Patent Application
20180065824
The invention relates to a conveyor for a web with at least one attachment for a leading end or a trailing end of the web, the conveyor extending generally along on a horizontal plane from an upstream portion to a downstream region of a system.
Such a conveyor is provided, for example, in an apparatus for impregnating a material web or in a printer.
In the furniture industry and for laminate floor panels, decorative papers are used for visible surfaces of wood or fiberboard panels. For this purpose, a printed paper web with synthetic resins such as urea resin or melamine is impregnated and optionally provided with abrasion-resistant particles such as corundum, for example, in order to impart certain characteristics to the web. The web is subsequently dried and cooled. Unprinted paper, i.e. paper without decorative elements, is also used in part. An apparatus and method for making an impregnated web (impregnates) is known from the prior art and described, for example, in DE 20 2007 011 437 and DE 197 10 549.
Manufacturers of furniture and/or laminates are taking measures to drastically reduce their warehoused stock. This means that they order relatively small quantities of a given decorative element that is to be delivered on a certain date.
The impregnation and coating of paper webs is very elaborate when using the known methods and systems. In particular, the production of rejects during start-up and shut-down of the devices, as well as the effort involved, are very high. To wit, the web must first be threaded by hand into an impregnation station and optionally through impregnation baths. The web is impregnated and discarded until an adequate impregnation outcome is achieved. Only then is the web cut, and the new leading end of the web extends by an intake device through a dryer and a cooler. Rejects also occur downstream of these devices initially until a satisfactory final web quality has been achieved. It is only then that the production of usable impregnate is begun, and it is cut into sheets or spooled. Where necessary, the desired impregnation/coating agents must be gathered and exchanged for those already present in the system. Relatively large quantities of about 800 l of resin are required for this. The setup time for preparation takes more than an hour. All things considered, the costs of labor and rejects during startup and shutdown are therefore high. For this reason, impregnation operations are not able to economically produce small quantities of impregnated goods and are forced to reject such orders or fill them at a loss. The speed of the web during threading and drawing-in are much slower than the production speed.
One approach to solving the above-described problem is described in DE 10 2009 021 164. There, it is proposed that an intake device for a web be moved generally along a horizontal plane from a region upstream of an impregnation station to downstream of a cooler.
In terms of the invention, the term “impregnation station” refers to the application of resin to a web, independently of the type of application used, for example dipping, spraying, or coating, and of the function, whether the resin is being applied for the purpose of impregnation or coating (for example of a pretreated web). The term “impregnation” is used generically.
It is the object of the invention to improve a conveyor for a leading end or a trailing end of a web such that smaller quantities of impregnated decorative paper can be manufactured with little effort and minimum waste.
The object is achieved by the features of claim 1. The attachment comprises a bar magnet that extends during the operation of the conveyor below the web, extends over at least the width of the web, and cooperates with a magnetizable sheet-metal plate that can be moved above the web out of a rest position into a holding position.
For one, this enables the web to be drawn automatically into the complete device. All that needs to be made available is a sufficiently long leading end of the web that hangs freely from a supply roll. The leading end is then clamped between the magnet and the sheet-metal plate and can be pulled through the conveyor to downstream of the cross-cutter. Moreover, once the required production quantity has been reached, one end of the web can be guided downstream of the dryer by the conveyor. Beforehand, for example during the operation of the device, the magnet and the sheet-metal plate must be brought into their second starting positions. The work involved for operation is further reduced. All in all, the web can be largely be treated and used in its entirety. The production of rejects is avoided almost completely, thus enabling even smaller quantities of impregnate to be produced in an economical manner. The device can be operated by one person.
The subclaims relate to the advantageous embodiments of the invention.
In one embodiment, the magnet is formed by a plurality of individual plates. This renders the magnet less mechanically sensitive, more economically obtainable, and easier to install in the device.
In another embodiment, the magnet is supported in a housing that has at least one first pair of pickers for the sheet-metal plate. The housing is preferably made of non-magnetizable material, protects the mechanically sensitive magnet from breakage, for example, and ensures the usual functioning even in case of breakage. In particular, the individual plates can be arranged securely and in a predefined position.
In another embodiment, a second pair of pickers is provided on the sheet-metal plate. This enables differently designed sheet-metal plates to be selectively taken off.
In another embodiment, the magnet is provided with a cover made of non-magnetizable material. The magnet is thus protected from the impacting sheet-metal plate, thereby ensuring the durability of the magnet without interfering with the magnetic field.
In another embodiment, the conveyor is provided in a system for impregnating the web. The conveyor is especially well suited for this purpose.
In another embodiment, a first rest position is provided in a region between an unwinder and an impregnation station, and a second rest position is provided between the impregnation station and a dryer. On the one hand, this enables a leading end of the web to be pulled in reliably and automatically through the complete impregnation station and, on the other hand, a trailing end of the impregnated web to be guided to a cross-cutter, resulting in an especially small amount of waste.
In another embodiment, a second sheet-metal plate that is provided for the second rest position has a cutter for the web. The required separation of the web is thus performed automatically.
In another embodiment, a pusher for pressing the sheet-metal plate onto the magnet is associated with the second rest position. This ensures the secure severing even of more stable webs.
The invention will be explained in further detail using the example of an impregnation station and with reference to the schematic drawing in which:
According to
In the present application, directional information such as upstream or downstream refers to the web travel direction.
In an unillustrated embodiment, the supply roll 2 that holds a quantity of the web 1, is rotatable in an unwinder such that the web 1 can be pulled off of it. The supply roll 2 is either drivable, in which case the web 1 is deflected over a roller 3, or an intake station is provided between the supply roll 2 and the impregnation station 4 that comprises several rollers, at least one of which is drivable.
The impregnation station 4 comprises an applicator roller 11 with a first deflection roller 14, an immersion roller 12, two metering rollers 13, and two distributing rollers 15. The applicator roller 11, the immersion roller 12, the metering rollers 13, the first deflection roller 14, and the distributing rollers 15 extend parallel to one another.
The applicator roller 11 is drivable and supported in a first trough 16 such that it projects with approximately half of its circumference upward out of the first trough 16. During operation, the first trough 16 is filled to a predetermined level with impregnating agent, so that a portion of the circumference of the applicator roller 11 dips into the impregnating agent. The first deflection roller 14 is mounted in a vertically displaceable manner at a short spacing upstream of the applicator roller 11.
The immersion roller 12 is mounted at a predetermined spacing downstream of the applicator roller 11 so as to be displaceable vertically or approximately vertically into an upper loading position or into a lower immersion position in a second trough 17. The expander roller 8 is mounted upstream of and above the second trough 17 such that it is contacted by the web 1 in its upper apex region during operation. During operation, the second trough 17 is filled with a second impregnating agent that can be different from the impregnating agent in the first trough 16, and the immersion roller 12 dips at least partially into the second impregnating agent. The web 1 wraps partially around the immersion roller 12 in a lower region.
Downstream of and above the immersion roller 12, two metering rollers 13 are mounted such that they form a narrow, width-adjustable gap. One of the metering rollers 13 is vertically displaceable for this purpose.
The distributing rollers 15 are mounted downstream of the metering rollers 13, with an upstream distributing roller 15 being vertically displaceable in the web travel direction.
After a predefined transport through a distance of 1 m, for example, downstream of the impregnation station 4, the web 1 extends into the dryer 5 where energy can be applied to it in a known manner, preferably in the form of heat.
The cooler 6 and then the web control rollers 9 are provided downstream of the dryer 5 in order to regulate the directional stability of the web 1. One of the rear web control rollers 9 can pivot as indicated by the double-headed arrow.
At the downstream end there is the cross-cutter 7 with an upstream second deflection roller 18 and a sheet stacker 20 for the sheets cut from the web 1. The second deflection roller 18 is supported so as to be vertically adjustable.
According to this embodiment, the first deflection roller 14, the front distributing roller 15, the immersion roller 12, the rear web passage control roller 9, and the second deflection roller 18 are referred to collectively as displaceable elements.
It will readily be understood that all of the rollers, with the exception of the web passage control rollers 9, are parallel to one another and to the plane of the web 1.
The conveyor 10 extends through the entire impregnating apparatus. It comprises two endless guide members 10a, such as for example chains or punched steel belts, as well as a magnet 22 and a magnetizable sheet-metal plate 23 that together form an attachment 27. The guide members extend parallel and in a straight line from a region below the supply roll 2 to downstream of the cross-cutter 7, deflected there, and thence back. For guiding the guide members, rails and deflection rollers 21 for example, are provided such that an upper reach 10a of the conveyor 10 extends in a substantially horizontal plane. At least one of the deflection rollers 21 per guide member is drivable. A direction of transport of the conveyor 10 corresponds to that of the web 1.
A bar magnet 22 is associated with the guide members and can be seen more clearly in
In an alternative embodiment, the first pair of pickers 24 is fastened to ends of an upstream longitudinal side of the sheet-metal plate 23. The pickers 24 point downward when the sheet-metal plate is fitted into one of the holders 25, 26.
A first rest position of the magnet 22 is below the supply roll 2, and a second rest position thereof is between the rear distributing roller 15 and the dryer 5.
In an alternative, the magnet 22 is formed by a plurality of magnetic plates that jointly form the overall size of the magnet 22.
The sheet-metal plate 23 is made of magnetizable material such as a suitable steel, for example. Its length and width correspond substantially to the dimensions of the magnet 22.
In a first embodiment shown in
In a second embodiment shown in
For the sheet-metal plate 23, the two holders 25 and 26 are provided in the impregnating apparatus that define the rest positions of the sheet-metal plate. The holders 25 and 26 are fastened at a short spacing above the plane on which the web 1 extends. A spacing between the plane and a lowermost side of the holders 25, 26 is 2 cm to 10 cm, for example. Each of the holders 25, 26 is made of an angle profile, for example, whose short leg at a rear end of the angle profile points upward perpendicularly or inclined slightly forward; the long leg is thus either horizontal or sloped downward slightly in the direction of transport at an angle of up to 3°.
The first holder 25 is provided between the supply roll 2 and the impregnation station 4.
The second holder 26 is fastened between the impregnation station 4 and the dryer 5. The second rest position of the magnet 22 is thus located between the impregnation station 4 and the second holder 26.
Pushers 28 can be provided between the second holder 26 and the dryer 5. These are composed, for example, of a roller or of at least two spaced-apart rollers. Preferably, a circumference of the roller or rollers is coated at least over a predetermined width with an elastic coating. A lowermost side of the roller or rollers has a spacing of 2 mm to 8 mm to the plane of the web 1.
In order to put the impregnating apparatus into operation, the troughs 16 and 17 are filled with liquid resin. A leading end of the web 1 is drawn off the supply roll 2 so far that it can be guided at least to the downstream side of the first holder 25. The leading end hangs freely down from the supply roll 2. The first embodiment of the sheet-metal plate 23 is placed into the first holder 25, with the bent-over flange pointing upward.
The displaceable rollers are in an intake position. For this purpose, the rear web passage control rollers 9 are moved into a lower position and the first deflection roller 14, the front distributing roller 15, the immersion roller 12, the upper metering roller 13, and the second deflection roller 18 are each moved into an upper position. The loading positions of the rollers and a path of the web 1 that deviates from normal operation are shown with broken lines.
All of the drivable rollers are started up at a rotational speed that corresponds to the production speed, with the applicator roller 11 here being rotated in the opposite direction. The dryer 5 and the cooler 6 are put into operation and set to the required temperatures. As soon as those temperatures are reached, a drive of the conveyor 10 and a drive of the supply roll 2 and/or of the loading station are switched on at production speed, thereby moving the magnet 22 that is clamped in the guide members in the direction of transport. The magnet 22 entrains the hanging leading end of the web 1. As soon as the magnet 22 is below the first holder 25, the pickers 24 engage the sheet-metal plate 23, so that it slides onto the cover 22b of the magnet 22 and is held there by the magnetic force. The leading end of the web 1 is immovably clamped between the sheet-metal plate 23 and the cover 22b, so that it is pulled through the impregnating apparatus. The web 1 is unwound from the supply roll 2 and guided around the roller 3, with the web 1 under a predefined tension.
After the magnet 22 has passed the applicator roller 11, the first deflection roller 14 is moved into the lower position, so that the web contacts a portion of the circumference of the applicator roller 11 and is thus wetted with the liquid impregnating agent from the trough 16.
The magnet 22 with the leading end of the web 1 travels further above the expander roller 8 and between the distributing rollers 15. As soon as it has passed through the latter, the immersion roller 12, the upper metering roller 13, and the front distributing roller 15 are moved into their lower positions.
The magnet 22 and thus the web 1 passes further through the dryer 5, where the web 1 is dried to a predefined residual moisture. Heat is preferably used as the drying energy, for example in the form of hot air or infrared radiation, but other energy sources such as microwaves, for example, can also be employed. The web 1 is then cooled in the cooler 6. Moreover, after the magnet 22 passes through, the rear web passage control roller 9 is moved upward and the web passage control switched on.
The web 1 is then guided under the second deflection roller 18 that, after the passing of the magnet 22, is moved into its lower position, to the cross-cutter 7, where it is cut into sheets having a predefined length, and the sheets are placed in the sheet stacker 20. As soon as the magnet 22 has reached the leading end of the sheet stacker 20, the drive of the conveyor 10 is switched off, and normal operation continues. The loading speed and the production speed are substantially the same and are 0.5 to 20 m/min.
In order to shut the impregnating apparatus down, the magnet 22 is first hung in a location between the distributing roller 15 and the dryer 5 such that it is located upstream of the second holder 26 with the sheet-metal plate 23. The conveyor 10 is switched on at production speed, so that the magnet 22 is transported toward the dryer 5. The magnet 22 removes the sheet-metal plate 23 with the second pair of pickers 24. The sheet-metal plate 23 is held by the magnet 22, so that the web 1 is clamped here between the magnet 22 and the sheet-metal plate 23. At the same time, the web 1 is severed just upstream of the magnet 22 by the longitudinal strip 23a, optionally with the aid of the pusher 28, thereby creating a new leading end of the web 1 as well as a web end that is transported further. The unwinder or the loading station and the impregnation station 4 are stopped, and the associated displaceable elements are moved into their loading positions.
The web end extends through the dryer 5 and farther until just before the sheet stacker 20, so that the web 1 is processed completely to the web end. The web 1 can thus be utilized without substantial waste. The conveyor 10, the dryer 5, the web tension control 9, the cooler 6, and the cross-cutter are stopped. Just upstream of the trailing web end, a displaceable element is reached that is moved into its loading position.
Unusable remnants of the web 1 are removed and, if necessary, the impregnating/coating device is emptied and cleaned.
It is then available for the impregnation of a new web 1.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2016/058172 | 4/14/2015 | WO | 00 |
