PROCESS AND DEVICE FOR PREPARING PLATES FOR CYLINDERS TO TREAT ITEMS OF THE PAPER PROCESSING INDUSTRY

Abstract

A process for preparing plates (22,32) for cylinders (20,30) to treat items of the paper processing industry (40) is described, the process comprising the following steps: acquisition of a treating pattern (50) to be produced on the item of the paper processing industry (40); creation of a 3D reference model of the treating profile elements (25, 35) according to the treating pattern (50); application of the treating profile elements (25,35) on the plate (22,32) by means of an additive manufacturing process of polymeric material, preferably thermoplastic polymeric material, in accordance with the 3D reference model of the treating profile elements (25, 35), carried out by means of at least one printing nozzle (80) of said polymeric material. A device (250) for preparing plates (22,32) is also described, in addition to a plate (22,32) to treat items of the paper processing industry comprising at least one treating profile element (25,35) of polymeric material, preferably thermoplastic polymeric material, deposited on said plate by means of an additive

Claims

1. A process for preparing plates (22,32) for cylinders (20,30) to treat items of the paper processing industry (40), the process comprising the following steps: a) acquisition of a treating pattern (50) to be produced on the item of the paper processing industry (40); b) creation of a 3D reference model of the treating profile elements (25, 35) according to the treating pattern (50); c) application of the treating profile elements (25,35) on the plate (22,32) by means of an additive manufacturing process of polymeric material, preferably thermoplastic polymeric material, in accordance with the 3D reference model of the treating profile elements (25, 35), carried out by means of at least one printing nozzle (80) of said polymeric material.

2. The process according to claim 1, wherein said additive manufacturing process is a fused deposition modelling (FDM) process.

3. The process according to claim 1 or 2, wherein said additive manufacturing process is carried out by a 3D printer (200) which comprises said at least one nozzle (80), preferably heated.

4. The process according to any one of the preceding claims, wherein in said application step of the treating profile elements (25,35) on the plate (22,32) by means of an additive manufacturing process of polymeric material, said plate (22, 32) is positioned on a supporting plane (90) or a cylindrical support (91).

5. The process according to claim 4, wherein said plate (22, 23) is fixed to said supporting plane (90) or to said cylindrical support (91) by means of magnetic interaction.

6. The process according to any one of the preceding claims, wherein said polymeric material printed by said nozzle (80) is PTEG and/or said at least one plate (22, 32) is made of polymeric material, preferably PVC.

7. The process according to any one of the preceding claims, wherein the nozzle (80) is movable along at least one axis (X), preferably along at least two axes (X, Y) perpendicular to each other.

8. The process according to any one of the claims from 4 to 7, wherein the supporting plane (90) or the cylindrical support (91) moves at least along a vertical axis (Z).

9. The process according to one of the claims from 4 to 8, wherein said cylindrical support (91) is rotatable around its own rotation axis.

10. The process according to one of the preceding claims, wherein the application of the treating profile elements (25,35) on the plate (22,32) by means of an additive manufacturing process comprises the formation of a plurality of stacked layers (70).

11. The process according to claim 10, wherein the nozzle (80) prints polymeric material, preferably thermoplastic material, preferably in the form of a wire, which is deposited on the plate (22, 32) so as to form a plurality of superimposed layers (70), to produce at least one treating profile element (25, 35) in accordance with the 3D reference model.

12. The process according to claim 10 or 11, wherein at least one layer (70) of polymeric material of at least one treating profile element (25, 35) adheres permanently to the plate (22, 32), preferably as a result of cooling and/or solidification of the polymeric material.

13. The process according to any one of the preceding claims, wherein a step of displaying and/or modification of the deposition parameters of the treating profile elements (25,35) is provided, said deposition parameters of the treating profile elements (25,35) preferably comprising at least the height (h) of the nozzle (80) relative to the deposition surface, the displacement speed of the nozzle (80) relative to the deposition surface, the delivery speed of the material, or any combination of the preceding parameters.

14. A device (250) for preparing plates (22,32) for cylinders (20,30) to treat items of the paper processing industry (40), preferably according to the process according to any one of the preceding claims, the device comprising at least one nozzle (80) for the deposition of polymeric material, preferably thermoplastic polymeric material, on at least one plate (22, 32) by means of an additive manufacturing process for the production of treating profile elements (25, 35) according to a 3D model of the treating profile elements (25, 35).

15. The device according to claim 14, characterized in that it comprises at least one supporting plane (90) or a cylindrical support (91) for the plate (22, 32), said printing nozzle (80) being movable along at least one axis (X), preferably on a plane X-Y substantially parallel to the surface on which said plate (22, 32) lies.

16. A plate (22,32) to treat items of the paper processing industry comprising at least one treating profile element (25,35) of polymeric material, preferably thermoplastic polymeric material, deposited on said plate by means of an additive manufacturing process of polymeric material, preferably by means of a process according to any one of the claims from 1 to 13.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0097] Further characteristics and advantages of the invention will be evident from reading of the following description provided by way of non-limiting example, with the help of the figures illustrated in the attached drawings, wherein:

[0098] FIG. 1 is a schematic representation of a machine for treating items of the paper processing industry;

[0099] FIG. 2 shows an operation for deposit (printing) of the treating profile elements according to the 3D reference model by means of additive manufacturing, according to a possible embodiment of the invention;

[0100] FIG. 2a shows a possible embodiment in section of a treating profile element obtained by means of deposition of material according to a possible embodiment of the present invention;

[0101] FIG. 2b shows the deposition step of a layer of material according to a possible embodiment of the present invention;

[0102] FIG. 3a shows schematically a possible embodiment of the device for the deposition of a treating profile on the plate positioned on a cylindrical support;

[0103] FIG. 3b shows schematically a possible embodiment of the device for the deposition of a treating profile on the plate positioned on a support plane;

[0104] FIG. 4 shows schematically in section a view of the support plane on which the plate is positioned on which a male treating profile has been produced by means of additive manufacturing, following the process illustrated in FIG. 3b;

[0105] FIGS. 4a-4c show some possible section views of treating profile elements produced by means of the process according to the present invention by deposition of several layers of the same material or several different materials;

[0106] FIG. 5 shows schematically in section a possible embodiment of a female treating profile deposited on the plate;

[0107] FIGS. 5a and 5b show two possible section views of male and female profile elements according to the invention;

[0108] FIG. 6a shows two male profiles in an overhead view relatively arranged to form two creasing lines reciprocally inclined by an angle of less than 90°;

[0109] FIG. 6b shows schematically in an overhead view a possible embodiment of profiles for embossing of Braille symbols, for example;

[0110] FIG. 6c shows schematically in an overhead view a possible embodiment of the combination of profiles for embossing, of Braille symbols for example, and profiles for creasing;

[0111] FIG. 7 shows a pair of rollers composed of a first rotating cylinder having a plate provided with a male profile and a second rotating cylinder having a plate provided with female profile; and

[0112] FIG. 8 shows a block diagram of a possible embodiment of the process of the invention.

DETAILED DISCLOSURE OF SOME EMBODIMENTS OF THE PRESENT INVENTION

[0113] FIG. 1 shows schematically a possible embodiment of a machine for treating items of the paper processing industry, such as cardboard, card stock and like materials, according to an embodiment of the present invention.

[0114] The treating is performed by means of the use of a treating machine which comprises a pair of counter-rotating cylinders 10.

[0115] The pair of cylinders 10 is composed of a lower cylinder 20 and an upper cylinder 30 which rotate around their own axis of symmetry (central axis) in opposite directions, by means of appropriate movement means not shown.

[0116] In one embodiment, on the outer surface of the upper cylinder 30 an upper plate 32 is positioned by fastening means 24, while on the outer surface of the lower cylinder 20 a lower plate 22 is positioned by fastening means 24.

[0117] In a further embodiment, the upper plate 32 and the lower plate 22 are positioned on respective cylinders by means of magnetic force.

[0118] The upper plate 32 and the lower plate 22 are preferably made of polymeric material, preferably magnetized, more preferably magnetic PVC, or they can be made of flexible metal elements. The plates can have a thickness between 0.2 mm and 3 mm, preferably 2.5 mm, and can be shaped respectively on the outer surface of the upper cylinder 30 and on the outer surface of the lower cylinder 20. Other thicknesses can be used as required. Further materials can be used to produce the plates 22, 32.

[0119] In general, the plate 22, 32 can be made of a material, or comprises at least a layer of material, that facilitates the union and therefore bond with the polymeric material which, as will be seen below, is deposited on the surface of the plate.

[0120] It should be noted that, according to an aspect, the plate 22, 32 is preferably flexible, namely made so as to adapt to a curved surface, for example to the surface of a cylinder of a treating machine on which the plate is installed.

[0121] It should be noted that the term plate is used to indicate a two-dimensional form, namely a flat extension in which two dimensions are dominant with respect to the third dimension, and the plate can therefore comprise a sheet or a film having a single layer or several layers.

[0122] On the upper plate 32 elements (portions) of treating profile and in particular male type profiles 35 are applied, preferably deposited (printed) by means of an additive manufacturing process, and in particular by means of a 3D printing process, while on the lower plate 22, elements (portions) of treating profile and in particular female type profiles 25 are printed. Obviously, the opposite arrangement can also be provided, in which the female profiles 25 are printed on the upper plate 32 and the male profiles 35 are printed on the lower plate 22.

[0123] According to an aspect, the male type profiles 35 form projections on the upper plate 32, while the female profiles form hollows (recesses) on the lower plate 22. The male profiles 35 and the female profiles 25 are preferably made of polymeric material, preferably thermoplastic, for example PETG.

[0124] The creasing profiles of male type 35 and female type 25 are positioned on the respective plates 32, 22 so as to assume a given relative position such that the projections of the male profiles 35 match (are arranged corresponding to) the hollows of the female profiles 32.

[0125] The position of the male profiles 35 and the position of the female profiles 32 on the respective plates is therefore determined so that the maximum deviation from the predefined relative position of the male profiles 35 and female profiles 32 is less than 0.15 mm, preferably less than 0.1 mm.

[0126] According to a possible embodiment of the machine, adapted for example to a creasing or embossing operation of an item of the paper processing industry, as can be seen, for example, in the overhead view of FIG. 6a and in the section view of FIG. 4, each of the male or female profile elements is preferably printed by the superimposition of several layers 70, namely by means of successive deposition of several layers.

[0127] According to a possible embodiment, the male treating profiles 35 and the female treating profiles 25 comprise a lower support portion 38, and an upper projecting portion 37 (for example a rectilinear ridge, or for example a substantially cylindrical or rounded relief, or other substantially convex geometrical shapes for formation of the male profile 35), or said lower support portion 38 is printed so as to present a hollow (for example a rectilinear seat or a circular or rounded seat, or other substantially concave geometrical shapes, adapted to be configured as housing seats for the convex projecting portions 37 of the male elements 35) for formation of the female profile 25.

[0128] It should be noted that in a possible embodiment, the lower support portion 38 and the upper portion 37 do not have interruptions.

[0129] It should be noted that the support 38 can assume different shapes if seen in an overhead plan view, according to the type of treating desired. For example, according to a possible embodiment adapted to creasing, the plan view shape of the support 38 can be substantially rectangular or (as illustrated, for example, in FIG. 6a) can have for example a hexagonal shape with, at its ends, oblique sides 39 which preferably define an angle equal to or smaller than 90°. In general, the plan view shape of the support 38 of the treating profile can comprise an inclined side.

[0130] According to a further possible embodiment adapted for example to embossing an item of the paper processing industry, the plan view shape of the support 38 can be substantially circular or have the profile of the pattern or form to be impressed, as shown for example in FIGS. 6b and 6c.

[0131] The elements (portions) of male profile 35 and female profile 25 adhere to the respective plates. In fact, according to a possible embodiment, the male profiles 35 and the female profiles 25 are printed directly on the plate 22, 32 by means of an additive manufacturing process, and in particular by means of a fused deposition modelling process.

[0132] In a possible embodiment shown in FIG. 3b, the male profiles 35 and/or the female profiles 25 are printed directly on the plate 22, 32 positioned on a supporting plane 90.

[0133] In a further embodiment shown in FIG. 3a the male profiles 35 and/or the female profiles 25 are printed directly on the plate 22, 32 positioned on a cylindrical support 91.

[0134] As said, according to a further embodiment, the male profiles 35 and/or the female profiles 25 are printed directly on the plate 22, 32 fixed on a cylinder 20, 30 of the treating machine.

[0135] According to an aspect of the present invention, the profiles are printed by a device 200 for preparing plates 22, 32 indicated below for the sake of simplicity also as 3D printer, provided with a nozzle 80, preferably a heated nozzle, which prints polymeric material on the plate in the form of a plurality of layers 70 which, by superimposition, form the treating profile element 25, 35.

[0136] Deposition of the polymeric material is performed for example by means of a motor (not shown) positioned upstream of the nozzle 80 which pushes a strip, or wire, or filament of polymeric material, preferably thermoplastic polymeric material, through the nozzle 80.

[0137] As shown schematically in FIGS. 2, 3a, 3b for example, the polymeric material is preferably fed from a reel in which the polymeric material is present in the form of a wound strip, or wire, or filament. However, further methods of feeding the polymeric material to the nozzle 80 are not excluded.

[0138] Preferably, heating of the nozzle 80, or the presence of a heating chamber, upstream of the nozzle, allows the polymeric material to be brought to a substantially fused condition so that it can pass through the nozzle and be deposited on the plate surface 22, 32 or on a layer 70 of previously deposited polymeric material.

[0139] As said, according to an aspect of the invention, the material for the printing is preferably polymeric material, more preferably thermoplastic material, for example PETG, and is delivered from the nozzle 80 in the form of a wire or filament, preferably at high temperatures.

[0140] According to possible embodiments, the heated nozzle 80 has an outlet diameter between 2 mm and 6 mm, preferably 4 mm.

[0141] The filament of thermoplastic material is deposited on the plate 22, 32, in a substantially fused state. The filament, or wire, of material deposited cools and solidifies, adhering to the plate.

[0142] The 3D printer 200 can be provided with temperature control means, not shown in the figure, adapted to maintain the supporting plane 90 heated, or the cylindrical support 91 or the cylinder 20, 30 at the desired temperature.

[0143] If the plate 22, 32 is fixed to the supporting plane 90, the layers 70 of fused material are deposited on the plate so as to adhere to a flat rectilinear surface. Consequently, the first layer deposited 70 will have a substantially flat shape.

[0144] If the plate 22, 32 is fixed to a cylindrical support 91 or to a treating cylinder 20, 30, the layers 70 of fused material are deposited on the plate so as to adhere to a curved surface. Consequently, at least the first layer deposited 70 will have a substantially curved shape, having a curvature equal to that of the cylindrical surface on which it lies.

[0145] After the cooling and solidification process of the treating profile elements 25, 35 has been completed, said elements adhere perfectly and in a permanent manner to the plate 22, 32 below.

[0146] At this point, if the additive manufacturing operation (and in particular printing) is carried out on a plate 22, 32 positioned on a supporting plane 90 or on the cylindrical support 91, the plate 22, 32 is removed from the supporting plane 90 and secured to one of the two rollers by fastening means 24.

[0147] If the additive manufacturing operation (and in particular printing) is performed on a plate 22, 32 positioned on the cylinder 20, 30, said intermediate operation is not necessary, and the treating cylinder 20, 30, is appropriately positioned inside the treating machine.

[0148] Once the rotation of the pair of rollers 10 has been activated, as can be seen for example in FIGS. 1 and 7, the interposition of an item of the paper processing industry such as, for example, a cardboard 40 or a greetings card or a card stock for producing packaging or micro-packaging boxes or other items of the paper processing industry, between the male profiles 35 of the upper cylinder 32 and the complementary female profiles 25 of the lower cylinder 22 allows the treating 60 to be carried out on the cardboard 40.

[0149] Obviously, it should be noted that the distance between the upper cylinder 30 and the lower cylinder 20 can be adjusted according to the thickness of the cardboard 40 to be treated.

[0150] Going back to the printing of the male profiles 35 (or female profiles 25) on the upper plate 32 (or on the lower plate 22), as said, it is carried out by means of an additive manufacturing process, preferably by means of a 3D printer 200, which operates according to the 3D reference model of the treating profile elements 25, 35. In other words, printing of the portions, or elements, with male profile 35 (or female profile 25) on the upper plate 32 (or on the lower plate 22), is guided by a specific software (called Slicer in the additive manufacturing sector), in which the parameters of the additive manufacturing process can be entered and/or modified, such as, for example, the material used for the printing, the diameter at which the wire of material for the printing shall be deposited, the height (or thickness) desired for each layer 70 of each treating profile element, the displacement speed of the nozzle (80) relative to the deposition surface, the delivery speed of the material, the infill (or filling) desired for each layer 70, the printing temperature, or any combination of the preceding parameters.

[0151] According to one aspect of the invention, the profile elements are preferably made of PETG, but can also be made of ABS (acrylonitrile-butadiene-styrene), PLA (polylactic acid), HIPS (high-impact polystyrene), TPU (thermoplastic polyurethane), nylon, or any other thermoplastic material that can be used in an additive manufacturing process.

[0152] According to an aspect of the present invention, the polymeric material used has a Shore hardness of approximately 80-100 on a type A Shore scale.

[0153] The layers 70 deposited can be made of different polymeric materials or using different deposition parameters such as, for example, one or more of the parameters referred to above. Preferably the polymeric materials are compatible with one another to obtain a better reciprocal adhesion of the layers.

[0154] FIGS. 2a, 4a and 4b show for example some possible embodiments of the shape of the treating profile elements 35, obtained by means of successive deposition of several layers 70 of polymeric material. FIG. 4c shows a possible embodiment in which the treating profile element 35 is made by means of the deposition of layers 70 of different materials (see the different crosshatching of the layers).

[0155] FIGS. 5a and 5b show a section view of two possible embodiments of treating profiles according to the invention.

[0156] The male and female profiles 35, 25 have predefined dimensions, namely the profiles are printed on the respective plates 22, 32 so that the male profile 35 has a lower supporting portion 38 with height L.sub.m and a projecting portion 37 with height L.sub.s and width D.sub.s, while the female profiles 25 have a height L.sub.f with hollows of depth L.sub.i, and width D.sub.i adapted to house the projecting portions 37 of the male profiles 35.

[0157] For example, as shown in FIGS. 5a and 5b, the dimensions of the male profiles 35 are such that the lower supporting portion 38 has a height L.sub.m of less than 0.8 cm, preferably equal to 0.6 cm, and the projecting portion 37 has a height L.sub.s of less than 1 cm, preferably equal to 0.85 cm. The width D.sub.s of the projecting portion 37 is less than 1 cm, preferably it is equal to 0.8 cm.

[0158] The dimensions of the female profiles 25 are such that the height L.sub.m is less than 1.5 cm, preferably equal to 1 cm, and the hollow has a depth L.sub.i less than 1 cm, preferably equal to 0.8 cm. The width D.sub.i of the hollow is less than 1.5 cm, preferably it is equal to 1.3 cm. As can be noted for example from FIGS. 5a and 5b, according to an aspect, the height L.sub.s of the projecting portion 37 of the male profile 35 is preferably greater than the depth L.sub.i, of the female profile, so that during the treating only the portions of the item of the paper processing industry to be processed (folded or embossed) come into contact with the creasing profiles.

[0159] As shown for example in the figures, according to an aspect of the invention, the section of the male treating profile 35 can comprise at least a curved surface, and preferably an end having curved or circular shape (see for example the embodiments of FIGS. 5a, 5b), or can have a flat end or upper surface. The two sides of the section can be parallel to each other and rectilinear or at least one of the two sides can be inclined so as to be incident. The material used for deposition on the plate and/or on a previously deposited layer 70, and therefore for the printing, for example the thickness (height h) of each layer 70, the width (l) of the printed layer (see for example FIG. 2b), the filling percentage of the layers 70 printed by the nozzle 80 of the 3D printer 200, or a combination thereof, are appropriately chosen to allow precise and clear realization of the profile elements. For example, printing parameters can be selected such that the wire of material printed by the nozzle 80 has a diameter between 2 mm and 6 mm, preferably 4 mm, and each layer of material has a thickness of 0.1 mm-2 mm.

[0160] The printing temperature is adjustable for each material, and varies in a range of values between 180° C. and 300° C., preferably between 200° C. and 290° C.

[0161] At said temperatures, the printed thermoplastic material is in a substantially fused state when it is deposited on the plate 22, 32. When it cools, the polymeric material returns to the solid state, adhering perfectly to the plate 22, 32.

[0162] According to an aspect of the present invention, to facilitate adhesion of the profile elements 25, 35 to the plate 22, 32, the supporting plane 90 or the cylindrical support 91 or the cylinder 20, 30 to which the plate 22, 32 is secured, on which said profile elements 25, 35 are printed, is maintained at a temperature with values ranging from 100° C. to 120° C., preferably between 110° C. and 115° C.

[0163] According to a further aspect of the invention, additives with binding properties can be sprayed on the plate 22, 32 prior to the printing operation, to further facilitate said adhesion. Said additives are preferably such as not to leave residues on the plate.

[0164] According to an aspect of the invention, an additive manufacturing device is used, preferably a 3D printer 200 for fused deposition modelling, comprising a heated nozzle 80 and a supporting plane 90 or a cylindrical support 91 for the plate 22, 32. The nozzle 80 can be guided along at least one axis (X), preferably along two axes and thus along a plane X-Y by a CAM software, in accordance with the 3D reference model of the treating profile elements to be printed. The nozzle 80 can be guided according to different types of kinematics, for example, according to core XY kinematics or gantry kinematics.

[0165] In the embodiment shown in FIG. 2, in which the plate is positioned on the supporting plane 90, the kinematics used are preferably of core XY type, according to which the nozzle 80 is moved along the plane X-Y parallel to the plane on which the supporting plane 90 lies, while the supporting plane 90 on which the plate 22, 32 is arranged is movable along an axis Z perpendicular to the above-mentioned plane X-Y along which the nozzle 80 moves. It should be noted that embodiments are also possible in which the relative movement along the Z axis between the supporting plane 90 and the nozzle 80 can occur by means of movement of the latter relative to the supporting plane 90, which can be fixed.

[0166] A section view of a detail of the treating profile element is shown in FIG. 2a. In particular, it should be noted that the layers 70 of material are deposited on the plate 22, 32 so as to form portions generally having a rectilinear extension.

[0167] In the further embodiment shown in FIG. 3a, in which the profile elements 25, 35 are printed on the plate 22, 32 positioned on the cylindrical support 91, the nozzle 80 is moved in at least one direction X (parallel to the axis of the cylinder 91) and if necessary can also be moved in the direction Y, perpendicular to the direction X, and therefore be movable along the plane X-Y.

[0168] The cylindrical support 91 on which the plate 22, 32 is arranged can be movable along an axis Z perpendicular to the axis X (or relative to the above-mentioned plane X-Y) along which the nozzle 80 is movable. It should be noted that the movement along the vertical axis Z can be obtained also by vertically moving the nozzle 80 and maintaining the support cylinder 91 fixed.

[0169] Furthermore, according to a further possible embodiment, the cylindrical support 91 can be rotated around its own central axis (for example via a motor 91a connected to the support cylinder 91 for example by means of a drive belt), which therefore constitutes the rotation axis.

[0170] The printing process of the 3D reference model of the treating profile elements 25, 35 is carried out in a controlled manner, through a CAM control software, so as not to involve the parts of the plate 22, 32 on which no portion of profile element 25, 35 has to be printed.

[0171] Advantageously, according to an aspect of the present invention, the 3D reference model of the treating profile elements to be printed on the plates 22, 32 is determined and then produced with a 3D modelling software, according to the treating pattern 50. The pattern 50 can be stored in a memory unit 130 associated with a control unit 110 of the plate preparation device, and in particular of the 3D printer used.

[0172] As discussed above, the 3D model of the treating profile elements 25, 35, and in particular the shape and/or the dimensions of said elements and/or the relative distance that said elements shall maintain when printed on the same plate 22, 32, are determined according to the treating pattern 50 to be produced. Determination of the shape, dimensions and positioning of the profile elements on the plate can be advantageously carried out by the control unit 110, according to the desired treating pattern 50.

[0173] In other words, the 3D model of the treating profile elements to be printed on the plate 22, 32 by means of an additive manufacturing process preferably performed by a 3D printer 200 is obviously defined according to the desired treating pattern 50 and is therefore determined or calculated based on it.

[0174] For example, the shape and the dimensions of the 3D reference model of the profile elements, and the relative distance which said elements shall maintain when printed on the same plate, can be determined according to the shape and dimensions of the treating profile which is applied on the plate. In further detail, for example the dimensions and the shape of the lower supporting portion 38 of the treating profile (on which an upper projecting or hollow portion 37 can be printed, without interruption) are taken into consideration for production of the 3D reference model according to the acquired pattern 50.

[0175] For example, according to an embodiment adapted to carry out creasing of an item of the paper processing industry, the shape of the profiles can be rectangular or another polyhedral shape, for example of the type shown in FIG. 6 where two male profiles 35 are shown adapted for a creasing operation, seen from above.

[0176] In particular, the profile has a projecting upper portion 37 which is positioned without interruption on a lower supporting portion 38, where the support 38 has a hexagonal shape with, at its ends, oblique sides 39 that define an angle a equal to or smaller than 90°, preferably an acute angle smaller than 45°.

[0177] FIG. 6a shows for example two adjacent male profiles 35 seen from above for the realization of two reciprocally inclined creasing lines.

[0178] It should be noted in general that the treating lines of the pattern 50 correspond preferably to the projecting portions 37, or hollows (shown for example in FIG. 5 and in the lower part of FIGS. 5a, 5b), which are arranged on the support 38. The treating profile elements, having a generally rectilinear extension, which are printed on the plate 22,32, are produced in such a way that the projecting portion 37 (or the hollow) determines the desired creasing line based on the pattern 50.

[0179] The same concepts relative to the shape of the support can be applied to the female profiles where the upper portion 37 is printed with hollow shape (not shown in the figures for the sake of simplicity).

[0180] In a further embodiment adapted to carry out embossing on an item of the paper processing industry, the shape of the profiles can be rectangular or another polyhedral shape.

[0181] In particular, the profile has a plurality of upper projecting portions 37 with rounded shape, positioned without interruption on a lower support portion 38 (or directly on the plate), where the support 38 has a rectangular shape.

[0182] In a further embodiment, adapted both to embossing and creasing an item of the paper processing industry, on the plate 22, 32 different profiles can be printed, adapted to embossing and creasing respectively, such that the two operations can be carried out simultaneously by the treating machine.

[0183] It should be noted, obviously, that the lower support portion may not be present. According to an aspect of the present invention, the movement of the printing nozzle 80 of the 3D printer 200 is controlled by the control unit 110 which has acquired the 3D reference model of the treating profile elements, produced based on the pattern 50 of the treating lines to be obtained.

[0184] In an embodiment, as shown for example in FIG. 2 or 3b, the plate 22, 32, is fixed to the supporting plane 90 of the 3D printer by means of reference pins (or dowels) 95, inserted in reference holes 72 of the plate, so as to form an assembly 92 comprising the plate, which is in turn arranged on the supporting plane 90. Below, said assembly is also called flat treating complex 92.

[0185] The reference pins or dowels 95 engage with the relative reference holes 72 present in the plate 32.

[0186] In a further embodiment, shown in FIG. 3a, the plate 22, 32, is fixed to the cylindrical support 91 of the 3D printer due to the magnetic force between the sheet 22, 32 made of magnetized polymeric material and the support 91, for example metallic, so as to form the assembly 92 comprising the plate. Below, said assembly is also called curved treating complex 92.

[0187] The treating complexes (or assemblies) 92, 93 allow precise effective printing of the male profiles 35 and female profiles 25 on the plates 22, 32, since they constitute a solid and stable support during the printing operation.

[0188] As said, according to a possible embodiment, a preparatory step can comprise heating of the supporting plane 90 and the support cylinder 91 and possible addition of additives on the plate 22, 32 prior to the step of printing the profile elements 25, 35.

[0189] According to a possible embodiment, the preparation device for preparing the plates and in particular the 3D printer 200 is provided, or is associated, with a control unit 110 for printing the male and/or female profile elements.

[0190] In further detail, according to a possible embodiment, as shown for example schematically in FIGS. 3a, 3b, male profile elements 35, or female profile elements 25, are printed by a 3D printer 200 coupled with a control unit 110. The control unit 110 is associated with a memory unit 130. The 3D printer 200 can deposit (as said, by means of printing, for example) portions of wire or filament of polymeric material which form the layers 70 of which each element (portion) of treating profile 25, 35 is composed in accordance with the 3D reference model, namely with length and shape that allows a given portion, or segment, of the treating pattern to be obtained. The control unit 110 controls the printing parameters for printing portions (or segments) of wire of polymeric material which will form the layers 70 of the treating profile elements such as, for example, the movement pattern performed by the print nozzle 80 in terms of coordinates X-Y (or movement along at least an axis X), lowering or raising of the supporting plane 90 of the 3D printer 200 along the axis Z perpendicular to the plane X-Y of said surface, speed and amplitude of rotation of the cylindrical support 91 around its axis, lowering or raising of the cylindrical support 91 along the axis Z perpendicular to the plane X-Y, diameter of the wire, filling percentage for each layer 70, height (h) of the nozzle 80 relative to the deposition surface, displacement speed of the nozzle (80) relative to the deposition surface, material delivery speed, printing temperature, temperature of the supporting plane 90 or of the cylindrical support 91 of the 3D printer, printing order of the profile elements, or any combination of the preceding parameters.

[0191] According to an aspect of the present invention, to obtain the treating profile elements 25, 35 with the desired geometries and dimensions, the control unit 110 coordinates the height (h) and the displacement speed of the nozzle (v.sub.n), relative to the printing surface, and the delivery speed (v.sub.f) of the filament of polymeric material fed into the nozzle 80. The theoretical model of the section of the wire printed at the outlet of the deposition nozzle is shown, for example, in FIG. 2b. As shown schematically in FIG. 2b, for example, I and h are respectively the width and the height of the wire to be obtained by means of the printing nozzle 80.

[0192] The volumetric flow rate {dot over (V)} is given by

[00001]$\stackrel{.}{V}=v_n\left(\left(l-h\right)h+\frac{\pi h^2}{4}\right)$

[0193] The volumetric flow rate at the inlet, on the other hand, is defined by the dimension of the section of the wire or filament of the incoming polymeric material:

[00002]$\stackrel{.}{V}=v_f\frac{\pi D_f^2}{4}$

[0194] Since the flow rate at the inlet and at the outlet is the same, it is possible to relate the delivery speed with the displacement speed of the nozzle. The height is coordinated independently. In this way it is possible to control the dimension of the section of the printed wire and, consequently, the geometries and dimensions of the section of the treating profile elements 25, 35 that can be obtained.

[0195] According to an aspect, the step of adhesion of the profile elements 25, 35 to the plate 22, 32, begins simultaneously with the beginning of the printing step. When the wire is deposited on the plate 22, 32, it is in a substantially fused state, at high temperature, preferably in a range of temperature values between 180 and 400° C., and as it cools layer after layer it solidifies, adhering to the plate 22, 32 below.

[0196] According to an aspect of the present invention, the printing operation and consequent adhesion of the profile elements 25, 35 is guided by the control unit 110 which displays the treating pattern on a screen 140 to facilitate monitoring of the operation by the operator.

[0197] According to a possible embodiment, the control unit 110 allows display of the printing operation control parameters on a screen 140 in order to assist the operator and speed up the operations.

[0198] The operator can select different printing parameters for each portion (element) of male profile 35 according to the treating pattern 50 to be produced.

[0199] FIG. 4 shows a section of the creasing complex 92, 93 once the male profiles 35 have been printed in accordance with the 3D reference model.

[0200] Following the same procedure as used for the upper plate 32, the lower plate 22 can be provided with female profiles 25.

[0201] The upper plate 32 provided with the male profiles 35 is detached from the supporting plane 90 or from the cylindrical support 91 and fixed to the upper cylinder 30 by means of the fastening means 24 or by means of magnetic force.

[0202] Following the same procedure used for the upper plate 32, the lower plate 22 can be provided with female profiles 25 and fixed to the lower cylinder 20 by means of the fastening means 24 or by means of magnetic force.

[0203] The preparation step of the pair of rollers 10 described is shown, for example, in FIG. 7 and is performed with the upper cylinder 30 and the lower cylinder 20 not in rotation.

[0204] The male profiles 35 adhere to the upper plate 32 which is positioned on the outer surface of the upper cylinder 30, while the female profiles 25 adhere to the lower plate 22 which is positioned on the outer surface of the lower cylinder 20.

[0205] By rotating the pair of rollers 10 it is possible to carry out treating of the cardboard 40.

[0206] Lastly, FIG. 8 shows a block diagram of a possible embodiment of the process of the invention.

[0207] In particular, the process according to the possible non-limiting embodiment comprises acquisition by a control unit 110, for example in a memory unit 130 associated with it, of a treating pattern 50 (block 300).

[0208] This step can serve for example to acquire a file in one of the known formats, for example the .pdf format, contains a plurality of information such as, for example, the graphics of the pattern to be printed on the card stock, a layer with the profile to be die-cut and another layer containing the treating pattern.

[0209] According to an aspect of the invention, in the process, the treating layer is automatically chosen and according to the treating lines and/or dots and/or shapes (and in general the profile), a 3D reference model of the treating profile elements to be made (block 310) is created by means of a 3D modelling software, for example the shape is determined (for example hexagonal) and/or the dimensions (for example the length) of the lower support portion 38 of the treating profile to be applied on the plate 22, 32 to obtain one or more treating portions of the pattern 50; the relative distance between the profile elements that shall be maintained during the printing is also determined, in accordance with the pattern 50. Said reference model is saved as a file in a format suitable for 3D printing (vector format, set (sequence) of *dxf or *plt* for example .stl file, or a CAD model usable for 3D printing).

[0210] The parameters saved in said file suitable for 3D printing are used by the 3D printer 200 to print the treating profiles 25, 35 on the plate 22, 32.

[0211] A plate 22,32 to be prepared is fixed on a supporting plane 90 or on a cylindrical support 91 (block 320) of the 3D printer 200. The supporting plane 90 or the cylindrical support 91 can be heated and/or the plate 22, 23 can be furthermore sprayed with additives, in order to increase the adhesion capacity with the treating profile elements 25, 35 which are printed (block 330). As said, this step is optional, for example if the material deposited and the material of the plate are chosen so as to allow effective adhesion of the material deposited on the plate. For example, as said, by depositing PTEG on a PVC plate, the applicant obtained effective adhesion that does not require heating of the plate and/or the addition of additives such as adhesives.

[0212] This is followed by a step of printing of the treating profile elements according to the 3D reference model, in accordance with the pattern 50 (block 340).

[0213] As said, the step of printing treating elements on a plate 22,23 in accordance with the 3D reference model is performed preferably by means of an additive manufacturing process, and in particular by means of a 3D printer 200 having a print nozzle 80 of polymeric material, and which can be moved in a known manner, for example preferably according to core XY kinematics for formation of the layers 70 which, by superimposition, form the treating profile element 25, 35.

[0214] A 3D printer 200 is then activated, by means of a control unit 110, to print, through the nozzle 80, segments of polymeric material which are deposited on the plate 22, 23 forming the layers 70 which, by superimposition, constitute the treating profile elements.

[0215] The nozzle 80 deposits the wire following XY kinematics, remaining fixed relative to the vertical axis Z, while the supporting plane 90 of the printer 200 moves along the axis Z perpendicular to the plane X-Y or the cylindrical support 91 moves along the axis Z and/or rotates around its axis, according to formation of the layers 70. In further detail, according to a possible embodiment, the surface 90 or the cylindrical support 91 move in the direction of the axis Z as the printing operation proceeds, in order to create the space necessary for the superimposition of further layers 70.

[0216] It should be noted that if a cylindrical support 91 is used to support the plate 22, 32 during deposition of the polymeric material, the nozzle 80 can be moved along an axis X, preferably parallel to the central axis of the cylinder 91.

[0217] The wire printed by the nozzle 80 is deposited on the plate in a substantially fused state, to produce the treating profile elements 25,35 according to the parameters set by the operator via the control unit 110 (block 350).

[0218] Lastly, after completing the printing operation, the treating profile elements 25,35 are left to cool on the plate 22,32 to which they adhere (block 360).

[0219] As described above, the operations for printing the treating profiles of a plate can be repeated for printing profiles, for example complementary profiles, on the second plate.

[0220] Obviously modifications or improvements can be made to the invention as described, dictated by contingent or particular reasons, without departing from the scope of the invention.