U.S. patent application number 10/006887 was filed with the patent office on 2002-06-13 for installation for the manufacture of a multi-layermaterial and material thus obtained.
This patent application is currently assigned to Asitrade AG. Invention is credited to Gilgen, Werner.
Application Number | 20020069993 10/006887 |
Document ID | / |
Family ID | 4568957 |
Filed Date | 2002-06-13 |
United States Patent
Application |
20020069993 |
Kind Code |
A1 |
Gilgen, Werner |
June 13, 2002 |
Installation for the manufacture of a multi-layermaterial and
material thus obtained
Abstract
Installation for the manufacture of a multi-layer material,
particularly for the manufacture of a material using paper webs,
comprises a formation station (1) of a first paper web (8) issued
from a first paper feeding station, a gluing unit (9), a second
paper feeding station producing a second paper web (14) to be laid
on the first paper web (8), which have been deformed in the
formation station (1), by means of a pressing cylinder (15), a
longitudinal cutting station (17), a transverse cutter (22) and a
stacking station (29). The formation station (1) produces a
structured web (2) comprising alveolar deformations, the structure
configuration of said structured web (2), once this one is covered
by the second paper web (14), constituting an assembled unit with a
mechanical resistance identical in at least two directions.
Inventors: |
Gilgen, Werner; (Zug,
CH) |
Correspondence
Address: |
OSTROLENK FABER GERB & SOFFEN
1180 AVENUE OF THE AMERICAS
NEW YORK
NY
100368403
|
Assignee: |
Asitrade AG
|
Family ID: |
4568957 |
Appl. No.: |
10/006887 |
Filed: |
December 5, 2001 |
Current U.S.
Class: |
162/298 ;
162/358.3 |
Current CPC
Class: |
B31F 2201/0784 20130101;
B31F 2201/0787 20130101; B31F 5/04 20130101; B31F 1/07 20130101;
B31F 2201/0743 20130101; B31F 2201/0723 20130101; B31F 2201/0733
20130101; B31F 2201/0761 20130101 |
Class at
Publication: |
162/298 ;
162/358.3 |
International
Class: |
D21F 011/04; D21F
003/08 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 7, 2000 |
CH |
2000 2389/00 |
Claims
1. Installation for the manufacture of a multi-layer material,
particularly for the manufacture of a material using paper webs,
comprising a formation station (1) of a first paper web (8) issued
from a first paper feeding station, a gluing unit (9), a second
paper feeding station producing a second paper web (14) to be laid
on the first paper web (8), which has been deformed in the
formation station (1), by means of a pressing cylinder (15), a
longitudinal cutting station (17), a transverse cutter (22) and a
stacking station (29), characterized by the fact that the formation
station (1) produces a structured web (2, 34), by the fact that the
structured web (2, 34) comprises alveolar deformations and by the
fact that the structure configuration of said structured web (2,
34), once it is covered by the second paper web (14), constitutes
an assembled unit with a mechanical resistance identical in at
least two directions.
2. Installation according to claim 1, characterized by the fact
that the aforementioned structured web (2) is alveolarily deformed
on one side (48).
3. Installation according to claim 1, characterized by the fact
that the aforementioned structured web (34) is alveolarily deformed
on both sides (48, 49).
4. Installation according to claim 3, characterized by the fact
that the aforementioned structured web (34) alveolarily deformed on
both sides (48, 49) is covered on one side (48) by said second
paper web (14) and on its other side (49) by a third paper web (33)
issued from a third paper feeding station.
5. Installation according to claim 1, characterized by the fact
that the alveolar deformations are slightly spherically shaped and
that they are laid out in a staggered arrangement.
6. Multi-layer material obtained through an installation according
to one of the preceding claims, characterized by the fact that it
comprises a structured web (2) alveolarily deformed on one side
(48), said structured web (2) being covered on said side (48) by a
paper web (14).
7. Multi-layer material obtained through an installation according
to one of claims 1 to 5, characterized by the fact that it
comprises a structured web (34) alveolarily deformed on both sides
(48, 49), said structured web (34) being covered by a paper web
(14) on one side (48) and by another paper web (33) on its other
side (49).
8. Multi-layer material according to claim 7, characterized by the
fact that the structured web (34), alveolarily deformed on both
sides (48, 49), shows a decorative pattern.
Description
[0001] The present invention refers to an installation for the
manufacture of a multi-layer material and to the material thus
obtained.
[0002] The multi-layer materials are present in many different
fields and particularly in the packaging industry. One material
usually used is the corrugated cardboard. For report, the
corrugated cardboard is produced by covering a sheet, which is
beforehand corrugated by travelling through two fluted cylinders,
with two cover sheets which are stuck on the top of the central
sheet corrugations.
[0003] In the packaging industry, the corrugated cardboard finds
its main use as particularly resisting protective packaging, while
being associated to an environmental respect related to its
relative easy recycling.
[0004] Another use of a relatively thin corrugated cardboard finds
its way in more attractive-looking packaging needed for a special
range of products. It is necessary, in this case, to print this
corrugated cardboard. This printing process is possible thanks to
the progress reached with flexographic printing techniques which
allow to reach high quality printings in several colors.
[0005] However, the printing of a corrugated cardboard should be
inconvenient, that means that this printing will show lines related
to each corrugations top since, at the time of the printing
process, the corrugated cardboard will be slightly crushed. The
different resistance between the top of the corrugations and the
segment between two consecutive tops is the main reason for these
lines to appear at the time of the printing process.
[0006] The manufacture of a corrugated cardboard is carried out by
means of a complex machine such as a corrugating device which
includes a paper feeding station, made of reels, for a corrugating
station, a paper feeding station, made of reels, for a first cover
sheet, a paper feeding station, made of reels, for a possible
second cover sheet, a gluing device for the glue deposit on the top
of the corrugations, a pressing station for the gluing of the
second cover sheet on the tops of the corrugated sheet, devices for
longitudinal and transverse cutting of the corrugated sheet and a
delivery station for cardboard sheets cut at the requested format.
Generally, all the operations carried out on the various sheets
comprised in the corrugated cardboard are carried out at high
temperature, up to around three hundred degrees, and often in a wet
ambient.
[0007] More than its bad printability, the corrugated cardboard
shows a bad mechanical resistance into a parallel direction related
to the corrugations and it is very often "warped "; that means that
it is curved and effectively not easy to handle with either within
the printing or the die-cutting machines. The corrugations require
a significant quantity of paper and the gluing of cover sheets on
the top of the corrugations requires also a significant supply of
glue.
[0008] The processes currently used to manufacture a multi-layer
material show all the above mentioned disadvantages, essentially
related to the configuration of the reference materials.
[0009] The aim of this invention is to overcome, at least partly,
the disadvantages shown by a multi-layer material of a kind such as
said one.
[0010] To this end, the invention relates to an installation for
the manufacture of a multi-layer material as defined by claim 1 and
to the material thus obtained as defined by claims 6 to 8.
[0011] However, thanks to its layout, the installation effectively
allows a wide using flexibility and adaptability to the manufacture
of a multi-layer material which allows the lowering of its unit
weight when ensuring a rigidity into at least two directions as
well as an excellent printability.
[0012] Several other characteristics and significant advantages of
this installation as well as of the material thus obtained will be
shown with the following description and also with the enclosed
drawings which illustrate, schematically and as an example, an
embodiment of the installation and of said material.
[0013] FIG. 1 is a schematic view of an installation for the
manufacture of a first multi-layer material,
[0014] FIG. 2 is a schematic view of an installation for the
manufacture of a second multi-layer material,
[0015] FIG. 3 is a perspective view of a material structured on
only one side,
[0016] FIG. 4 is a perspective view of a material structured on
both sides,
[0017] FIG. 5 is an increased sectional view of the material of
FIG. 3 structured on only one side,
[0018] FIG. 6 is an increased sectional view of FIG. 4 structured
on both sides,
[0019] FIGS. 7a to 7c relate the different structures of the
materials,
[0020] FIG. 8 is a view representing a box manufactured by the
multi-layer material issued from the installation of FIG. 1,
[0021] FIG. 9 is a sectional view of a tool used to perform a
material structured on one side and,
[0022] FIG. 10 is a sectional view of a tool used to perform a
material structured on both sides.
[0023] FIG. 1 is a schematic view of an installation for the
manufacture of a first multi-layer material 13. On this fig., one
missed to show, in order to simplify the drawing, the paper feeding
stations, which are well-known from the machines manufacturers.
These paper feeding stations usually comprise a reel stand equipped
with a reels driving and braking device related to a device used to
connect a new reel to the last part of a reel at the end of its
unfolding to ensure the paper feeding continuity for the next
installation bodies.
[0024] The installation of FIG. 1 comprises a formation station 1
of a structured web 2. This formation station 1 includes a cassette
3 comprising two side frames 4, 5 between which two cylindrical
tools upper 6 and lower 7 are settled and intended to deform,
primarily on one side, a paper web 8 issued from a first paper
feeding station (not represented). The lower cylindrical tool 7 is
preferably connected to a vacuum source so that the structured web
2, deformed on one side at the engaging point between the upper
cylindrical tool 6 and the lower cylindrical tool 7, is maintained,
by sucking, against part of the circumference of the latter. An
example of a tool allowing the deformation of the structured web on
one side will be described related to FIG. 9. The asperities of the
structured web 2 which are in the sucking area of the cylindrical
tool 7 are glued by means of a gluing unit 9 comprising a gluing
roller 10 dipping into a glue tank 11. The glue quantity laid onto
the asperities of the structured web 2 is controlled by a drying
roller 12. For obtaining a first multi-layer material 13, a second
paper web 14 issued from a second paper feeding station (not
represented), similar to the said first feeding station, is laid
onto the tops of the glued asperities of the structured web 2 by
means of a pressing cylinder 15. The first multi-layer material web
13 travels then around an idling cylinder 16 before it comes into a
longitudinal cutting station 17. This well-known longitudinal
cutting station 17 comprises two side frames 18 and 19 between
which circular cutting tools 20 and 21 are arranged. The also
well-known circular cutting tools 20 are made of circular blades
adjustably secured, into the width of the longitudinal cutting
station 17, in order to obtain first multi-layer material webs 13
of different widths. The side cut of the first multi-layer material
web 13 is also completed in this station. The circular cutting tool
21 generally comprises an anvil tool with adjustable sleeves, into
the width of the longitudinal cutting station 17, said sleeves
showing circular grooves, which can be located at the opposite side
of the circular blades of the circular cutting tools 20. One
noticed that in a special kind of longitudinal cutting machines,
the circular cutting tool 21 can be shaped like an anvil cylinder
covered, for example, with a material such as polyurethane. The
first multi-layer material web 13 is then introduced into a
transverse cutting machine 22 comprising two side frames 23 and 24.
This transverse cutting machine 22 is also well-known from machines
manufacturers. It comprises, first of all, an upper rotary tool 25
provided with a knife, generally helocoidally shaped and a lower
anvil cylinder 26 which can either be out of steel or covered with
polyurethane. Knowingly, the higher rotary cutting tool is actuated
in order to carry out cuttings of different lengths of the first
multi-layer web 13, in accordance to the various required formats.
At the output of the longitudinal cutting station 22, sheets 27 of
the first multi-layer material 13 are conveyed on a belt conveyor
28 to a stacking station 29, schematically represented here by a
device comprising a piling member 30 able to form a pile 31.
[0025] FIG. 2 is a schematic view of an installation for the
manufacture of a second multi-layer material 40. The installation
of this fig. is different from the one represented on FIG. 1 only
due to the addition of an insertion station 32 of a cover web 33 on
the multi-layer material 35 to carry out the second multi-layer
material 40. Consequently, the common bodies to both achievements
will have the same references.
[0026] On this FIG., one missed, in order to simplify the drawing,
to show the paper feeding stations which are well-known from
machines manufacturers. Knowingly, one recalls that these paper
feeding stations generally comprise a reel stand equipped with a
paper reels driving and braking device related to a device for
connecting a new reel to the last part of a reel at the end of its
unfolding, so that the paper supply continuity is ensured for the
next bodies of the installation.
[0027] The installation of FIG. 2 also comprises a formation
station 1 of a web structured on both sides 34. This formation
station 1 includes a cassette 3 with two side frames 4, 5 between
which two cylindrical upper 6 and lower 7 tools are arranged and
intended to deform, on both sides, a paper web 8 issued from a
first paper feeding station (not represented). The lower
cylindrical tool 7 is preferably connected to a vacuum source so
that the structured web 34 deformed at the engaging point between
the upper cylindrical tool 6 and the lower cylindrical tool 7 is
maintained, by sucking, against part of the circumference of the
latter. An example of a tool allowing the deformation of the
structured web on both sides will be described related to FIG. 10.
The asperities of one side of the structured web 34 located in the
sucking circumference area of the cylindrical tool 7 are glued by
means of a gluing station 9 including a gluing roller 10 dipping in
a tank 11. The glue quantity laid onto the asperities of one side
of the structured web 34 is controlled by means of a drying roller
12. This gluing unit 9 can either use a starch-based glue or a
vinyl glue. For obtaining a multi-layer material 35, a second paper
web 14 issued from a second paper feeding station (not
represented), identical to said first feeding station, is laid onto
the tops of the glued asperities of one side of the structured web
34 by means of a pressing cylinder 15. The multi-layer material web
35 travels then around an idling cylinder 16 before being conveyed
into an insertion station 32 of a cover web 33 issued from a third
paper feeding station (not represented), identical to said first
and second feeding stations. The asperities of the other side of
the structured web 34 are glued by means of a gluing unit 36
identically arranged as the gluing unit 9 related to FIG. 1. This
gluing unit also can either use a starch-based glue or a vinyl
glue. The gluing roller 38 of this gluing unit 36 deposits glue on
the asperities of the other side of the structured web 34 owing to
the idling cylinder 16. The glued asperities of the other side of
the multi-layer web 35 are thus overlapped by the cover web 33 by
means of the pasting down cylinder 39 for obtaining the second
multi-layer material 40. This multi-layer material 40 is then
conveyed onto a pressing device 41 including a table 42 and a
pressing device equipped with a range of rollers 43. It is obvious
that several of these pressing devices 41 may comprise a belt
conveyor instead of a feed table 42.
[0028] The web of the second multi-layer material 40 is then
conveyed into a longitudinal cutting station 17 identical to said
one related to FIG. 1. Knowingly, this well-known longitudinal
cutting station 17 comprises two side frames 18 and 19 between
which circular cutting tools 20 and 21 are settled. The also
well-known circular cutting tools 20 are made of circular blades
adjustably secured in the width of the longitudinal cutting station
17, for obtaining first multi-layer material webs 13 with different
widths. The side cutting of the second multi-layer material web 40
is also achieved in this station. The circular cutting tool 21
generally comprises an opposite tool equipped with adjustable
sleeves, arranged in the width of the longitudinal cutting station
17, said sleeves showing circular grooves which can be located
opposite to the circular blades of the circular cutting tools 20.
One notices that for some longitudinal cutters, the circular
cutting tool 21 can be shaped like an anvil cylinder (?) covered,
for example, with a material such as polyurethane. The web of the
second multi-layer material 40 is then introduced into a transverse
cutter 22 which comprises two side frames 23 and 24. This
transverse cutter 22 is also well-known from the machines
manufacturers. It comprises first of all an upper rotary tool 25
equipped with a blade, usually helicoidally shaped, and a lower
anvil cylinder 26 which is either of steel or covered with
polyurethane. Knowingly, the rotary upper cutting tool is driven
for ensuring cuttings of the second multi-layer material web 40 of
different lengths, according to different required formats. At the
output of the transverse cutting station 22, sheets 44 of the
second multi-layer material 40 are conveyed on a belt conveyor 28
up to a stacking station 29, schematically represented here by a
device comprising a piling member 30 intended to form a pile 31.
The stacking stations are also well-known from the machines
manufacturers and will thus not be described in details. More
likely, the paper web 8 having to be deformed will be accordingly
humidified in the same way as it is the case for corrugated
cardboard production machines.
[0029] FIG. 3 is perspective view of a material 2 structured on one
side. Said structure is made of cells 45, issued for example from
the tool which will be described further related to FIG. 9.
[0030] FIG. 4 is a perspective view of a material 34 structured on
both sides. The structure represented here is made of cells 46 and
47, issued for example from the tool which will be further
described related to FIG. 10.
[0031] FIG. 5 is an increased sectional view of material 2 of FIG.
3 only structured on its side 48.
[0032] FIG. 6 is an increased sectional view of material 34 of FIG.
4 structured on both sides 48 and 49.
[0033] FIGS. 7a to 7c show the structure of materials 2 and 34.
[0034] FIG. 8 is a view representing a box 50 manufactured by the
multi-layer material 13 issued from the installation of FIG. 1.
This box 50 is obviously the use example of a multi-layer material
13 with an aesthetic looking related to the promotion of a product.
A possible use for advertising material is also intended.
Obviously, such results cannot be reached by using a multi-layer
material like corrugated cardboard.
[0035] FIG. 9 is a partial sectional view of a tool 51 used to
perform a material 2 structured on its side 48. This tool 51
comprises an upper cellar cylinder 52 and a lower cellar cylinder
53. The two cylinders cells interpenetrate and deform the paper web
8 and thus obtain a web material 2 only structured on its side 48.
The lower cellar cylinder 53 is arranged to ensure the maintenance
of the textured web material 2 at the bottom of the cells of part
of its circumference, by means of channels 54 connecting each cell
to the empty central part of cylinder 53 connected itself to a
vacuum source (not represented). For obtaining a structured web
material 2 with a structure of low thickness, it is not necessary
for the tool 51 to reach a high temperature. In case of structures
with more significant thickness, it will be necessary to heat the
tool 51 up to a temperature of about 300.degree. centigrades. For
structures with very low thickness, of about 0.2 to 0.6 millimeter,
one can carry out a more simple tool 51 using only one lower cellar
cylinder 53 connected to a powerful vacuum source so that the
vacuum action on the paper web 8 at the bottom of the cells
produces the required deformation for obtaining the structured
material web 2. The achievement of the upper and lower cellar
cylinders can be easily carried out for example by an
electro-erosion process.
[0036] FIG. 10 is a sectional view of a tool 55 used to perform a
structured material 34 on both sides 48 and 49. This tool 55
comprises an upper cellar cylinder 56 and a lower cellar cylinder
57. The two cylinders cells interpenetrate and deform the paper web
8 for obtaining a structured web material 34 on both sides 48 and
49. The lower cellar cylinder is arranged for maintaining the
textured material web 34 at the bottom of the cells of part of its
circumference, and thus by means of channels 58 connecting each
cell to the grooved section in the middle of the cylinder 57
connected itself to a vacuum source (not represented). For
obtaining a structured material web 34 with a low-sized thickness
structure, it is not necessary for the tool 55 to reach a high
temperature. In case of more important thickness structures, it
will be necessary to deal with the heating of the tool 55 up to a
temperature of 300.degree. centigrades. For very slight thickness
structures, of about 0.2 to 0.6 millimeters, one can deal with a
more simple tool 55, as for the tool 51 of FIG. 9, using only one
lower cellar cylinder 57 connected to a powerful vacuum source so
as the vacuum action on the paper web 8 at the bottom of the cells
causes the required deformation for obtaining the structured web
material 34. The achievement of the upper and lower cellar
cylinders can advantageously be carried out for example by an
electro-erosion process.
[0037] The above mentioned installation for the manufacture of a
multi-layer material allows, among others, obtaining, if one uses a
web structured on both sides with a special decorative printing, as
the ones shown for example on FIGS. 7a to 7c, an embossing
multi-layer material, which offers a wide range of use of this
material either for an ornamental supply or another one.
* * * * *