U.S. patent number 3,775,211 [Application Number 05/202,190] was granted by the patent office on 1973-11-27 for method for facing a single-faced corrugated web.
This patent grant is currently assigned to David C. Dowd. Invention is credited to Frank A. Gill.
United States Patent |
3,775,211 |
Gill |
November 27, 1973 |
METHOD FOR FACING A SINGLE-FACED CORRUGATED WEB
Abstract
Methods and apparatus are provided for adhering a plurality of
discrete sheets sequentially to the open side of a single-faced
corrugated web to produce a plurality of double-faced corrugated
pieces of varying size, as desired, for the subsequent formation
thereof into cartons or containers. Included herewith are means for
separating the leading portion of the single-faced web after the
initial adherence of the leading edge thereof with one of said
discrete sheets for producing separate double-faced corrugated
pieces with a single-faced overhang at each end thereof upon exit
from the apparatus, and means causing the leading edge of the
single-faced web to pick up and combine with the leading edge of
one of said discrete sheets upon movement of the leading edge of
said web through the nip of the combining rolls. Also included are
means for momentary movement of a subsequently cut leading edge of
the single-faced web away from the cutting station at the moment of
severance of the foremost separated portion of said moving
single-faced web to prevent jamming of the cut leading edge against
the knives at the cutting station.
Inventors: |
Gill; Frank A. (Stoughton,
MA) |
Assignee: |
Dowd; David C. (Westboro,
MA)
|
Family
ID: |
22748843 |
Appl.
No.: |
05/202,190 |
Filed: |
November 26, 1971 |
Current U.S.
Class: |
156/205; 156/250;
156/281; 156/207; 156/256 |
Current CPC
Class: |
B31F
1/289 (20130101); Y10T 156/1016 (20150115); Y10T
156/102 (20150115); Y10T 156/1062 (20150115); Y10T
156/1052 (20150115) |
Current International
Class: |
B31F
1/28 (20060101); B31F 1/20 (20060101); B31f
001/28 () |
Field of
Search: |
;156/205,250,210,207,263,256,264,281,519,520 ;271/50,53,60
;83/250,251 ;226/176,177 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Leavitt; Alfred L.
Assistant Examiner: Frisenda, Jr.; Frank
Claims
What is claimed is:
1. In a method for adhesively combining sequentially a plurality of
discrete sheets along one surface of a continuously moving web, in
a combining nip with a source of continuously moving web for
feeding to said nip, and a source of overlapped discrete sheets
sequentially fed to said nip; the steps which comprise moving said
sheets sequentially into said nip and against a rigid stop disposed
therein; adjusting the said nip from a first position in which said
nip is wider than the thickness of the combined sheets and web to a
second position in which said nip is adjustably spaced for
combining said sheets and said web together, said adjusting step
moving the leading edge of the foremost of said discrete sheets
below the bottom surface of said rigid stop; engaging the bottom
surface of the said leading edge of said discrete sheet below said
stop with the leading edge of said discrete web; combining at least
a portion of said discrete sheet with a portion of said
continuously moving web; readjusting the width of said nip from
said second position back to said first position while said
combining step is continuously being carried out; severing a
portion of said continuously moving web at a point prior to said
nip, said severed portion of said web being of desired length to
combine with said discrete sheet, said combining step continuing to
be carried out during said severing step, removing the combined
severed product from said nip; and repeating said sequence of steps
continuously for forming a plurality of combined severed
products.
2. A method as described in claim 1, in which said second position
of said nip is adjusted to provide for engagement by the leading
edge of said continuously moving web with the bottom surface of
said leading discrete sheet at a point spaced from the leading edge
thereof.
3. A method as described in claim 1, which includes the step of
applying adhesive to the combining surface of said web prior to the
entry thereof into said nip.
4. A method as described in claim 1, which includes the additional
step of moving at least a portion of the severed leading edge of
said web away from the point of severance momentarily, in a
direction opposite its direction of travel during said severing
step.
5. A method as recited in claim 1, in which said continuously
moving web is a single-faced corrugated web; said discrete sheets
have printed lithographs disposed on one side thereof; and said
combining step is carried out by applying the non-printed side of
said sheets to the open faced side of said single-faced web.
Description
Generally speaking, this invention relates to methods and apparatus
for facing the open-faced surface of a single-faced corrugated web.
More particularly, this invention relates to methods and apparatus
for applying sequentially a plurality of discrete sheets to the
open-faced surface of a single-faced corrugated web, to produce
upon exit from the apparatus a plurality of double-faced corrugated
pieces of a desired size, having an overlapping of the applied
single-facing on each end thereof without the need for any cutting
or separation subsequently. Even more particularly, this invention
relates to the production of a plurality of double-faced corrugated
pieces for subsequent formation thereof into so-called cardboard
boxes, with one surface of the double-faced pieces having disposed
thereon, a preprinted lithograph of desired identifying printing,
pictures and other indicia, as desired.
As is well known, it has become increasingly important in recent
years to produce corrugated cartons or containers of all sizes and
shapes for the distribution of a variety of goods for sale, with
the outer surfaces of those cartons having appropriate fine
printing, pictures, etc. in the form of advertising slogans, in
order to identify the contents of the carton. However, in order to
produce such cartons in the past, the size of the cartons or
containers was limited with respect to the extent of the printing
on one surface thereof, to the dimensions (that is the
circumference) of the printing press rolls if a continuous web of a
printed facing sheet was to be combined with a single-faced
corrugated web in a continuous manner. This was required because
the printed material was printed continuously and sequentially
along one face of the facing sheet for the single-faced corrugated
web.
In order to overcome this problem, a variety of methods and
apparatus have been developed for producing discrete printed sheets
individually of the desired size, which are subsequently applied in
a sequential manner to the open-face of a single-faced corrugated
web. One of these methods includes first adjoining the discrete
printed sheets after the printing thereof into an elongated series
of sheets, which are subsequently formed into a roll and then
applied to the open-faced web. Whereas, such methods and apparatus
proved appropriate for overcoming the size and/or dimension
problems previously encountered, and as noted above, such joining
procedures involve a substantial amount of time and labor, thus
making the final product too expensive except for specialized
applications.
Further developments along this line have included the application
sequentially of a plurality of printed sheets by adhering the
sheets individually in a sequential manner along the open face of a
single-faced corrugated web, with subsequent severance after
lamination into a plurality of desired double-faced corrugated
pieces, having one surface thereof printed with the desired
identifying material.
Whereas, these developments have proved generally appropriate for
combining the printed facing sheets to the single-faced web and
producing the desired results at a cost making the product more
desirable on a mass production basis, certain difficulties have
arisen in the coordination between the registration of the printed
sheets in combination with the single-faced web and the subsequent
sequential cutting operations, so as not to cut the formed
double-faced web in the middle of the printed design thereon. In
addition, certain other difficulties have arisen with the feeding
apparatus for feeding the individual discrete printed sheets into
the nip of the combining rolls for combining of these sheets onto
the open-faced surface of the single-faced web, in that the feeding
apparatus will sometimes fail to feed sheets in the appropriate
desired sequence and therefore cause the subsequent cutting
apparatus to cut into the center of the printed design.
Some of these difficulties noted above have been overcome by the
development of a variety of positive feed type arrangements and
complicated sequential control apparatus, so that the discrete
printed sheets are fed by the utilization of a positive drive into
the nip of the combining rolls, to be combined with the
single-faced corrugated web. These developments include the
utilization of photocell arrangements for sequentially activating a
positive feed, which in turn utilizes a complicated drive with a
clutch and brake. Usually, with this form, the photocell "reads"
preprinted marks on the discrete printed sheets.
Although these control arrangements have proved appropriate for
producing the desired results, the cost of the complicated
apparatus involved and the maintenance of such apparatus is such
that the cost of the final product is affected to the point of
making the product less than appropriate for certain mass
production operations.
Thus, the problem arises that in order to produce the desired size
double-faced corrugated pieces, having the appropriate fine
printing or other indicia on one surface thereof, one must choose
between methods and apparatus which produce such a product in a
manner whereby there may be substantial wastage because of
misalignment between the discrete printed sheets and the subsequent
cutting apparatus, or selecting more expensive and complicated
apparatus, which is expensive to maintain, for producing a more
accurate product with little or no waste. With both choices,
because of the problems noted, there is substantial increase in the
cost of the final product.
This invention, by contrast, provides methods and apparatus for
applying sequentially a plurality of discrete printed sheets to the
open faced side of a single-faced corrugated web, in a manner so
that there is always appropriate alignment of the discrete sheets
in the appropriate sequential manner along the longitudinal extent
of the single-faced web, and with the combined laminate exiting
from the combining rolls being in the form of individual pieces of
the double-faced carton material having disposed on one surface
thereof, the desired printed formation.
The above is achieved by the utilization of a controlled nip
arrangement for the combining rolls, with a non-moveable gate or
stop disposed in the nip thereof for engaging sequentially the
leading edge of the foremost discrete printed sheets. Thereafter,
upon approach of the leading edge of the single-faced web, one of
the combining rolls moves in a manner whereby the leading edge of
the foremost sheet moves into position for engagement of the bottom
surface thereof with the leading edge of the single-faced web. This
movement of one of the combining rolls also serves to change the
size of the nip, so as to cause a gripping action between the
printed sheet and the leading edge of the web moving through that
nip.
A simple control for the movement of the combining roll adjusts the
nip for different widths of corrugation for the single-faced
corrugated web, and also provides for a slight adjustment so that
the leading edge of the single-faced web does not engage the
adjacent surface of the printed sheet until a point spaced from the
leading edge thereof. This arrangement provides a final product in
which the printed sheets are overlapping tne single-faced web on
each end of the finally combined plurality of double-faced pieces.
It should be understood that prior to this combining of the
discrete single sheets with the single-faced web, that an adhesive
is applied to the points of the corrugation of the single-faced
web, so that after the initial combining in the combining rolls,
the two joined parts are drawn together through the combining
rolls.
Subsequent to this initial combining of the two pieces being
joined, the following edge of the single-faced web which is to form
a single, individual final piece, is cut from the rest of the
moving single-faced web. This cutting or severing action takes
place prior to the combining of the entire length of the
single-faced web with the printed facing sheet, so that upon
exiting of the combined pieces from the combining rolls, the
desired individual double-faced pieces are already formed.
Also provided, in accordance herewith, are means for moving the
newly formed leading edge of the continuously fed web away from the
cutting station momentarily, so that the newly formed leading edge
is not jammed against the cutting knives as they move across the
axis of movement of the single-faced moving web. All of the above
sequence of operations is controlled by a simple, adjustable cam
arrangement for accommodating different lengths of printed sheets
to be combined with the single-faced web, in order to produce
finally different sizes of double-faced pieces, as desired, and
depending upon the size and configuration of the printing on the
individual discrete sheets to be applied to the single-faced
web.
Accordingly, it is one object of this invention to provide methods
and apparatus for applying a facing to the open faced side of a
single-faced corrugated web. It is another object of this invention
to provide methods and apparatus for applying discrete facing
sheets sequentially along the open faced surface of a single-faced
corrugated web in a manner whereby the sheets are always in proper
register with the corrugated web portion of the final product.
It is a further object of this invention to provide a double-faced
final product which is severed from the single-faced corrugated web
when it exits from the compression rolls; and it is an additional
object of this invention that no positive feed mechanism is
required for feeding the discrete facing sheets to the compression
rolls, and therefore, no synchronization is required between such
feeding apparatus and the combining rolls or the web feeding
speed.
With the foregoing and additional objects in view, this invention
will now be described in more detail, and other objects and
advantages thereof will be apparent from the following description,
the accompanying drawings, and the appended claims.
Before describing this invention in more detail, it may be well to
note that this invention has been found appropriate for use of a
variety of different kinds and configurations of corrugations for
the single-faced web, including E, B, C or A flute. This
accommodation of a variety of corrugations, as well as sizes of
printed facing sheets, is particularly appropriate for the
arrangements in accordance herewith, because of the infinite
variety of adjustments which can be made in the adjustable nip of
the combining rolls, and because this simple, single adjustment not
only accommodates different thicknesses of corrugated single-faced
web, but also accommodates different lengths of overhang of the
printed facing sheets in conjunction with the extent of length of
the combined piece of single-faced web adhered to a particular
printed facing sheet.
In the drawings:
FIG. 1 is a side elevational view of apparatus embodying and for
practicing this invention;
FIG. 2 is a sectional side elevational view of FIG. 1, having
certain parts removed for clarity, and showing parts in different
positions of movement;
FIG. 3 is an additional sectional side elevational view of FIG. 1,
with certain parts removed for clarity, and showing parts in an
additional point of movement in the sequence of operations of
apparatus embodying this invention;
FIG. 4 is a sectional view along lines 4--4 of FIG. 2; and,
FIG. 5 is a longitudinal sectional view of a double-faced
corrugated piece of material produced, in accordance herewith.
Referring to the drawings in which like reference characters refer
to like parts throughout several views thereof, FIG. 1 shows a
combiner or laminator generally designated as 10, having an upright
supporting structure 12, supported on a base 14. It is to be
understood that this is a side elevational view and a like side
will be disposed on the opposite side of the apparatus in mirror
image fashion.
Journaled for rotation in the upright supporting structure 12 is a
drive shaft 100, having a drive roll 18 disposed thereon. Drive
shaft 100 is driven by main drive motor 16, through a chain drive
connection, all in well known manner, and not shown because it does
not form any part of this invention. Shown in the lower left-hand
corner of FIG. 1 is an entering, continuously moving supply of
single-faced corrugated web 20, moving in the direction of arrow
11.
The supply of single-faced web may be from any well-known source,
such as a plurality of supply rolls of such single-faced web, or a
separate single-faced web producing station, including a supply of
the single-facing and a supply of the material to be corrugated,
together with a corrugating station and an adhesive station for
joining the single-face to the corrugated portion of the
single-faced web, all in well known manner.
Web 20 proceeds around guide rolls 22 and 24, and thereafter
upwardly and around pressure roll 26, which in connection with
drive roll 18, serves to draw the web 20 through the apparatus. As
can be seen in FIG. 1, shaft 25 of pressure roll 26 is journaled
for rotation at one end of lever 28, which is pivoted at 30 to a
supporting bracket 32. The opposite end of lever 28 is pivotly
connected at 34 to piston rod 36 of a reversible fluid operated
cylinder 38. In the position shown in FIG. 1, the piston rod of
cylinder 38 is in its extended position to force pressure roll 26
into an engaging position with drive roll 18, in order to draw the
single-faced web 20 through the nip formed therebetween.
If for some reason it becomes necessary to release the drive of the
web 20 through the apparatus, the operator can move the valve, not
shown, controlling cylinder 38 for changing the direction of
compressed air feed against the faces of the piston in cylinder 38
for moving piston rod 36 to the left, and moving pressure roll 26
away from pressure engagement with the surface of drive roll 18.
With such a movement, the driving of the single-faced web 20
through the apparatus ceases.
Disposed midway in the apparatus are cooperating shearing blades 40
and 42, for shearing web 20, in an appropriate sequence of
operations which will be described below. Shearing blade 40 is
stationary but can be adjusted from right to left, as shown in FIG.
1, for accommodating different widths of web 20. Blade 42, on the
other hand, is slideable into shearing action with blade 40. This
is accomplished by the action of arm 46, pivoted at one end at 48,
and slidingly pivoted at the other end at 44, connecting to the
sliding blade 42. Disposed in the middle of arm 46 is cam follower
43, which engages the surface of cam 50, journaled on shaft 57.
Disposed in the left-hand side of FIG. 1 is blade drive motor 52,
having drive shaft 53, with drive pulley 54 disposed thereon.
Pulley 54, is in turn drivingly connected to pulley 58, journaled
on shaft 60, by drive belt 56. Also journaled on shaft 60 is gear
51 in driving engagement with gear 53, journaled on shaft 57. Also
journaled on shaft 60 is blade drive clutch 62, having an abutment
which engages a clutch-engaging bar 70, pivoted at 72, for movement
in and out of engagement with clutch 62 under the action of shaft
66 of solenoid 64. Disposed between bar 70 and shaft 66 is a spring
68 for resiliently holding bar 70 into engagement with clutch 62.
The action of solenoid 64 is controlled by switch 126, the movement
of which will be described below.
Slidingly disposed on upright supporting structure 12 is an
adhesive unit, designated generally at 74. Adhesive unit 74 is
moveable from the right to the left, in relationship to supporting
structure 12, under the control of an adjusting wheel 82, which
controls the pressure of applicator roll 98 against web 20, and the
width of nip 99 between applicator roll 98 and vacuum roll 110.
Rigidly connected to the upright supporting structure 76 of
adhesive unit 74 is a bracket 80, which is in turn rigidly
connected to a pressure cylinder 78. By controlling the direction
of fluid to either end of the piston in cylinder 78, glue unit 74
can be released from contact with web 20 at any time by the
operator, so as to eliminate application of an adhesive material to
web 20 if the entire unit should fail in operating for some
reason.
Supported in adhesive unit 74, is an adhesive tray 77, containing
adhesive 79 for application to web 20. Journaled for rotation in
supporting structure 88 is shaft 86, having a metering roll 84
disposed thereon. Metering roll 84 rotates in adhesive 79 for
picking up and applying adhesive to applicator roll 98 in a metered
amount, all in well known fashion. Connected to metering roll 84 is
variable speed drive motor 94 for driving the metering roll
together with applicator roll 98, at a variety of speeds, as
desired, and all in well known fashion.
Rigidly connected to supporting bracket 88 for metering roll 84 is
an adjusting shaft 92, having screw adjustment 90 connected
thereto, for adjusting the depth of metering roll 84 in adhesive
79, for adjusting the amount of adhesive picked up from tray 77 by
metering roll 84. Also connected to bracket 88 is reversible
pressure cylinder 96, the control of which will cause withdrawal of
metering roll 84 from contact with adhesive 79, contained in
adhesive tray 78. As can be seen in FIG. 1, upwardly moving web 20
is engaged in nip 99 between applicator roll 98 and vacuum roll 110
for application of adhesive to the points of the corrugations of
web 20, immediately prior to web 20 being carried around vacuum
roll 110.
Journaled on drive shaft 100 is pulley 102, which drives a pulley
106, journaled on shaft 108 of vacuum roll 110, through the action
of drive belt 104. Gear 112 is, in turn, journaled on shaft 108,
which gear 112 is in engagement with a gear 114, journaled on shaft
111. Also journaled on shaft 111 are a plurality of change gears
115, for engagement with a gear 116, journaled on shaft 118. The
change gears 115 can be adjusted for different speed engagement in
differing ratios with gear 116, for driving shaft 118 at different
speeds. Also journaled on shaft 118 are cams 120 and 124, for
operating switches 122 and 126, the operation of which will be
described below. Non-moveable combining roll 128 is shown in FIG.
1, which combining roll 128 is driven through a pulley arrangement
with a pulley disposed on shaft 108 of vacuum roll 110, with this
pulley arrangement not being shown, for clarity, because it does
not form any part of the invention herein.
Disposed immediately above non-moveable combining roll 128 is a
plurality of moveable rolls 130, which are disposed transversely
across the extent and above non-moveable roll 128, as shown in FIG.
4. A feed table 142 is shown, arranged for feeding individual
facing sheets, which are fed to nip 152 (FIG. 2) between combining
rolls 128 and 130.
Also shown in FIG. 1 is a non-moveable stop 136, for engaging the
leading edges of sheets momentarily fed to and into nip 152. As can
be seen in FIG. 1, the sheets are fed in overlapping fashion, with
sheet 138 already partially joined to web 20 and moving under the
bottom surface 185 of rigid stop 136, whereas the next succeeding
sheet 140 has been moved against the non-moveable stop 136 for
subsequent joining with web 20 in the sequence, in accordance
herewith, and as described below. Moveable combining rolls 130 are
journaled on shafts 133, which in turn are journaled on moveable
arms 132 (FIG. 4), which is pivoted at the opposite end thereof on
supporting rod 137. Arms 132 are pivoted on shaft 137 by the action
of reversible fluid pressure cylinder 134, the control of which
will be described below. The piston rod for cylinder 134 engages a
cross brace, not shown, interconnecting arms 132.
As can best be seen in FIG. 2, an upwardly extending arm 145 is
rigidly connected at substantially right angles to at least one
moveable pivot arm 132, with arm 145 having contact pressure
adjusting screw 146 disposed thereon. Screw 146 engages stop 148
for controlling the extent of downward movement of moveable arm 132
and compression rolls 130. It is within the purview of this
invention that adjusting screw 146 can be adjusted for controlling
the width of nip 152 between rolls 128 and 130, for accommodating
different widths of single-faced web passing through, for joining
with the individual sheets being fed by table 142. Also, this
adjustment is such so as to control the point of engagement of the
leading edge of web 20 with the bottom surface of the leading edge
of the sheet being joined thereto at nip 152, so that there is a
slight overhang produced, if desired, during the joining procedure
of the leading edge of the sheet with respect to the leading edge
of the single-faced web.
Disposed internally of vacuum roll 110 is a non-rotating baffle
146, which baffle is foraminous in area 148 for controlled
application of vacuum only in area 148, only around approximately
one-quarter of the circumference of vacuum roll 110, as shown in
FIG. 2.
As a further feature of this invention, an arrangement is shown in
FIG. 2 for preventing jamming of the leading edge of web 20 below
shearing blades 40-42 at the moment of severing action. It should
be understood that during the operation of the apparatus, in
accordance herewith, the single-faced web 20 is being fed
continuously through the apparatus. Thus, during the moment when
the shearing blades join for severing the leading portion of the
web being joined to a sheet at nip 152, there would be a jamming
action of the newly formed leading edge of the web below shearing
blades 40-42.
In order to accommodate the continuous movement of web 20,
therefore, a loop control pan 156 is arranged to carry the opposed
arcuate surface 158 opposite the surface of feed roll 18. Loop
control pan 156 is supported for vertical movement on bracket 163,
connected at 162 to loop control pan 156. Bracket 163, is in turn
connected to the piston rod 164 of a pressure fluid reversible
control cylinder 166, which is operated through the action of valve
172 through lines 168 and 170, directed to each face of the piston
in control cylinder 166. Valve 172, is in turn controlled by the
action of plunger 174, having a cam follower 176 attached thereto,
which cam follower 176 follows the surface of cam 178, journaled on
shaft 60. As can be seen in FIG. 3, when the raised portion of cam
178 moves into contact with cam follower 176, valve 172 operates to
activate control cylinder 166 to lower loop control pan 156
momentarily when moveable shearing blade 42 moves into engagement
with stationary blade 40. Thus, the entire longitudinal extent of
web 20 following arcuate surface 158 opposite feed roll 18 and the
upper extension 160 thereof is moved slightly downward so that the
severed new leading edge 180 of web 20 is moved away from the
vicinity of engaging blades 40-42.
With regard to feed table 142, sheets may be fed therealong by hand
or by any appropriate mechanical feeding apparatus, the only
limitation being that the sheets be fed in overlapping fashion, so
that after a joined sheet is being drawn around the bottom edge of
permanent stop 136 (such as sheet 140 in FIG. 3), another sheet
moves against the permanent stop 136 for subsequent joining in nip
152, with a subsequent portion of web 20, such as sheet 181 in FIG.
3.
Angled support 187 (FIG. 1) connected to the end of feed table 142
at 201, serves to support moveable compression rolls 130. In this
connection, shaft 137 is journaled in a pair of braces 203 at each
end of compression rolls 130, which braces 203 are connected to
support 187.
Adhesive 79 used may be of any composition known in the art,
including a thermosetting adhesive requiring subsequent heat
setting, after exiting from the apparatus at nip 152, in accordance
herewith. However, it has been found appropriate, in accordance
herewith, to utilize a cold resin adhesive, eliminating the
necessity for subsequent heat application.
In operation, and referring to FIG. 1, preliminarily web 20 is fed
into the apparatus around guide rolls 22 and 24, for threading
operations of the initial leading edge of web 20. During this
procedure, reversible fluid cylinder 38 is actuated to move the
piston rod 36 thereof to the left in FIG. 1, so as to move pressure
roll 26 away from engagement with drive roll 18. Thus, the leading
edge of web 20 may be fed through and threaded between the nip of
rolls 18 and 26, and into the area between the surface of drive
roll 18 and arcuate surface 158 of loop control pan 156.
Thereafter, cylinder 38 is actuated to move pressure roll 26 to the
position shown in FIG. 1, for pressure engagement of the web 20 in
the nip between rolls 18 and 26. This action begins the continuous
driving movement of the web 20 through the apparatus, around roll
18 and upwardly through the open blades 40-42, and into nip 99
formed between rolls 98 and 110. It should be understood that at
this point, controls 82 and 90 will be adjusted according to the
type of web 20 passing through the apparatus to control the width
of the nip between rolls 98 and 110, as well as the extent of
movement of metering roll 84 into adhesive 79 contained in tray 78.
Also, the speed of motor 94 will be adjusted to accommodate the
appropriate amount of adhesive applied by metering roll 84 to
applicator roll 98, which in turn applies the adhesive to the
points of the corrugations of web 20, all in well known
fashion.
As web 20 enters nip 99, the open face side of web 20 is applied
with adhesive simultaneously with the surfaced side thereof coming
into engagement with the vacuum engaging portion 148 of vacuum roll
110. Thus, web 20 is carried partially around the extent of vacuum
roll 110 until it comes into engagement with supporting surface
150, whereupon the web follows surface 150 toward nip 152, as shown
in FIG. 2.
As shown in FIG. 1, upper compacting rolls 130 are in their raised
position and the leading portion of web 20 has been partially
joined with a sheet 138, the rear portion of which is being pulled
from feed table 142 around the lower edge 185 of permanent stop
136, while the leading edge of the next succeeding sheet 140 is
held stopped against the surface of permanent stop 136. In FIG. 2,
a finished outgoing product 144 is shown with the sheet 138
permanently affixed to the open faced surface thereof.
At this point, cam 120 has come into engagement with the follower
for switch 122 (FIG. 1), for activating reversible cylinder 134,
for moving upper compression rolls 130 downwardly to form the
adjusted nip 152. In this connection, and as noted above, adjusting
screw 146 has come into engagement with stop 148, for limiting the
downard movement of upper compression rolls 130. This downward
movement of the compression rolls 130 serves to move the leading
edge of sheet 140 (FIG. 2) downwardly, out of engagement with
permanent stop 136, and to form the width of nip 152 according to
the adjustment previously made of adjusting screw 146. Thus, when
the severed leading edge of web 20 moves into nip 152, the initial
corrugation points of the open face side of web 20 engage sheet 140
in nip 152, slightly behind the leading edge thereof, and
continuous movement of the web 20 serves to pull sheet 140 off feed
table 142 and simultaneously combine sheet 140 with web 20.
Thereafter, further continuous movement of web 20 through nip 152
carries the sheet 140 therealong, as shown in FIG. 3. In the
meantime, cam 120 has moved out of engagement with the follower for
switch 122, and causes cylinder 134 to be actuated for raising the
upper compression rolls 130 away from nip 152. Thus, as can be seen
in FIG. 3, sheet 140 is being continuously drawn through nip 152,
while the compression rolls 130, in their raised position, allow
the next succeeding sheet 181 to come to rest against permanent
stop 136.
While this action is taking place, cam 124 has moved into
engagement with the follower of switch 126. Switch 126 serves to
operate solenoid 64 for moving clutch bar 70 downwardly out of
engagement with clutch 62, which in turn allows the rotation of
gear 51 on shaft 60, engaging gear 53 on shaft 57. The rotation of
shaft 57 in turn causes the rotation of cam 50, which rotates so
that the higher portion thereof engages cam follower 43 on arm 46,
for moving arm 46 and blade 42 to the right to shear web 20. The
position of the shearing blades 40-42 at this instant are shown in
FIG. 3. With this arrangement, the leading portion of web 20 will
be joined with sheet 140 to form a single separated two-sided
product upon exiting from nip 152. In this connection, it should be
understood that permanent stop 136 is arranged so that the lower
surface thereof is spaced from the surface of lower compression
roll 128 to an extent causing the sheet, such as 140 in FIG. 3, to
follow a path which will cause the sheet to come into engagement
with the adhesively applied points of the open face of web 20
passing through nip 152.
Simultaneously with the shearing action of blades 40-42, and the
rotation of shaft 60 for carrying out this function, the rotation
of shaft 60 also serves to rotate cam 178, as shown in FIG. 3, so
that the wide portion thereof comes into contact with cam follower
176 of valve 172. Thus, simultaneously with the shearing action of
blades 40-42, cylinder 166 will be actuated to move loop control
pan 156 downwardly, to move the newly severed leading edge 180 of
web 20 below cooperating shearing blades 40-42 and out of an
engagement with those blades, momentarily.
Thereafter, cam 124 (FIG. 1) will move out of engagement with the
cam follower of switch 126, for causing blade clutch bar 70 to move
back into engagement with clutch 60 and stop rotation of gear 51
and cooperating gear 53, after the wide portion of cam 50 has
passed follower 43 and moved blade 42 back to the left, as shown in
FIG. 1. Simultaneously, the wide portion of cam 178 will have
passed follower 176, causing plunger 164 of control valve 172 to
move upwardly and cause cylinder 166 to move its piston and
associated rod 164 upwardly, to move loop control pan 156 back into
the position shown in FIG. 2.
It should be understood, that during this entire sequence the web
20 is continuing to be fed between the nip formed between rolls 26
and 18. After this sequence, leading edge 180, as shown in FIG. 3,
will be continuously fed upwardly toward nip 99, for subsequent
engagement of further portions of web 20, with succeeding sheets
being fed from table 142 into nip 152. It should be understood
that, in accordance herewith, the adjusting screw 146 is so
adjusted to provide that the leading edge of the web 20 engages the
lower surface of a sheet in nip 152, slightly behind the leading
edge thereof, in order to provide an overlap 141 (as shown in FIG.
3).
Further, the adjustments of the change gears are arranged, in
accordance herewith, so that the web is severed after joining with
the sheet, to provide a severed length of web, which is slightly
less than the length of the sheet being joined thereto, so that
there is an overhang of the sheet at the rear edge of the produced
product as well. Thus, as shown in FIG. 5, a finished product 182
has a sheet 140 disposed on one surface thereof with sheet 140
having overhangs 141 at each end thereof. This arrangement is
particularly appropriate for subsequent formation of the product
obtained, in accordance herewith, into cartons or containers
because the corrugated portion thereof does not have to be cut in
order to conform with the sheet applied thereto, thus eliminating a
substantial amount of wastage. As can be seen in FIG. 4, the
plurality of upper compression rolls 130 are moveable into cutout
portions 205 of the permanent stop 136. Upon movement of the
pivoted arms 132 downwardly, the arms (one arm at each side of each
roller 132) moves the shafts 133, carrying the plurality of upper
compression rollers 130 downwardly below the lower surface 185 of
the stop 136, for moving the leading edge of a sheet downwardly and
under the bottom edge 185 and into engagement with the leading edge
of the web 20, passing into nip 152.
The various lines for controlling the pressure cylinders herein are
not shown for purposes of clarity since they do not form any part
of the invention herein. It should be understood that the cylinders
may be hydraulic or pneumatic, as desired, but preferably are
pneumatically driven. Also, electrical controls may be used. The
power source for the cylinders may be from any well known source
such as a compressor for a pneumatic system, all in well known
manner.
Thus, it can be seen with the arrangements, in accordance herewith,
that a plurality of discrete sheets having fine lithographic
printing and designs thereon, may be applied sequentially to a
continuously moving web of single-faced corrugated material in a
manner whereby the final product, upon exiting from the combining
apparatus, is a completely separated two-faced corrugated piece
having on one surface thereof the appropriate and desired fine
printing and design, and without the necessity of any further
severing procedures. With such an arrangement, the sheets are
always effectively aligned with the associated piece of the
single-faced web joined with those sheets, and in a manner to
provide appropriate and desired overhangs at each end of the
combined product exiting from the machine. In addition, because of
the unique loop control pan arrangement herein, there is no jamming
of the severed leading edge of the web, even though it is
continuously being fed at the point of severance prior to the
severing blades withdrawing from the path of movement of the
continuously fed web.
Also, because of the controlled nip arrangement of the combining
rolls herein, no special provisions have to be made for
coordinating the feeding of the discrete printed sheets in
relationship to the movement of the web through the nip, since each
succeeding leading edge of web serves to make contact with the
lower surface of the sheet already stationed at the nip.
Furthermore, because of this particular adjustable nip arrangement,
a power feed to the nip of the discrete printed sheets is
unnecessary. As noted above, the apparatus herein accommodates both
hand feeding and mechanical feeding, as desired.
Furthermore, the adjustments for accommodating different lengths of
sheet are extremely simple, requiring only an adjustment of the
change gears in order to change the sequence of cams 120 and 124
for controlling the switches 122 and 126, and the adjustment screw
146 for controlling the adjustable nip 152, as desired. The only
further adjustments required in addition to this, are the usual
adjustments of the metering roll and the pressure applied by the
applicator roll at nip 99.
Accordingly, the methods and apparatus, in accordance herewith,
serve to laminate an appropriate lithographic preprinted, precut
sheet to a single-faced corrugated web, preferably by the use of a
cold resin adhesive. Because of the use of the sequence of cutting
the single-face web portion prior to its complete combination with
the individual sheets, the apparatus herein provides a modular type
construction, permitting an extremely compact design requiring a
minimum of space. In addition, the arrangements herein accommodate
a variety of different size flute configurations and a variety of
different sized printed sheets.
The products obtained, in accordance herewith, may be formed into
containers having life-like images, enhancing the merchandising of
the products contained therein, which containers are particularly
appropriate for point-of-purchase products, such as toys, games,
small household appliances, cosmetics and gift items. This is
achieved simultaneously with a substantial reduction in cost of
such containers, because of the substantial reduction in wastage
achieved with the precise registration brought about with the
methods and apparatus herein. Furthermore, because of the
utilization of continuous web feeding, a larger quantity of product
is produced over a period of time than with the prior art devices
requiring intermittent feeding, all of which make the arrangements
herein highly advantageous commercially.
While the methods and apparatus herein described constitute
preferred embodiments of the invention, it is to be understood that
the invention is not limited to these precise methods and
apparatus, and that changes may be made therein without departing
from the scope of the invention, which is defined in the appended
claims.
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