Patent Application
20130068369
The present invention relates to a laminating unit for laminating a first web onto a second web in a laminating machine. The invention concerns to a laminating machine comprising a unit for laminating a first web onto a second web. The invention relates also to a method for manufacturing a multi-layer composite by laminating a first web onto a second web.
Multi-layer composite materials are used in the field of packaging, after they have been cut, folded and glued. One of these composites commonly used is corrugated board. It is used mainly as a protective packaging that is particularly strong while being readily recyclable.
Corrugated board is for example made up of an inner board provided with flutes, bonded onto a first flat coverboard on one side of the flutes. This inner board with first flat coverboard constitutes a single-face corrugated board. The single-face corrugated board obtained is also assembled by bonding, i.e. laminating, with a second flat board on the other side of the flutes.
To make the packaging more attractive, the corrugated board is often modified, for example printed. This operation is performed by flexography in order to obtain quality prints in multiple colours. However, printed corrugated board may exhibit defects, for example in the case of relatively thin corrugated board. The defects are not acceptable for packaging for expensive products.
Some printing defects among others are lines corresponding to each tip of the flutes because, during printing, the corrugated board will be crushed slightly. The difference in strength between the tips of the flutes and the regions separating two consecutive flute tips is the main reason why these lines appear during the printing operation.
For avoiding these defects, one technique then is to use laminating to assemble a sheet-like element in the form of a pre-modified for example preprinted sheet of board, onto a backing in the form of a single-face corrugated board or single-face corrugated web. Another second technique is to use laminating to assemble a first web in the form of a first preprinted solid board web, onto a second web in the form of a second single-face corrugated board web.
The manufacture of a corrugated cardboard according to the second technique is carried out by means of a laminating machine which includes, upstream to downstream:
If the second web is a single-face corrugated board, it could also be produced in line with a corrugator, which is placed upstream of the laminating machine.
In usual production of corrugated board, the glue is starch-based glue. This glue requires a heating device inserted in the laminating unit into the production line. The glue is inexpensive and widely used for obtaining a strong fastening of the upper, intermediate fluted and lower layers together. However this glue is not adapted for the production of quality packaging sheets, as it penetrates the paper layers. The high content of glue leads to printings that include defects, such as spots or lines.
For obtaining a better quality, the producers use cold glue, for example a vinylic glue. It is observed a less penetration of this cold glue into the layer of the paper substrate on which it is coated because it is not necessary to introduce additional heat. This avoids defects at the printed surface or surfaces of the end product. In the laminating unit, the gluing of cover sheets on the tip of the flutes requires also a significant supply of glue. The vinylic glue is a costly one.
In the known laminating unit, the lamination is performed at a convergence line situated between a top laminating roll and a bottom maintaining roll or a bottom vacuum table. A second, driven top roll is intended to pull the first web by squeezing it against the laminating roll. The first web and the laminating roll are driven by the second web which is itself longitudinally driven by a transport device such as a vacuum belt.
A slipping of the first web influences badly the register of the printed first web to the printed second web. For instance, the printing on the surface of the first web does not correspond to the printing on the opposite surface of the second web. A production batch will be wasted by defects and be rejected.
Moreover for obtaining the driving movement without sliding, delamination or pulling out of the first web with respect to the second web, the operator increases the quantity of glue. The prices of the packaging increase with higher quantity of glue. At the opposite, if the quantity of glue is not sufficient, small sliding may occur, with the result that the strength of the composite obtained by the lamination decreases.
It is a main objective of the present invention to produce a unit for manufacturing a multi-layer composite by the lamination of a first web onto a second web in a laminating machine having a high productivity. A second objective is to enhance the register of one web with respect to the other web, being laminated together. A third objective is to develop a method for manufacturing a multi-layer composite by laminating together two webs with a high accuracy. A fourth objective is to provide a laminating method in which positions of the first web are adjusted precisely and rapidly. A fifth objective is to obtain a laminating unit allowing the glue consumption to be reduced. Yet another objective is to create a laminating machine that includes a laminating unit that operate at high speed and yielding to a low level of rejected boards.
In the present invention a laminating unit laminates a first web onto a second web to manufacture a multi-layer composite in a laminating machine. The laminating unit comprises a laminating rotating roll, laminating the first web onto the second web to manufacture the laminated multi-layer composite.
According to one aspect of the invention, the unit is characterized in that it further comprises:
In other words, the laminating rotating roll is able to be accelerated or decelerated in a forward running according to the respective positions of the first and second webs. If the first web is late with respect to the second web, the driving means increases the speed of the roll to make up the time of same first web. If the first web is ahead of the second web, the driving means decreases the speed of the roll to obtain a delayed advance of same first web.
The accurate register is obtained by the regulated synchronisation of the first and second webs. The control means of the driving means are in electrical connection with the first and second detection means. A desynchronizing between the two webs is detected and immediately corrected directly thanks to the laminating roll. The composite emerging from the laminating roll corresponds exactly to the requested correction.
The gripping means avoids a slippage of the first web on the laminating roll. The first web is maintained by the roll during the lamination and positioned onto the second web without any loosening. The first web modified surface will not be damaged by slippage.
The positioning of one web onto the other is performed with a higher accuracy thanks to the driving means. This avoids the formation of a longitudinal shifting between the two webs. Without any significant displacement of one web on the other, the laminating process requires less glue. With the driving means, the movement speed of the first web is continuously and accurately adapted to the movement speed of the second web.
The first and second web are for example paper board, cardboard, single-face corrugated cardboard, double-face corrugated board, flexible plastic or foam, which are modified. The first and second webs comprise modifications or are already modified, for example printed using flexography, photogravure or offset printing machines, creased, embossed, calendered, metalized, hot or cold foil stamped, or stuck with holograms, labels, etc.
In another aspect of the invention, a laminating machine comprising a first feeding unit for feeding the first web and a second feeding unit for feeding the second web is characterized in that it comprises the laminating unit, that has one or more of the technical features described and claimed hereinbelow, and positioned downstream the first and second feeding units.
According to yet another aspect of the invention, a laminating method for manufacturing a multi-layer composite by laminating a first web onto a second web in a laminating machine, comprising, in this order, the steps consisting of:
is characterized in that it further comprises the steps consisting of:
In other words, a step of moving the first web with additional longitudinal small acceleration or deceleration running is added to the usual step of longitudinal transport of this first web. All ranges of distances for the incorrect positions of the first web are covered and can be corrected. This correction permits an accurate positioning of the first web to match exactly the positions of the second web. The modifications on both sides of the composite do correspond to each other.
The longitudinal, upstream and downstream directions are defined with reference to the direction in which the first and second webs travel in the longitudinal direction through the laminating unit and through the laminating machine along their central longitudinal axis. The transverse or lateral direction is defined as being the direction perpendicular to the direction of travel of the first and second webs in the plane formed by such first and second webs respectively.
The invention will be clearly understood and its various advantages and features will become better apparent from the following description of the non-limiting exemplary embodiment given with reference to the attached schematic drawings in which:
As shown in
The machine 1 can comprise a feed unit (not represented) for the single-face web 4 in its upper upstream part. For the described example, the machine 1 is fed by an unwinder, the single-face web 4 coming from a reel (not visible). The machine 1 can also be arranged for instance at the exit of a corrugating machine (not shown) that produce the single-face web 4.
The single-face web 4 is then driven toward the longitudinal downstream direction (Arrow F in
The machine 1 in its upper upstream part can comprise a feed unit (not represented) for the cardboard web 3. The feed unit comprises an unwinder for unwinding a reel 11. The cardboard web 3 is conveyed in the longitudinal direction (Arrow C in Figs.) by means of a pull unit 12 in the form of two friction rollers, the web 3 being inserted between the two rollers. Following the pull unit 12 is a dancer 13 to ensure a continuous tensioning of the cardboard web 3.
The machine 1 next comprises a laminating unit 14 positioned, on the one hand, downstream of the glue-coating unit 9 and, on the other hand, downstream of the dancer 13. The laminating unit 14 comprises a top rotating laminating roll 16. A convergence or lamination line 17 for the lamination corresponds to the line 17 where the cardboard web 3 reaches and is bonded to the single-face web 4. This line 17 is situated between the laminating roll 16 and a bottom laminating roll (not shown).
The cardboard web 3 reaches the line 17 thanks to the pull unit 12. The single-face web 4 reaches the line 17 thanks to the main conveying section 8. At this line, the cardboard web 3 is positioned and bonded onto the adhesive-coated single-face web 4. The composite 2 is thus formed thanks to the rotation of the laminating rolls 16 as the single-face web 4 and the cardboard web 3 simultaneously advance.
The composite 2 is pulled downstream by a transportation section 18. The composite 2 is then cut into a cutting unit 19 to produce individual plate elements or corrugated board sheets 21. The sheets 21 leave the machine 1 downstream (Arrow F in Figs.). The composite 2 and each of the sheets 21 have an upper face 22 consisting of the cardboard web 3 and an under face 23 consisting of the bottom layer 6 of the single-face web 4. In most case, the upper face 22 and the under face 23 are printed, depending on the cardboard web 3 and the single-face web 4.
The laminating unit 14 is designed to position the cardboard web 3 very precisely on the single-face web 4. As shown in
A gap between the second roll 24 and the laminating roll 16 is adjusted to the thickness of the cardboard web 3. For this, the laminating unit 14 comprises advantageously means for moving away and closer the second roll 24 from the laminating roll 16. The second roll 24 is thus mounted on a lifting arm 26 acting as a lever. The lifting arm 26 pivots on a rotation axis 27 provided at a first end thereof. A jack 28 is mounted at the opposite end of the lifting arm 26 with pivot means 29. The jack 28 is attached to an eccentric 31 to smoothly adjust the gap between the laminating roll 16 and the second roll 24.
The lifting arm 26 pivots up and down (Arrow U in
To ensure a lamination with a high quality without crushing the obtained composite 2 or without delamination of the cardboard web 3 from the composite 2, the gap between the laminating roll 16 and the bottom laminating roll is controlled. The laminating roll 16 can thus be lifted and lowered (Arrow T in
For this, the laminating unit 14 comprises means for lifting and lowering the laminating roll 16. The laminating roll 16 is mounted on a structure body 32. The structure body 32 pivots on an axle 33 by being driven via a linear motorised motion system (not shown).
The laminating roll 16 of the laminating unit 14 rotates (Arrow R in
The laminating roll 16 is in the form of a hollow cylinder. The cylinder has an outer wall 37 and an internal chamber 38, which is cylindrically shaped. According to the invention, the laminating roll 16 comprises first gripping means, preferably in the form of at least one suction opening 39.
The openings 39 are drilled through the outer wall 37 for a connection of the internal chamber 38 with an external surface 41 of the laminating roll 16. The external surface 41 of the laminating roll 16 is in contact with the cardboard web 3. For instance, twelve openings 39 are evenly spaced from each other and distributed around the circumference of the laminating roll 16.
The internal chamber 38 is connected to a vacuum source via a suction duct. A first end of the cylinder and of laminating roll 16 extends with a portion of an axial rotation shaft that includes the suction duct (not shown). The internal chamber 38 and thus the suction openings 39 are in connection with the vacuum source. The cardboard web 3 is laid and maintained by suction in contact on the surface 41 of the laminating roll 16.
The laminating roll 16 comprises second gripping means, the external surface 41 being favourably coated by a layer of a high grip material, such as rubber. With the two gripping means, suction openings 39 and high grip material, the gripping of the cardboard web 3 on the laminating roll 16 is enhanced. The cardboard web 3 is thus positioned on the single-face web 4 without any slippage. The operator can decrease the quantity of glue as the cardboard web 3 and single-face web 4 move simultaneously at the convergence line 17.
The laminating roll 16 is driven into rotation on its axis 34 thanks to driving means, such as an electrical motor 42. A second end of the cylinder and of laminating roll 16 extends with a portion of an axial rotation shaft that is mechanically connected to the motor 42.
The laminating unit 14 comprises first means for detecting longitudinal positions of the cardboard web 3. The first detection means are able to detect the flow rate of modifications that have been provided previously on the surface of the cardboard web 3 and that give the modified upper face 22 of the composite 2.
The first detection means comprises advantageously a first detector 43. This first detector 43 is placed upstream the laminating roll 16 and near the second roll 24. The first detector 43 scans the surface of the cardboard web 3 as the latter runs on the second roll 24, and before being laminated on the single-face web 4. A first detection signal 44 is emitted by the first detector 43 whenever the detection is done so in accordance with detected longitudinal positions of the cardboard web 3.
The first detection means comprises advantageously a second detector 46. This second detector 46 is placed downstream the laminating roll 16. The second detector 46 scans the surface of the cardboard web 3 as the latter leaves the laminating roll 16 and after being laminated on the single-face web 4. A second detection signal 47 is emitted by the second detector 46 whenever the detection is done so in accordance with detected longitudinal positions of the cardboard web 3.
The first and second detectors 43 and 46 are preferably in the form of longitudinal optical detectors that read or detect the arrival of printings, such as printed register marks or just images, that are printed beforehand longitudinally on the surface of the cardboard web 3. Such register marks give the accurate longitudinal positions of all the printings of the cardboard web 3.
The laminating unit 14 comprises further second means for detecting longitudinal positions of the single-face web 4. The second detection means are able to detect the flow rate of modifications that have been provided previously on the surface or bottom layer 6 of the single-face web 4 and that give the modified under face 23 of the composite 2.
The second detection means comprises advantageously a third detector 48. This third detector 48 is placed upstream the laminating roll 16 and underneath the laminating unit 14 as the printed surface of the single-face web 4 is oriented downwardly. The third detector 48 scans the surface of the single-face web 4 before being laminated with the cardboard web 3. A third detection signal 49 is emitted by the third detector 48 whenever the detection is done so in accordance with detected longitudinal positions of the single-face web 4.
The second detection means comprises advantageously a fourth detector 51. This fourth detector 51 is placed downstream the laminating roll 16. The fourth detector 51 scans the surface of the single-face web 4 as the latter leaves the laminating roll 16 and after being laminated with the cardboard web 3. A fourth detection signal 52 is emitted by the fourth detector 51 whenever the detection is done so in accordance with detected longitudinal positions of the single-face web 4.
The third and fourth detectors 48 and 51 are preferably in the form of longitudinal optical detectors that read or detect the arrival of printings, such as printed register marks or just images, that are printed beforehand longitudinally on the surface of the single-face web 4. Such register marks give the accurate longitudinal positions of all the printings of the single-face web 4.
According to the invention, the laminating unit 14 is used to correct the positions of the cardboard web 3 and laminate it accurately with the laminating roll 16 on the single-face web 4. The speed of the laminating roll 16 is controlled so as to correspond to the advanced and measured position of the single-face web 4. With the invention and with the control of the laminating roll 16, the printing of the upper face 22 is exactly in register with the printing of the under face 23 for the obtained composite 2 and corrugated board sheet 21.
The laminating unit 14 comprises means 53 for controlling the motor 42 to convey and correct longitudinally the positions of the cardboard web 3. The control means 53 and the motor 42 are capable to generate all the accelerations and decelerations required for moving forth the laminating roll 16. A regulation signal 54 is emitted to the motor 42 for calculating and regulating a rotation speed of the laminating roll 16.
This regulation is a function of the signals 44, 47, 52 and/or 49 from the first and second detection means to convey, correct longitudinally positions of the cardboard web 3, and laminate the cardboard web 3 in register onto the single-face web 4. So the registering is made on the basis of the detected longitudinal positions of the printed cardboard web 3 and on the basis of the detected longitudinal positions of the printed single-face web 4 before and after laminating.
A first and coarse regulation is made by using the first signal 44 of the first detector 43 that corresponds to the longitudinal positions of the cardboard web 3 together with the third signal 49 of the third detector 48 that corresponds to the longitudinal positions of the single-face web 4 before laminating. The control means 53 receiving both first and third signals 44 and 49 generates and sends a main regulation signal 54 to the motor 42 for this first regulation. The main regulation signal 54 corresponds to an acceleration or deceleration of the motor speed so that detected register marks on cardboard web 3 have a good matching with detected register marks on the single-face web 4. This first regulation corresponds to a pre-positioning of the cardboard web 3 onto the single-face web 4.
A second and fine regulation is added by using the second signal 47 of the second detector 46 that corresponds to the longitudinal positions of the laminated cardboard web 3 together with the fourth signal 52 of the fourth detector 51 that corresponds to the longitudinal positions of the laminated single-face web 4 forming part of the composite 2. The control means 53 receiving both second and fourth signals 47 and 52 generates a secondary regulation signal to the motor 42 for this second regulation.
This secondary regulation signal is added to the main regulation signal 54. Owing to the positions of both second and fourth detectors 46 and 51 after the laminating roll 16, the second regulation maintains the synchronisation obtained with the first regulation. The other aim of the second regulation is to check the registering quality of the obtained composite 2 after the lamination. The secondary regulation signal provides a slight adjustment to the main regulation, leading to slight speed corrections and slight angular adjustments of the laminating roll 16.
The cutting device in the cutting unit 19 is also controlled by the laminating unit 14 to cut the composite 2 into sheets 21 with a high accuracy. The signals emitted by the first detection means, i.e. one or both of the first and second signals 44 and 47 emitted by only one or both of the first and second detectors 43 and 46 respectively, and/or by the second detection means, i.e. one or both of the third and fourth signals 49 and 52 emitted by only one or both of the third and fourth detectors 48 and 51 respectively are used to give the rate to the cutting unit 19. This operation is also known as being a “cut to mark”.
A laminating method for manufacturing the multi-layer composite 2 is performed by the laminating machine 1 and comprises several steps. In a first step, the cardboard web 3 is conveyed C in a longitudinal direction. In a second step, the single-face web 4 is conveyed F in the longitudinal direction.
In a third step, the longitudinal positions of the cardboard web 3 are detected. In a fourth step, the longitudinal positions of the single-face web 4 are detected. In a fifth step, the positions of the cardboard web 3 are corrected longitudinally on the basis of the detected positions during the third step and of the detected positions during the fourth step. The correction is done by calculation. In a sixth and final step, the cardboard web 3 is bonded by being glued onto the single-face web 4 in the registered position.
The third step is divided in two sub steps. In a first sub step of the third step, longitudinal positions of the first web 3 are detected before the sixth step of bonding the first web 3 onto the second web 4. In a second sub step of the third step, longitudinal positions of the first web 3 are detected after the sixth step of bonding the first web 3 onto the second web 4.
The fourth step is divided in at least one of two sub steps. In a first sub step of the fourth step, longitudinal positions of the second web 4 are detected before the sixth step of bonding the first web 3 onto the second web 4. In a second sub step of the fourth step, longitudinal positions of the second web 4 are detected after the sixth step of bonding the first web 3 onto the second web 4.
All the detection steps consist in reading one or more modifications, i.e. printings or printed marks in longitudinal direction.
The present invention is not restricted to the embodiments described and illustrated. Numerous modifications may be made without thereby departing from the context defined by the scope of the set of claims. The laminating unit 14 can make use of only one detector chosen from the third and fourth detectors 48 and 51.
| Number | Date | Country | Kind |
|---|---|---|---|
| 11007666.8 | Sep 2011 | EP | regional |
