apparatus as required.
Registration sensor means in the form of registration sensor 326 are provided downstream of digital printer 318 and upstream of tension nip 320 to detect, alignment of the embossed registration mark(s) and the digitally printed registration mark(s). The alignment data is signalled back to the digital printer via computer 328 to allow control of the printing of the image on the web in the longitudinal and/or lateral directions.
Thus, in all the above embodiments, the digital printer is arranged so as to scale the image being printed in a longitudinal and/or lateral direction to the web movement in the apparatus to match/align with a pattern already embossed on the web or a pattern which is to be embossed on the web. This allows for changes in the. emboss repeat pattern on. the web which can occur as a result of changes in humidity7, formulation, coating weight thickness, tension, temperature, web material type, web material consistency and/or the Eke. Even a very small error in the size difference of the embossed pattern and the printed image will build up over several repeats of the image/pattern such that printed image will drift out of position relative to the embossed pattern.

Claims (23)

Claims
1. Printing and Embossing Apparatus for printing and embossing a web of material, said apparatus comprising printing means for printing at least one image on a web of material in use, embossment means for embossing at least one pattern on the web of material in use, and sensing means for sensing a position of the at least one printed image on the web of material relative to registration means provided on or associated with the web of material and/or relative to a pattern or mark embossed on the web of material to provide registration data, characterised in that the printing means includes or consists of digital printing means, and said digital, printing means is arranged so as to be able to adjust the size and/or position of the image being printed or to be printed on the web of material by the digital printing means in response to the registration data sent from said sensing means.
2. Apparatus according to claim 1 wherein the digital printing .means is arranged so as to be able to adjust the size and/or position of the image being printed or to be printed on the web material in a longitudinal direction and/or a lateral direction of die web material as the web material passes through the apparatus in use.
3. Apparatus according to claim 1 wherein the digital printing means is arranged so as to be able to adjust the size and/or position of the image being printed or to be printed by scaling the at. least, one image to be printed.
4. Apparatus according to claim 1 wherein the apparatus includes tensioning means for applying a tension of the web of material as it passes through the
5. Apparatus according to claim 4 wherein the tensioning means includes one or more rollers, nips, nip rollers and/or at least one pair of opposing rollers.
6. Apparatus according to any preceding claim wherein the tension of the web of material into the embossment means is arranged to be constant or substantially constant in use.
7. Apparatus according to claim 1 wherein the apparatus is in-line apparatus.
8. Apparatus according to claim 1 wherein the apparatus is an off-line apparatus.
9. Apparatus according to claim 1 wherein the embossment means are provided downstream of the digital printing means.
10. Apparatus according to claim 1 wherein the embossment means are provided upstream of the digital printing means.
11..Apparatus according to claim 1 wherein the embossment means includes rotary embossment means, stamping embossment means, at least one pair of embossment rollers or at least one pair of opposing embossment rollers.
12. Apparatus according to claim 11 wherein the embossment means are provided with an engraved on a surface of the same to form the embossment pattern to be embossed on the material web in use.
13. Apparatus according to claim 1 wherein the web of material includes any or any combination of material, that can be embossed in use, paper, laminated material, wall paper, cardboard, board material, textile fabric, foil, plastic film, sheet material, coated material, non-woven material and/or leather.
14. Apparatus according to claim 1 wherein the web of material is in a continuous form or a non-continuous form.
15. Apparatus according to claim 1 wherein the digital printing means includes any printer arranged to use a digital data file to provide image data for the printing process, at least one digital printer, or consists of a single digital printer in the apparatus.
16. Apparatus according to claim 1 wherein embossment data or an embossment data file relating to the embossment pattern applied, or to be applied, by the embossment means in use is communicated to or provided in the digital printing means or an associated computer or micro-processing means.
17. Apparatus according to claim 4 wherein at least one tensioning means is provided upstream of the digital printing means in the apparatus.
18. Apparatus according to claim 4 wherein at least one tensioning means is provided upstream of the embossing means, or upstream of the embossing means and downstream of the digital printing means.
19. Apparatus according to claim 4 wherein at least one tensioning means is provided downstream of tire embossing means.
20. Apparatus according to any preceding claim wherein drive means or one or more motors are provided on or associated with the tensioning means and/or the embossing means.
21. Apparatus according to claim 20 wherein control means are provided on or associated with the drive means or one or more motors for controlling one or more parameters of the same in use including any or any combination of the speed of one or more of the embossment means, the tensioning means and/or one or more rollers; adjustment of the tension of the web material moving through the apparatus in use; adjustment of an angular position of the embossment means, tensioning means, and/or one or more rollers with respect to the web material,
22. Apparatus according to claim. 1 wherein the sensing means includes any means which allows determination of a position of one or more printed images, registration means and/or registration marks relative to one or more positioning means, registration means and/or embossed marks, means or pattern provided on or associated with the web material; at least one longitudinal direction or length, sensing means and at least one lateral direction or width sensing; means; one or more optical sensors, colour sensors, contact sensors, cameras, image processing means and/or sensors.
23. A method of printing and embossing a pattern on a. web of material, said method including the steps of printing at least one image on a web of material using printing means; embossing at least one pattern, on the web of material using embossment means; sensing a position of the at least one printed image on the web of material relative to registration means provided on or associated with the web of material and/or relative to a pattern or mark embossed on the web of material using sensing means to provide registration data, characterised in that the printing means includes or consists of digital printing means, and said digital printing means is arranged so as to be able to adjust the size and/or position of the image being printed or to be printed on the web of material by the digital printing means in response to the registration data sent from said sensing means.
GB1814904.7A 2017-09-19 2018-09-13 Printing and embossing apparatus and a method of use Withdrawn GB2569421A (en)

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2036649A (en) * 1978-12-08 1980-07-02 Ditzel Gmbh Gebr Embossing in register with printing
GB2206309A (en) * 1987-05-28 1989-01-05 Armin Steuer Hot embossing machine
US20040261639A1 (en) * 2003-06-23 2004-12-30 The Procter & Gamble Company Process for producing highly registered printed images and embossment patterns on stretchable substrates

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2036649A (en) * 1978-12-08 1980-07-02 Ditzel Gmbh Gebr Embossing in register with printing
GB2206309A (en) * 1987-05-28 1989-01-05 Armin Steuer Hot embossing machine
US20040261639A1 (en) * 2003-06-23 2004-12-30 The Procter & Gamble Company Process for producing highly registered printed images and embossment patterns on stretchable substrates

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