US3903791A - Small roll, thin belt embossing apparatus - Google Patents

Small roll, thin belt embossing apparatus Download PDF

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Publication number
US3903791A
US3903791A US393669A US39366973A US3903791A US 3903791 A US3903791 A US 3903791A US 393669 A US393669 A US 393669A US 39366973 A US39366973 A US 39366973A US 3903791 A US3903791 A US 3903791A
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United States
Prior art keywords
embossing
belt
roll
nip
backing
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Expired - Lifetime
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US393669A
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English (en)
Inventor
Ligt John De
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Westvaco Corp
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Westvaco Corp
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Filing date
Publication date
Application filed by Westvaco Corp filed Critical Westvaco Corp
Priority to US393669A priority Critical patent/US3903791A/en
Priority to DE19732348141 priority patent/DE2348141C3/de
Priority to CA182,233A priority patent/CA981081A/en
Priority to JP48110626A priority patent/JPS5232287B2/ja
Application granted granted Critical
Publication of US3903791A publication Critical patent/US3903791A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44B—MACHINES, APPARATUS OR TOOLS FOR ARTISTIC WORK, e.g. FOR SCULPTURING, GUILLOCHING, CARVING, BRANDING, INLAYING
    • B44B5/00—Machines or apparatus for embossing decorations or marks, e.g. embossing coins
    • B44B5/0047—Machines or apparatus for embossing decorations or marks, e.g. embossing coins by rolling

Definitions

  • ABSTRACT A web embossing machine capable of establishing a 52 0.5. CI. 101/23 desired Patter 0f qualiy both sides a hard 5 I] hit. cm B44B 5/02 web in a single Pass of embossing by engagmg [58] Field of Search". I 01/22 23 420 2) 220 the subject web between a relatively small diameter 101/221 I79 1 5 5 engraved embossing roll and a thin belt of resilient 308/1316 b i 362/1748 material.
  • the embossing nip may be either of the two nips formed by pressing the embossing roll into nip
  • the subject web is 389-949 9/1338 Baker 101/23 threaded between the small diameter engraved eml,593,20() 6/1925 Ball r 4 t A i i t 101/23 bossing l and h i belt. 1,669,885 5/1928 Webb et a].
  • FIG I PATENTED SEP 9 75 sum 2 0g 4 FIG.
  • the present invention relates to continuous web material embossing and, more particularly, to an appara tus for embossing high density web materials requiring concentrated application of high embossing pressures.
  • embossing is a simple mechanical process comprising the step of passing the subject web through the rolling nip between an embossing roll and a backing roll.
  • the embossing roll has the desired pattern three-dimensionally engraved on and into the surface thereof.
  • the backing roll may have a smooth surface of rubber or other resilient material having a Shore A-85 durometer hardness adhered thereto. With a force of approximately 700 pounds per lineal inch applied to the nip, a pound per ream paper will receive adequate permanent material deformation in a single pass of the nip for good embossing.
  • More dense materials such as 60 pound per ream paper, present compounded difiiculties for the embossing process, however.
  • the basic embossing objective is to stress the subject material beyond the yield limit along the selective lines of the desired pattern, high density materials, characteristic of fine papers, require considerable pressure applications to achieve the desired result.
  • Such pressures are difficult, if not impossible to attain against a conventional, rubber coated backing roll since higher force applications are merely distributed over a larger nip area.
  • the embossing roll must be fabricated with a substantial diameter of 12 inches or greater. Accordingly, the necessary physical size of the embossing roll further aggravates the nip force distribution area enlargement problem.
  • Another object of the present invention is to teach the construction of a two-face, single pass embossing apparatus for fine papers requiring significantly smaller capital expenditures than prior art apparatus for this purpose.
  • Another object of the present invention is to teach the construction of a fine paper embossing apparatus having a rapid. pattern change capacity.
  • an embossing nip between a relatively small diameter embossing roll and one of two, larger diameter backing rolls.
  • One backing roll is provided with a smooth steel surface whereas the other backing roll surface should be a smooth resilient surface.
  • the axes of the two backing rolls are parallel but selectively free to move within proximate limits.
  • the backing rolls are biased to a position of surface element tangency or contact.
  • the embossing roll is given full transverse support along the axial length thereof by a loading carriage having at least two loading struts.
  • the strut loaded carriage presses the embossing roll between the nip proximity of the two backing rolls to a desired limit position near but short of coplanar tangency.
  • an endless belt of thin (approximately 0.050 in. thickness or less) polyurethane is threaded an endless belt of thin (approximately 0.050 in. thickness or less) polyurethane.
  • This thin belt is of substantially greater periphery than the circumference of the steel surface backing roll and is carried about a closed circuit passing through said nip and around said steel surface backing roll.
  • Tendencies of the thin belt to slide to one side or the other of the desired tracking course around the smooth steel backing roll may be corrected by applying small increments of nip loading stress differential from the respective ioading struts.
  • the capacity to load one end of the embossing roll more or less than the other represents a mechanism for fine, belt steering trim.
  • FIG. 1 is a schematic representation of a side elevation of the present apparatus.
  • FIG. 2 is a static force vector diagram representative of the loading characteristics of the present apparatus.
  • FIG. 3 is a sectional elevation of the present apparatus as viewed from cutting plane III-III of FIG. 1.
  • FIG. 4 is a schematic representation of an elevational side section of an alternative embodiment of the invention.
  • FIG. 5 is a schematic representation of operational effects of the high pressure nip on the thin belt as viewed normal to the belt plane.
  • FIG. 6 is a stress profile diagram of the belt along the section S of FIG. 5.
  • FIG. 7 is a stress profile diagram of the belt along the section S of FIG. 5 under extreme tension conditions.
  • FIG. 8 is a schematic representation of operational effects on the thin belt by the air plenum as viewed along the belt plane.
  • FIG. 9 is an enlarged schematic representation of operational effects of the high pressure nip on the thin belt as viewed along the belt plane from the midsection thereof.
  • FIG. 10 is another enlarged schematic representation of operational effects on the thin belt.
  • FIG. 11 is another enlarged schematic representation of operational effects on the thin belt in a failure mode.
  • FIG. 1 the apparatus of the present invention is illustrated in line schematic form showing the frame standards as pivotally supporting backing roll carrying swing arms 12.
  • Indexing turrets 14 are provided with a number abutments 16 for engaging the swing arms 12 at a precisely predetermined position of relative separation.
  • the several abutments 16 are of different size for convenience in selecting the desired separation position.
  • Backing roll 20 is preferably a smooth, steel surface cylinder mounted for rotation about the swing arm 12 carried journal axis 21.
  • Backing roll 22 also is a steel cylinder mounted for rotation about the swing arm 12 carried journal axis 23.
  • the surface of roll 22, however. is preferably coated with a suitable resilient material that is softer than the embossing roll to prevent injury to the surface thereof.
  • Embossing roll 30 is a simple steel cylinder having a desired embossing pattern etched, cut or rolled into the surface thereof. No journal supports are required of the roll 30 thereby allowing a number of such rolls 30a, 30b, 300 of different diameters and patterns to be stored conveniently in a magazine carriage 32.
  • the carriage 32 is adapted to position the desired roll 30 within the reciprocation plane of the loading mechanism 40.
  • the primary design criterion of the embossing roll diameter is the repetitive period of the desired pattern. Accordingly, the embossing roll 30 diameter may be substantially less than that of either backing roll 20 or 22.
  • Loading mechanism comprises loading struts 42 in support of resilient section 44. Between the emboss ing roll 30 and the resilient section 44 is provided a wheel carriage section 46. Rotatably mounted along the length of the carriage section 46 are two rows of closely spaced, freely turning support wheels 47 and 48. Each wheel row 47 and 48 is laterally displaced from a plane passing through the axis of embossing roll 30 and normal to a plane common to backing roll axes 21 and 23. Such lateral displacement of support wheels 47 and 48 provides a measure of positive stability for the embossing roll 30'prior to nip engagement with backing rolls 20 and 22.
  • Loading struts 42 are illustrated as telescoping hydraulic cylinders but it should be understood that numerous other devices such as screw or rack mechanisms are suitable for the same purpose.
  • resilient section 44 may take numerous forms of mechanical equivalency.
  • the form of resilient section 44 shown in detail by FIG. 4, includes upper and lower channel member 51 and 52 resiliently sepa rated by a series of springs distributed along the length of the channels.
  • resilient section 44 The objective served by resilient section 44 is to uniformly distribute force applications from the two loading struts 44 but this is a matter of design choice and, if desired. resilient section 44 may be completely omitted or accomplished by other, equivalent means.
  • Web W the embossed subject, is threaded around lower turning roll 61, through nip 60 between embossing roll 30 and the smooth steel surface backing roll 20 and finally around upper turning roll 62. From upper turning roll 62, web W may be directed to a rewind station or to other web processing stations as desired.
  • the present invention requires the belt B to be free of any structural attachments. Accordingly, after departing from surface contact with backing roll 20, the back circuit of the endless belt B is coursed around air bearing stations 63 and 64.
  • Element 65 of the belt control circuit is an elongated, crescent-shaped air plenum having a multiplicity of air discharge orifices 66 (FIGS. 3 and 4) through the wall thereof adjacent the belt B.
  • plenum 65 serves an important secondary function as a final turning station for the belt circuit antecedent to entering the nip 60
  • a more important or primary function of the plenum 65 is that of transverse tension control of the belt in the region proximate of the nip 60 on the immediate in-feed side thereof. The mechanics of such tension control will be explained subsequently relative to FIGS. 7-11.
  • Rotational power may be delivered to either backing roll 20 or 22 but as shown in FIG. 3 such power is delivered to a driving element 24 of a gear cluster 25 for transfer to a driven element 26.
  • driven element 26 drives the final drive gear 27 which is rotationally rigid with backing roll 20.
  • loading strut 42 is retracted from nip 6O sufficiently to allow clearance for magazine 32 to position the desired pattern embossing roll 30 in line with the wheel carriage section 46.
  • turrets 14 are indexed to position the pair of abutments l6 appropriate for the selected embossing roll.
  • the desired embossing roll 30 Upon loading actuation of the struts 42, the desired embossing roll 30 is lifted from its magazine carriage cradle and pressed into the nip between backing rolls 20 and 22. As shown, rolls 20 and 22 are gravity biased to a position of surface element contact or tangency due to the unstable disposition of roll axes 21 and 23 relative to respective swing arm frame journals 28 and 29.
  • FIG. I unstable disposition between axes 21 and 23 relative to respective journals 28 and 29 is the substantive distinction of FIG. 4.
  • the swing arm 13 for backing roll 20 By disposing the swing arm 13 for backing roll 20 to the upper unstable position, the crowded condition of FIG. 1 and 3 lower section may be relieved. In such case the drive cluster 25 would be disposed concentric with journal 28 of FIG. 4.
  • the final or operational position of the embossing roll axis 31 should be as near to the plane common to backing roll axes 2] and 23 as is safe. Safety in this context means those op crational conditions whereunder the roll 30 could be dravm or pressed completely through the backing roll nip.
  • FIG. 2 vector diagram wherein a relatively small applied force, V from loading mechanism 40, is balanced by large nip forces V and V from respective backing rolls 20 and 22.
  • embossing nip 60 vector V is in the order of 500-700 pounds per lineal inch of nip for a 1.75 inch diameter embossing roll 30 and inch diameter backing roll 20 driven at 230 rpm.
  • the subject web W in the example was a 70 pound per ream, 0.004 caliper, coated and calendered paper.
  • the belt B used in the present example was of 0.015 inch thickness Shore A-95 durometer hardness polyurethane.
  • compressive stress within the nip has the effect of extrusively distorting the belt shape and thickness within the nip region 60. Since the belt material is essentially incompressible, the stressed portion thereof is merely displaced thereby causing bulges 71 at the web edges due to the absence of lateral restraint. Displaced material within the belt central portions, however, must be displaced along the machine running direction.
  • Such machine direction material displacement represents a countercurrent flow of belt material to create a region of compressive stress as represented by the stress profile diagram of FIG. 6 relative to the analytical plane S of FIG. 5.
  • the bounded area on the minus side of the FIG. 6 diagram represents the distribution of tensile forces within the belt sections.
  • the belt B also exhibits tensile yielding characteristics as manifest by the necking tendency of the belt in regions 72. Since friction drive from the embossing nip provides motive power to the belt 1, tensile strain to overcome the belt inertial, frictional and gravitational resistance would be greatest in the region 72. Although such longitudinal yielding as to cause lateral edge necking is within proportional limits, it is conceivable that coincident lateral stress toward the belt center axis further operates to create an excess of belt material in the region 70. Said excess of material in the region 70 is the substance of a standing wave in the belt course immediately ahead of the nip and is the cause of free running, embossing film belt failures.
  • Destruction may also occur from attempts to prevent standing wave accumulation by tensioning the belt over the unsupported span so greatly as to assure the stress distribution profile of FIG. 7 where even the midsection of the belt has at least a small degree of tensile stress.
  • belts of the present description having w/t greater than 1,000 running over conventional cylindrical turning rolls indicates a tendency to develop severe necking in the regions 72 and longitudinal fluting also begins to appear. When drawn into the nip, such longitudinal flutes are equally destructive as the standing wave failures.
  • the first factor to be acknowledged in this empirical approach is the standing period P (FIG. 9) for the particular belt and running conditions.
  • P is that distance, measured along the theoretical plane E of the belt W, from the theoretical nip point A between rollers 20 and 30, to a point D ahead of the nip where the actual plane of the belt E, (the standing wave 90) first crosses or coincides with the theoretical plane E
  • the theoretical nip point A is equidistant between the surface elements of rolls 20 and 30 and within the plane C of smallest separation between said surface elements which is the plane of roll tangency.
  • Nip point A is assumed to lie in the throat of the belt B constriction as it passes between rolls 20 and 30.
  • Angle a is the included angle between the nip tangent and the linear portion of the theoretical belt plane E Angle a may also be considered as the circular arc, about the center of backing roller 20, between the point A and the first point of normal coincidence between the theoretical belt plane E and a radii of backing roller 20.
  • the angle a at which a destructive degree of wrap 5 occurs shall be characterized as the critical wrap angle a Solution to the above described problem is won by sustaining sufficient longitudinal tension across the unsupported span of the belt B between the nip 60 and the plenum 65 so as to assure that the critical angle or is not exceeded at any point thereacross.
  • Consistent with achieving such sufficient tension is to position the plenum 65 relative to the nip 60 for as low an angle a as possible.
  • a smaller angle a requires less tensile exertion on the belt to keep the critical angle orC within tolerable limits.
  • parallel axis turning rolls, cylindrical or crowned, are unsatisfactory for this purpose as having only fixed geometry for tensile distribution.
  • high w/r embossing film belts w/t greater than 1,000 of the nature described herein, it is necessary to apply a smoothly distributed force, independent of position, to draw the standing wave period out from critical contact with the backing roll as localized accumulations of material develop.
  • the fluid bearing between the underside of belt B and the proximate surface elements of plenum 65 offer a relatively frictionless pivot station for the belt circuit, the more significant contribution of the fluid bearing is to provide, within tolerable limits, a uniformly distributed tensioning force across the belt width that is independent of fixed position. As the bearing space becomes larger coincident with a localized increase in the standing wave period or amplitude, the longitudinal belt tension remains constant to restrain the wave from further increasing.
  • a final point to be considered in the operation of the present invention relates to belt steerage and the particular technique of embossing roll loading taught herein.
  • small lateral force may be applied to the belt at the nip to oppose the built-in forces of instability.
  • Apparatus for high pressure embossing a continuous high density material web of indefinite length comprising:
  • support means to selectively engage the cylindrical surface of said embossing roll along the length thereof, said support means comprising loading means to press said embossing roll into the proximity between said backing rolls to form respective roll nips therebetween, each of said toll nips having a material in-flow and out-flow side respective thereto;
  • g. means to deliver rotational power to one of said backing rolls;
  • endless belt tensioning means disposed on the inflow side of said embossing nip, proximate thereof, and comprising fluid discharge means disposed within a curvilinear portion of said closed course for applying a substantially constant longitudinal tensile stress to said belt regardless of reasonable dimensional variations in the proximity between said belt and said fluid discharge means.
  • Apparatus for embossing a continuous web as described by claim I wherein said fluid discharge means comprises an air plenum extending across the width of said belt, said plenum having a perforated wall adjacent said closed belt course.
  • Apparatus for embossing a continuous web as described by claim 5 further comprising air support bearings supporting said belt along additional portions of said closed course.

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  • Machines For Manufacturing Corrugated Board In Mechanical Paper-Making Processes (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)
US393669A 1973-08-31 1973-08-31 Small roll, thin belt embossing apparatus Expired - Lifetime US3903791A (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
US393669A US3903791A (en) 1973-08-31 1973-08-31 Small roll, thin belt embossing apparatus
DE19732348141 DE2348141C3 (de) 1973-08-31 1973-09-21 Einrichtung zum Prägen einer Materialbahn
CA182,233A CA981081A (en) 1973-08-31 1973-10-01 Embossing apparatus
JP48110626A JPS5232287B2 (enrdf_load_stackoverflow) 1973-08-31 1973-10-03

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US393669A US3903791A (en) 1973-08-31 1973-08-31 Small roll, thin belt embossing apparatus

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US3903791A true US3903791A (en) 1975-09-09

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US (1) US3903791A (enrdf_load_stackoverflow)
JP (1) JPS5232287B2 (enrdf_load_stackoverflow)
CA (1) CA981081A (enrdf_load_stackoverflow)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5148741A (en) * 1992-03-11 1992-09-22 Reynolds Metals Company Method and apparatus for reflective enhancement of rotogravure printed material
WO2014115086A3 (en) * 2013-01-22 2014-11-27 Unilin, Bvba Method and device for manufacturing products having a surface provided with embossments, and products obtained thereby

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS60152334A (ja) * 1984-01-20 1985-08-10 Ig Tech Res Inc エンボス加工法
JPS60152336A (ja) * 1984-01-20 1985-08-10 Ig Tech Res Inc エンボス加工装置
JPS60152335A (ja) * 1984-01-20 1985-08-10 Ig Tech Res Inc エンボス加工装置

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US389949A (en) * 1888-09-25 Embossing-machine
US1593200A (en) * 1923-02-17 1926-07-20 Frank V Tischer Laminated structure and method of producing it
US1669885A (en) * 1926-04-28 1928-05-15 Eastern Mfg Company Method and mechanism for marking and finishing paper
US2878778A (en) * 1951-02-16 1959-03-24 Kusters Eduard Apparatus for squeezing webs utilizing alternate hard and soft rolls on different axes
US3542358A (en) * 1967-03-16 1970-11-24 Roland Offsetmaschf Sheet drum for a sheet printing press
US3730080A (en) * 1970-08-05 1973-05-01 Westvaco Corp Embosser using small diameter embossing rolls

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US389949A (en) * 1888-09-25 Embossing-machine
US1593200A (en) * 1923-02-17 1926-07-20 Frank V Tischer Laminated structure and method of producing it
US1669885A (en) * 1926-04-28 1928-05-15 Eastern Mfg Company Method and mechanism for marking and finishing paper
US2878778A (en) * 1951-02-16 1959-03-24 Kusters Eduard Apparatus for squeezing webs utilizing alternate hard and soft rolls on different axes
US3542358A (en) * 1967-03-16 1970-11-24 Roland Offsetmaschf Sheet drum for a sheet printing press
US3730080A (en) * 1970-08-05 1973-05-01 Westvaco Corp Embosser using small diameter embossing rolls

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5148741A (en) * 1992-03-11 1992-09-22 Reynolds Metals Company Method and apparatus for reflective enhancement of rotogravure printed material
WO2014115086A3 (en) * 2013-01-22 2014-11-27 Unilin, Bvba Method and device for manufacturing products having a surface provided with embossments, and products obtained thereby
US20150360504A1 (en) * 2013-01-22 2015-12-17 Unilin, Bvba Method and Device for Manufacturing Products having a Surface Provided with Embossments, and Products Obtained Thereby
US10486459B2 (en) * 2013-01-22 2019-11-26 Unilin, Bvba Method and device for manufacturing products having a surface provided with embossments, and products obtained thereby
US11161367B2 (en) * 2013-01-22 2021-11-02 Flooring Industries Limited, Sarl Method and device for manufacturing products having a surface provided with embossments, and products obtained thereby
US20220009272A1 (en) * 2013-01-22 2022-01-13 Flooring Industries Limited, Sarl Method and device for manufacturing products having a surface provided with embossments, and products obtained thereby
US11878546B2 (en) * 2013-01-22 2024-01-23 Flooring Industries Limited, Sarl Method and device for manufacturing products having a surface provided with embossments, and products obtained thereby

Also Published As

Publication number Publication date
JPS5232287B2 (enrdf_load_stackoverflow) 1977-08-20
JPS5050121A (enrdf_load_stackoverflow) 1975-05-06
DE2348141A1 (de) 1975-03-20
CA981081A (en) 1976-01-06
DE2348141B2 (de) 1976-07-29

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