WO2002072340A2 - Rouleau gaufreur dote de plateaux amovibles - Google Patents

Rouleau gaufreur dote de plateaux amovibles Download PDF

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Publication number
WO2002072340A2
WO2002072340A2 PCT/US2002/007337 US0207337W WO02072340A2 WO 2002072340 A2 WO2002072340 A2 WO 2002072340A2 US 0207337 W US0207337 W US 0207337W WO 02072340 A2 WO02072340 A2 WO 02072340A2
Authority
WO
WIPO (PCT)
Prior art keywords
roll
embossing
plates
roll body
embossing roll
Prior art date
Application number
PCT/US2002/007337
Other languages
English (en)
Other versions
WO2002072340A3 (fr
Inventor
Jeremy James Michael Papadopoulos
Original Assignee
Paper Converting Machine Company
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
Application filed by Paper Converting Machine Company filed Critical Paper Converting Machine Company
Priority to EP02707974A priority Critical patent/EP1370412A2/fr
Publication of WO2002072340A2 publication Critical patent/WO2002072340A2/fr
Publication of WO2002072340A3 publication Critical patent/WO2002072340A3/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F1/00—Mechanical deformation without removing material, e.g. in combination with laminating
    • B31F1/07—Embossing, i.e. producing impressions formed by locally deep-drawing, e.g. using rolls provided with complementary profiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0707—Embossing by tools working continuously
    • B31F2201/0715—The tools being rollers
    • B31F2201/0717—Methods and means for forming the embossments
    • B31F2201/072—Laser engraving
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0707—Embossing by tools working continuously
    • B31F2201/0715—The tools being rollers
    • B31F2201/0723—Characteristics of the rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0707—Embossing by tools working continuously
    • B31F2201/0715—The tools being rollers
    • B31F2201/0723—Characteristics of the rollers
    • B31F2201/0728—Material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0707—Embossing by tools working continuously
    • B31F2201/0715—The tools being rollers
    • B31F2201/0723—Characteristics of the rollers
    • B31F2201/073—Rollers having a multilayered structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0707—Embossing by tools working continuously
    • B31F2201/0715—The tools being rollers
    • B31F2201/0723—Characteristics of the rollers
    • B31F2201/0738—Cross sectional profile of the embossments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0707—Embossing by tools working continuously
    • B31F2201/0715—The tools being rollers
    • B31F2201/0741—Roller cooperating with a non-even counter roller
    • B31F2201/0743—Roller cooperating with a non-even counter roller having a matching profile
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0758—Characteristics of the embossed product
    • B31F2201/0761—Multi-layered
    • B31F2201/0764—Multi-layered the layers being nested
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0758—Characteristics of the embossed product
    • B31F2201/0761—Multi-layered
    • B31F2201/0766—Multi-layered the layers being superposed tip to tip
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0771—Other aspects of the embossing operations
    • B31F2201/0776—Exchanging embossing tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0784—Auxiliary operations
    • B31F2201/0787—Applying adhesive

Definitions

  • This invention relates to embossing rolls for tissue or plastic film or other webs, and, more particularly, to an embossing roll with removable embossing plates.
  • Paper products such as bathroom tissue and kitchen towels are commonly formed on a rewinder line in which one or more jumbo rolls of webs are unwound, perforated, and rewound into retail sized rolls.
  • Many rewinder lines include an embosser for forming embossments in one or both of the webs and perhaps a glue deck to bond webs together.
  • the embosser conventionally includes one or more embossing rolls having an embossing pattern and a cooperating backup roll which presses against each embossing roll.
  • the cooperating roll can be, for example, a meshing steel or paper roll or a compliant smooth rubber-covered roll.
  • a paper roll is formed from compressed paper or cloth.
  • Steel and paper cooperating rolls are formed with recesses which mesh with the projections on the embossing roll.
  • Each web is advanced between an embossing roll and its cooperating roll, and the embossing pattern is embossed into the web.
  • the embossing roll is manufactured integrally. That is, a roll body with journals is fabricated, and then the outer surface of this roll is engraved with an embossing pattern, commonly using acid and a resist, and/or indentation by a patterned tool.
  • the problems with an integral embossing roll relate to cost and changeover time:
  • a durable steel sleeve, thick enough for deep engraving, is very difficult to expand temporarily for installation on, and removal from, the supporting roll.
  • the conventional compressed-air "flotation" method of Miller Graphics U.K., Ltd., Stork Screens America, Inc., Charlotte, North Carolina, or Strachan and Henshaw Machinery, Inc. is inadequate.
  • the invention provides an embossing roll with embossing plates which are removably secured to a roll body.
  • the removable plates provide the following advantages:
  • the plates can be made of steel so that there is no sacrifice in durability.
  • the plates are held to the roll with a fixturing system of vacuum suction and/or mechanical devices. Because the engraved surface is not in sleeve form, it is possible to attach/remove it from a roll without cantilevering that roll or removing it from the embosser (and without requiring substantial side clearance) .
  • fixturing system includes quick-change features, it will be possible to change embossing patterns in minutes rather than hours.
  • the removable plates may be made of any sufficiently durable material.
  • a key requirement is to provide means to hold them accurately, firmly, and safely against the surface of a fast-turning roll, while they are being pressed against a co-operating roll (which creates heat and "creeping tendencies") .
  • Any holding method should permit reasonably quick changes and advantageously ensure safety in case power or vacuum is lost.
  • One embodiment uses vacuum to hold the plates, locating pins to guarantee precise location and prevent creeping (unimportant in some applications) , and quick-change mechanical interlocks to retain the plates safely when vacuum is turned off.
  • Other embodiments use vacuum alone or omit vacuum and use only mechanical attachments.
  • Figure 1 illustrates conventional prior art rubber-to-steel embossing of a tissue web to add decoration and bulk;
  • Figure 2 illustrates a prior art two-ply embossed paper product
  • Figure 3 is a schematic side view of a prior art embossing machine for producing foot-to- foot embossments
  • Figure 4 is a schematic side view of a prior art embossing machine for producing nested embossments ,-
  • Figure 5 is a perspective view of one embodiment of an embossing roll which is formed in accordance with the invention.
  • Figure 6 is a fragmentary end view of the body of an embossing roll which is similar to the embossing roll body of Figure 5;
  • Figure 7 is a fragmentary plan view of adjacent vacuum areas of the roll body of Figure 6;
  • Figure 8 is a view similar to Figure 5 of another embossing plate configuration
  • Figure 9 is an exploded sectional view of one embodiment of an embossing roll
  • Figure 10 is an exploded sectional view of another embodiment of a small embossing roll
  • Figure 11 is a plan view of a curved embossing plate with hidden fixturing studs
  • Figure 12 is a fragmentary view of a rod for removably retaining the embossing plate on an embossing roll;
  • Figure 13 is a top view of the rod of Figure 11;
  • Figure 14 is an exploded sectional view of another embodiment of a small embossing roll
  • Figure 15 is an end view of the vacuum control system for the roll body of Figure 13;
  • Figure 16 is an exploded fragmentary sectional view of the roll body of Figure 14;
  • Figure 17 is an exploded perspective view of the small embossing roll of Figure 14;
  • Figure 18 is another perspective view of the small embossing roll of Figure 14.
  • Figure 19 is a perspective view of a cylindrical steel sleeve which can be used to make embossing plates.
  • Figure 1 illustrates conventional rubber- to-steel embossing of a tissue web W to add decoration and bulk.
  • the web can be wound into retail sized rolls of bathroom tissue or kitchen toweling.
  • An embossing roll 31 includes an engraved surface 32 which is engraved with an embossing pattern.
  • the embossing roll 31 cooperates with a rubber-covered backup roll 33.
  • a web W is advanced between the cooperating rolls, and the embossed surface 32 presses the web into the rubber-covered roll and forms embossments 34 in the web.
  • the roll 33 is adjustable to vary the pressure on the web.
  • Figure 2 illustrates a two-ply web W 2 which has been embossed by the rolls 31 and 33.
  • the embossing of the two webs may create a minimal mechanical bond between the webs.
  • a multi-ply web having more than two plies can also be embossed.
  • the cooperating backup roll could have an outer surface which is harder than rubber.
  • the surface could be steel or other metal or paper.
  • Hard surfaces are generally formed with cooperating or matching recesses into which the projections of the embossing roll extend.
  • Figure 3 illustrates a conventional embossing machine for producing two-ply paper products with foot-to-foot embossments.
  • a top web 44 which is unwound from an unwind stand (not shown) passes between an upper rubber-covered roll 45 and a steel embossing roll 46.
  • the embossing roll is engraved to provide embossments or radially outwardly extending projections 47 and unembossed areas 48 between the projections.
  • the embossing roll 46 is rotatably mounted in a frame 49 of the embossing machine, and as the embossing roll 46 and the rubber covered roll 45 rotate, projections 47 on the embossing roll 46 press the upper web into the rubber-covered roll 45 and form embossments 50 on the upper web.
  • Adhesive or glue is picked up from an adhesive fountain (not shown) by a transfer roll 51, and the glue is transferred by transfer roll 52 to an applicator roll 53.
  • the applicator roll 53 contacts the embossments 50 of the upper web and transfers glue to the embossments .
  • a lower web 54 is unwound from another unwind stand and passes between a lower rubber- covered roll 55 and a second steel embossing roll 56.
  • the embossing roll 56 is also provided with embossments or projections 57 and unembossed areas 58.
  • the projections 57 on the second embossing roll press the lower web into the rubber-covered roll 55 and form embossments 59 on the lower web.
  • the two embossing rolls are geared so that the embossments of the two webs are aligned and are pressed together where the projections of the embossing rollers meet at the nip 62 between the embossing rolls.
  • the adhesive on one of the embossments 50 secures the two plies together.
  • the resulting laminated two-ply embossed product 63 advances away from the embossing machine for further processing operations, for example, in a rewinder line .
  • the second embossing roll 56 is rotatably mounted in the frame of the embossing machine.
  • the second embossing roll is also advantageously pivotable relative to the first embossing roll 46 so that the nip 62 can be adjusted.
  • the rotational or longitudinal axes 46a and 56a of the embossing rolls are parallel.
  • Figure 4 illustrates a conventional embossing machine for producing two-ply paper products with nested embossments.
  • An upper web 65 from an unwind stand advances over a spreader roll 66 and around an upper rubber-covered roll 67.
  • An upper embossing roll 68 having projections or embossments 69 presses the upper web into the rubber-covered roll 67 to form embossments in the upper web.
  • a lower web 71 is advanced from another unwind stand over a bowed roll 72 and around a lower rubber-covered roll 73.
  • a lower embossing roll 74 having projections or embossments 75 presses the lower web into the rubber-covered roll 73 to form embossments in the lower web.
  • Adhesive is applied to the embossments of the lower web (while they are still supported by the projections) by an adhesive-applying roll 76 which is supplied with adhesive by transfer rolls 77 and 78 and a fountain (not shown) .
  • the axes of rotation 68a and 74a of the upper and lower embossing rolls are parallel, and the rolls are separated to provide an open nip 80.
  • the projections 69 on the upper embossing roll are offset from the projections 75 on the lower embossing roll so that the projections of the two embossing rolls mesh at the nip 80.
  • the embossed upper web 65 leaves the upper embossing roll 68 at the nip 80 and meshes with the embossed lower web 71 on the lower embossing roll.
  • the two webs are pressed together at a nip 81 between a rubber-covered marrying roll 82 and the projections of the lower embossing roll 74, and the adhesive on the embossments of the lower web is pressed against unembossed areas of the upper web to secure the two webs together.
  • the rolls are rotatably mounted in a frame 83 of the embossing machine .
  • FIG. 5 illustrates an embossing roll 85 which is formed in accordance with the invention.
  • the embossing roll includes an elongated, generally cylindrical roll body 86 and a plurality of embossing plates 87.
  • the particular roll illustrated includes 16 plates arranged in four longitudinally extending rows or quadrants and four circumferentially extending rows.
  • the outside surfaces of the embossing plates form a cylindrical surface, and an embossing pattern is engraved on the outer surface of the plates .
  • the embossing roll has a length L and a diameter D.
  • the length of the embossing roll depends on the width of the web which is being embossed.
  • Typical embossing rolls may have lengths of up to 100 or 110 inches or more and diameters of up to 18 to 20 inches or more .
  • the roll body 86 includes a pair of ends 88 and journals 89 which extend away from the ends along the longitudinal axis of rotation 90 of the embossing roll.
  • a vacuum rotary union 91 is mounted on the end of one of the journals and is connected to a vacuum pump or other vacuum source by vacuum line 92.
  • the vacuum rotary union 91 is connected to four vacuum control valves 94 by an internal passage 95 in the journal 89.
  • internal passage 95 will extend to communicate with the roll interior, which can be used as a vacuum reservoir.
  • these are 3-way valves, which connect plate-suction areas either to vacuum (for holding) or to atmosphere (to release) .
  • Each vacuum control valve is connected through an opening 96 in the journal 89 and an internal passage 97 in the roll body 86 to deep longitudinal and shallow transverse vacuum grooves 98 and 99 in each quadrant of the outer surface of the roll body.
  • Each quadrant also includes at least one rectangular or oval groove 100 for a sealing gasket to form a vacuum suction area for holding a plate.
  • two axially adjacent embossing plates are held against adjacent oval sealing glands 100a which surround longitudinal vacuum grooves 98 and transverse vacuum grooves 99.
  • Adjacent longitudinal grooves 98 are connected by two shallow-angle drilled holes 98a and 98b which meet at 98c so that the vacuum areas for one longitudinal row of plates may be controlled by one valve.
  • the drilled holes 98a and 98b intersect below the surface of the roll body.
  • the embossing plates 87 include straight longitudinal and transverse side edges 101 and 102. However, straight-cut side edges might cause a minor disruption of the engraved pattern.
  • Figure 8 illustrates an embossing roll 103 which is similar to the embossing roll 85.
  • the embossing plates 104 of the roll 103 have nonlinear side edges 105 and 106 which avoid the important areas of the embossing pattern. While the non-linear side edges might not avoid all of the engraved portions of the plates, the disruption to the embossing pattern is substantially reduced or minimized.
  • the side edges 105 and 106 are shown in zig-zag fashion for illustrative purposes only. The actual preferred contour of the non-linear edges will depend on the embossing pattern.
  • FIG 9 is an exploded cross sectional view of an embossing roll 108 in which embossing plates 109 are removably secured to roll body 110 only by vacuum.
  • a vacuum source communicates with the surface of the roll body through internal passages 111, and shallow transverse surface grooves 99 in combination with deeper longitudinal grooves 98 (see Figure 6) distribute the vacuum force over substantially the entire surface of each plate.
  • Each plate is sucked by vacuum against a flexible and resilient sealing gasket 113.
  • One or more cylindrical locating studs 114 extend radially inwardly from each plate. Each locating stud is inserted into a circular opening 115 in the roll body. The locating studs prevent the plates from "walking” or “creeping” under the ironing influence of the moving band of pressure which is exerted on the embossing roll by the rubber-covered backup roll.
  • an electrical or mechanical sensor is used to halt the machinery if vacuum is lessened, and in addition, a check valve placed after the rotary union slows air leakage when the hose is cut.
  • FIG 10 illustrates an embossing roll 117 in which embossing plates 118 are removably secured to roll body 119 by only quick-change mechanical devices.
  • Each plate includes two or more locating and gripping studs 120 (see also Figure 11) which cooperate with a notched rod 121 (see also Figures 12 and 13) which extends longitudinally through the entire roll body.
  • the studs are cylindrical in cross section and include hook-shaped notches 122.
  • each rod is provided with a semicircular notch 124 for each stud.
  • the studs 120 can be inserted into the openings. The rods are then rotated one-half turn so that solid portions of the rod enter the hook-shaped notches of the studs and draw the studs into openings 123 and draw the plates against the roll body.
  • each plate advantageously has a radius of curvature which is less than the radius of curvature of the roll body when the plate is not secured to the roll body.
  • the curvature of the unattached plate is shown in solid outline. The plate will therefore flatten out and seat irmly against the roll body, to eliminate rattling and maintain contact despite centrifugal force in high speed operation, when it is drawn against the roll body by the rod 121.
  • the curvature of the attached plate is shown in dotted outline. The bending stiffness of the plate must permit the draw-down to develop a preload higher than the centrifugal force on the plate when the embossing roll rotates.
  • the rods 121 are rotatably supported in longitudinal grooves 125 which are machined in the surface of the roll body.
  • the grooves extend angularly with respect to a radius of the roll body.
  • One end of each rod can include a head or shoulder which bears against a shallow recess at one end of the roll body, and the other end of the rod can be threadedly engaged with a nut which bears against a shallow recess in the other end of the roll body.
  • the rod can be manually rotated to a latching or unlatching position, for example by a key or wrench fitted to an appropriate feature at the threaded end, and, while its orientation is held, the rod can be locked in place by tightening the nut.
  • attaching devices can be used, for example, sliding rods, screws, dovetails, any of a variety of releasable latch mechanisms, and equivalents thereof.
  • the disclosed studs and rotating rods have the advantages of quick change; no loose parts which might drop to floor, or be forgotten, or work loose to damage the cooperating roll; end actuation; and easy machining into a roll surface, i.e., no long drilled holes.
  • Many other sufficiently strong attaching mechanisms are possible, with or without a draw-down feature.
  • projecting grippers on the roll body can engage cooperating recesses or cavities in the plates. Any such locking system must have a feature to prevent unexpected loosening due to vibration.
  • FIG 14 illustrates an embossing roll 126 which uses both vacuum and mechanical devices to attach embossing plates 127 to roll body 128.
  • Each plate includes two or more locating studs 129 as described with respect to Figure 10.
  • the studs are inserted into openings 130 in the roll body and are captured by rotatable notched rods 131 as described with respect to Figure 10.
  • the positions of the studs relative to the openings are precise for locating purposes. However, the fit to the cooperating notched rod is loose to assure easy working.
  • angular clearance is necessary to prevent binding in the eventuality that the plate is slightly tilted.
  • the rods 131 are not designed to draw the plate down against the roll body. That is the function of the vacuum system. Rather, the rods serve to retain the plates when the vacuum is turned off or power for the vacuum source is interrupted. For safety, if this should occur while the roll is rotating, the plates must be provided with enough bending strength (by virtue of adequate thickness) to bear the cantilevered centrifugal force.
  • Each vacuum region is defined by a sealing gasket 133. Vacuum communicates with each region through a longitudinal internal passage 134 and branched internal passages 135. The branched passages communicate with grooves 136 in the surface of the roll body.
  • Figure 15 is an end view of the embossing roll 126 of Figure 14.
  • Three-way vacuum control valves 137 are connected to the vacuum passages 138 in the journal 139 of the roll and to the longitudinal passages 134.
  • Figure 16 illustrates the notched studs 129 of Figure 13 which are provided with circular notches 140 which are designed to latch the plates rather than draw the plates downwardly against the roll body.
  • the solid portions of the rod rotate into the notches 139.
  • variations in the contours schematically indicated at 140 and 131 may advantageously provide draw-down, ejection, and over- center locking functions.
  • FIGS 17 and 18 are exploded perspective views of the embossing roll 126.
  • Each of the embossing plates is drawn against the embossing rolls by two vacuum regions which are defined by oval sealing gaskets 133.
  • the ends of the rotating rods 131 extend beyond the ends of the roll body 128 and can be rotated by any convenient mechanism.
  • the embossing plates fully cover the surfaces of an embossing roll over which the web travels so that the continuous web is embossed with the embossing pattern without interruption. Although adjacent embossing plates are separated at their edges, the side edges of the plates create little if any interruptions or discontinuities in the embossing pattern.
  • a slight gap of approximately .010" or more between plates may be intentionally provided to prevent the plates from buckling, and (for the case of locating stud aligned in an axial row) , slight clearance in the axial direction of the roll may be provided in the locating holes.
  • any interruptions in the embossing pattern can be further reduced or minimized by contouring the side edges of the embossing plates to avoid the important areas of the embossing pattern as illustrated in Figure 7.
  • the contour would be placed close to protrusion bases, where the rubber roll never penetrates.
  • the plates can be urged together axially by springs or any other loading means.
  • the embossing plates can be formed from steel to maximize durability.
  • the thickness of the steel plates can be made sufficient so that the embossing protrusions are not flexed or fatigued by the periodic pressure of the rubber roll .
  • the embossing plates for a complete embossing roll can advantageously be formed by first forming an integral steel sleeve 142.
  • a steel sleeve having a wall thickness of 0.25 inch, a diameter of 18 to 20 inches or more, and a length of 100 to 110 inches or more can be formed depending upon the dimensions of the embossing roll.
  • the sleeve is prepared for later sectioning and precise mounting by drilling holes 114 at precise locations for future studs. If large holes are drilled, the holes can be tapped for installing threaded studs . Small holes can be welded closed on the outside surface of the sleeve, and the inside openings can be used to precisely position studs for welding.
  • the sleeve is then engraved with the embossing pattern, for example, by match engraving which is a low-force engraving method which will not damage a thin sleeve.
  • match engraving which is a low-force engraving method which will not damage a thin sleeve.
  • Other possible methods are photoengraving of brass or magnesium, spray etching of steel with laser-ablated resist, laser ablation of any plate with surface of polymer or ceramic, or any other low force engraving method which is known in the art .
  • the engraved sleeve is then cut into a plurality of plates.
  • the thinnest possible kerf e.g., 0.008-0.020 will minimize disruption to pattern.
  • the plates can be cut with straight side edges as indicated by the dashed lines 144 and 145 in Figure 19, or the edges can be contoured to minimize disruption of the pattern.
  • the plates can be cut either manually, for example, by a jigsaw, or automatically, for example, by laser or water jet.
  • the plates may be cut first and engraved second while held in position on a roll body.
  • higher-force engraving methods may be used.
  • This approach of engraving separate plates also offers the advantages of manufacturing curved plates by rolling flat plates; and eliminating any need for narrow-kerf sectioning.
  • the embossing plates can be retrofitted to a previously formed conventional embossing roll by removing the previously engraved layer and providing the embossing roll with the vacuum and/or mechanical latching mechanisms. All of the embodiments described herein involve relatively simple surface features and short holes which can be formed in an existing embossing roll by surface machining and drilling.
  • the thickness of the embossing plates can vary depending upon various criteria:
  • the centrifugal force acting on the cantilevered plate halves on either side of the attaching studs should not cause the plates to yield.
  • rotational speeds i.e., speeds substantially higher than current's speeds
  • this requires a heavy, rigid plate. In fact, the plate would be too heavy, to be held by vacuum alone .
  • the thickness which is required for mechanical engraving is about 1/8 inch. If laser engraving or etching can be used, a thinner plate can be used.
  • the thickness should be such that the centrifugal acceleration acting on the half plate freely cantilevered from the mechanical devices would not deflect the edges of the plate by an amount exceeding the drawn-down displacement of the mechanical devices. For high speeds this requires a thick, rigid plate.
  • the overall thickness t of the plate, including the height h of the embossments is preferably greater than 1.5h: t > 1.5 h
  • the thickness of steel plates is preferably within the range of 1/8 to 1/4 inch. Thicknesses of about 6 mm or 1/4 inch permit machining and provide sufficient plate strength at today's top operating speeds if the mechanical interlock is only in the center of the plate. If it is desired to use a thinner plate or operate at higher speeds, a more complex mechanical interlock system extending closer to the plate edges will be necessary.
  • the plates are heavy enough, and for some embossers require enough arms-outstretched maneuvering, that a supporting or counterbalancing system may be needed.
  • the plate has to gripped. And it is not practical to grip it in the normal way (pinching contact on front and back) since the back must be left clear for installation. (In fact, there is no access to the back side when trying to remove from a roll.)
  • One could use an edge grip e.g., on a small 2mm lip around the plate, or at least on the two edges formed by the circumferential cuts. That is, draw together two shallow hooks which engage the lip from the front side.
  • the roll should possess ejection means, such as one or more springs trapped under each plate, or an ejection funciton of the mechanical securing devices.
  • the plates to be removed would automatically move outwards half their thickness.
  • the plate to be removed can be tilted u (so its edge has moved outwards nearly one full thickness) while the adjacent plate can be tilted down (so as to uncover the lip, etc. of the plate to be removed.)
  • Alternate front-surface gripping means are vacuum (with highly flexible seals to prevent air leakage between pattern elements) and magnetic.
  • any of a number of obvious low-force attachment means may be used to secure the plates from dropping when the primary holding systems (e.g., vacuum and mechanical) are switched off.
  • the primary holding systems e.g., vacuum and mechanical

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)
  • Machines For Manufacturing Corrugated Board In Mechanical Paper-Making Processes (AREA)

Abstract

L'invention concerne un rouleau gaufreur pourvu d'un corps de rouleau et d'une pluralité de plateaux qui sont fixés de manière amovible sur ledit corps. Chaque plateau comprend une surface externe munie d'un motif de gaufrage. On peut fixer les plateaux sur le corps du rouleau au moyen d'appareils mécaniques et/ou sous vide.
PCT/US2002/007337 2001-03-09 2002-03-07 Rouleau gaufreur dote de plateaux amovibles WO2002072340A2 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP02707974A EP1370412A2 (fr) 2001-03-09 2002-03-07 Rouleau gaufreur dote de plateaux amovibles

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US80241201A 2001-03-09 2001-03-09
US09/802412 2001-03-09

Publications (2)

Publication Number Publication Date
WO2002072340A2 true WO2002072340A2 (fr) 2002-09-19
WO2002072340A3 WO2002072340A3 (fr) 2003-01-16

Family

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EP (1) EP1370412A2 (fr)
WO (1) WO2002072340A2 (fr)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2408486A (en) * 2003-11-25 2005-06-01 Waterproofing Group Plc Elongate embossing assembly with plurality of embossing elements
WO2005068175A1 (fr) * 2003-12-23 2005-07-28 Paper Converting Machine Company Plaques a gaufrer interchangeables destinees a etre montees sur un rouleau gaufreur
EP1702747A1 (fr) * 2005-03-14 2006-09-20 Sant'Andrea S.p.A. Dispositif de gaufrage
EP2275259A1 (fr) * 2009-07-14 2011-01-19 Pantec GS Systems AG Unité d'impression ou de gaufrage et cylindre de travail correspondant
WO2014173709A1 (fr) * 2013-04-22 2014-10-30 Mahle International Gmbh Procédé et dispositif de réalisation d'éléments filtrants
CN113400728A (zh) * 2021-07-21 2021-09-17 黑龙江职业学院(黑龙江省经济管理干部学院) 一种财务会计用可调节式平纸器

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1597490A (en) * 1924-08-09 1926-08-24 Storey William Henry Rotary type-duplicating machine
US3603256A (en) * 1968-07-08 1971-09-07 Albert Schnellpressen Device for fixing form saddles on the rotary press form cylinder
US4561355A (en) * 1982-05-27 1985-12-31 Cuir Jean P Device for fixing a plate on a cylinder
US4878407A (en) * 1986-05-01 1989-11-07 The Ward Machinery Company Vacuum die mount
EP1048452A1 (fr) * 1999-04-19 2000-11-02 Fort James Corporation Support modulaire à montage multiple pour plaques à presser sur un rouleau d'emboutissage
US6173496B1 (en) * 1996-10-16 2001-01-16 Fort James Corporation Embossing system including sleeved rolls

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1597490A (en) * 1924-08-09 1926-08-24 Storey William Henry Rotary type-duplicating machine
US3603256A (en) * 1968-07-08 1971-09-07 Albert Schnellpressen Device for fixing form saddles on the rotary press form cylinder
US4561355A (en) * 1982-05-27 1985-12-31 Cuir Jean P Device for fixing a plate on a cylinder
US4878407A (en) * 1986-05-01 1989-11-07 The Ward Machinery Company Vacuum die mount
US6173496B1 (en) * 1996-10-16 2001-01-16 Fort James Corporation Embossing system including sleeved rolls
EP1048452A1 (fr) * 1999-04-19 2000-11-02 Fort James Corporation Support modulaire à montage multiple pour plaques à presser sur un rouleau d'emboutissage

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2408486A (en) * 2003-11-25 2005-06-01 Waterproofing Group Plc Elongate embossing assembly with plurality of embossing elements
GB2408486B (en) * 2003-11-25 2006-12-13 Waterproofing Group Plc Improvements in and relating to embossing
WO2005068175A1 (fr) * 2003-12-23 2005-07-28 Paper Converting Machine Company Plaques a gaufrer interchangeables destinees a etre montees sur un rouleau gaufreur
US7028612B2 (en) 2003-12-23 2006-04-18 Paper Converting Machine Company Interchangeable embossing plates for mounting on an embossing roll
EP1702747A1 (fr) * 2005-03-14 2006-09-20 Sant'Andrea S.p.A. Dispositif de gaufrage
EP2275259A1 (fr) * 2009-07-14 2011-01-19 Pantec GS Systems AG Unité d'impression ou de gaufrage et cylindre de travail correspondant
WO2014173709A1 (fr) * 2013-04-22 2014-10-30 Mahle International Gmbh Procédé et dispositif de réalisation d'éléments filtrants
CN113400728A (zh) * 2021-07-21 2021-09-17 黑龙江职业学院(黑龙江省经济管理干部学院) 一种财务会计用可调节式平纸器
CN113400728B (zh) * 2021-07-21 2022-06-24 黑龙江职业学院(黑龙江省经济管理干部学院) 一种财务会计用可调节式平纸器

Also Published As

Publication number Publication date
EP1370412A2 (fr) 2003-12-17
WO2002072340A3 (fr) 2003-01-16

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