METHOD AND APPARATUS FOR THE PRODUCTION OF A PLANAR CUSHIONING MATERIAL MADE OF PAPER, AND A CUSHIONING MATERIAL

Abstract

An application mechanism is used to apply water to wet paper in a process for producing planar cushioning material and filler material made of paper having a spatial structure with embossing on each side. The water can be applied to the paper like ink, so as to keep it sufficiently moist for the embossing process. Likewise, it is possible to use ink to apply a two-dimensional imprint, whereby sufficient wetting can also take place, but at the same time an optical effect is achieved.

Claims

1. A method for the production of a planar cushioning material made of paper, wherein the paper is wetted with a liquid, and, preferably in the form of endless paper (13), passed through between two embossing means of an embossing press (6), and the embossing means have elevations and cavities that alternate with one another, as embossing elements, which are complementary to one another, in each instance, in such a manner that the embossing means engage into one another as a matrix (7) and a patrix (8), wherein the wetting with the liquid takes place by means of an application mechanism (3), with which the liquid is applied or coated over the full area or in a surface pattern, in a step that precedes embossing.

2. The method according to claim 1, wherein the wetting takes place with ink in one or more colors and/or with water.

3. The method according to claim 1, wherein the liquid is heated using a heating device, preferably a flow-through heater.

4. The method according to claim 1, wherein the embossing means are heated.

5. The method according to claim 1, wherein the paper is a long-fiber paper, preferably recycled paper.

6. The method according to claim 1, wherein the paper is crumpled in a crumpling mechanism (2) or folded in a folding mechanism before or after being printed, but before being embossed in the embossing press (6).

7. The method according to claim 6, wherein the paper is rolled after the crumpling process or folding process, afterward imprinted, and finally embossed.

8. The method according to claim 1, wherein the embossing elements are alternating spherical calottes (9) and complementary spherical cavities (10), or complementary embossing elements in the form of pyramids, truncated pyramids, cones, truncated cones or cylinders.

9. The method according to claim 1, wherein an adhesive substance is applied to the paper with the application mechanism (3) or a further application mechanism that follows the embossing press, in particular a gluing mechanism, wherein in a subsequent connection step, two layers embossed on one side, made of the planar cushioning material, are connected with one another, preferably with mirror symmetry, causing inclusion of a space between two corresponding convexities (15).

10. The method according to claim 9, wherein the gluing takes place over the full area or along one or more edges, preferably along three edges, forming a pocket.

11. The method according to claim 9, wherein connecting the two layers of planar cushioning material takes place with the interposition of at least one further paper layer.

12. An apparatus for the production of a planar cushioning material made of paper, comprising a paper feed that charges an embossing press (6) with the paper, preferably in the form of endless paper (13), wherein the paper is passed between two embossing means in the embossing press (6), which means have alternating elevations and cavities as embossing elements and are complementary to one another, wherein the embossing press (6) is preceded by an application mechanism (3) on which the paper can be wetted with a liquid, over its full area or in a surface pattern, wherein the liquid is ink or printing ink in one or more colors and water, or exclusively water.

13. The apparatus according to claim 12, wherein heatable liquid tanks (5) are assigned to the application mechanism (3).

14. The apparatus according to claim 12, wherein a line (4) for bringing the liquid from a supply network is assigned to the application mechanism (3).

15. The apparatus according to claim 14, wherein a flow-through heater is assigned to the line (4).

16. The apparatus according to claim 12, wherein heating elements (12) are assigned to the embossing means.

17. The apparatus according to claim 12, wherein a crumpling mechanism (2) for crumpling and/or a folding mechanism for folding the paper is arranged between the paper feed and the application mechanism (3) or between the application mechanism (3) and the embossing press (6).

18. The apparatus according to claim 12, wherein the embossing means are embossing plates or embossing rolls.

19. A planar cushioning material having a paper structure, comprising a first paper layer embossed on at least one side, which has shaped, preferably spherical embossings, wherein the paper structure has at least one second paper layer embossed on at least one side, which is inextricably connected with the first paper layer, with the interposition of at least one adhesive substance layer.

20. The cushioning material according to claim 19, wherein the first paper layer and the second paper layer are glued to one another over their full area or along one or several edges, preferably along three edges, forming a pocket.

21. The cushioning material according to claim 19, wherein a flat intermediate layer is interposed between the at least one first paper layer and the at least one second layer.

22. The cushioning material according to claim 19, wherein the embossings of the at least one first and the at least one second paper layer are arranged as a mirror image of one another, and supplement one another to form a cavity, if applicable one through which an intermediate layer passes.

23. The cushioning material according to claim 19, wherein the first paper layer and the second paper layer have different materials and/or different densities.

24. The cushioning material according to claim 19, wherein the first paper layer and the second paper layer are colored in different colors and/or provided with an imprint in different colors.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Other objects and features of the invention will become apparent from the following detailed description considered in connection with the accompanying drawings. It is to be understood, however, that the drawings are designed as an illustration only and not as a definition of the limits of the invention.

[0039] In the drawings,

[0040] FIG. 1 shows an apparatus for the production of a cushioning material made of endless paper, having multiple processing stations, in a schematic representation;

[0041] FIG. 2 shows an endless paper processed to form a cushioning material, in a schematic top view from above; and

[0042] FIG. 3 shows an endless paper passed through an embossing press and processed, in a schematic representation from the side.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0043] FIG. 1 shows a schematic representation of a production process for the production of a cushioning material from a paper. The paper is at first held on a paper drum 1 as the raw material, and is present as an endless paper 13. This paper is passed from the paper drum 1 first through a crumpling mechanism 2. In the crumpling mechanism 2 the endless paper 13 is at first compressed from the side, so that it develops folds and during this process assumes a narrower format. Using a roll within the crumpling mechanism 2, the endless paper 13 that has developed folds is pressed flat again, wherein it becomes irregularly multi-layered in certain locations and thereby it becomes more stable.

[0044] In a next step the endless paper 13 pre-treated in this way is now passed to an application mechanism 3. Here imprinting with one or more different liquids onto the paper can take place. First of all, it is possible to imprint a surface pattern onto the endless paper 13 in a conventional manner, which pattern, however, aside from the optical effect, above all has the background of saturating the paper with liquid, so that this liquid can penetrate into the fibers of the paper. In particular when using recycled paper, this saturation results in advantages, since the paper could tear in the next step, during textured embossing, without wetting. Wetting with water can also take place alternatively or supplementally in the application mechanism 3, however, which water can be applied to the paper in the application mechanism 3, analogous to ink, by way of the outlet nozzles. If necessary, the water can also be supplied to liquid tank 5 by way of a line 4 from a supply line. Furthermore, it is possible, in this connection, to heat the water using a flow-through heater, so that penetration of the paper is improved on the basis of the heat.

[0045] The endless paper 13 that has been pretreated with liquid in this manner and has now been moistened is subsequently passed through between two embossing plates of an embossing press 6, which is shown in greater detail in FIG. 2.

[0046] The embossing plates are structured as a matrix 7 and a patrix 8, so that they engage into one another in a complementary manner and in doing so clamp the paper, in particular the endless paper 13, between them from both sides. In this regard, the endless paper, the fibers of which have already been softened by the preceding printing, are newly pressed and during this process are heated and baked using the heating means or elements 12 that pass through matrix 7 and patrix 8. The moisture is at least partially driven out during pressing, and the endless paper is embossed to form an extensively rigid spatial structure. Spherical calottes 9 on the surface of the embossing plates (matrix 7, patrix 8) cause alternate convexities 15 and concavities 16 in the surface of the paper, while they are supported with spherical cavities 10 in the other embossing plate (patrix 8, matrix 7), in each instance. The resulting cushioning material becomes many times thicker as a result, and is excellently suited as a filler material due to its flexibility, and for absorbing impacts and shocks to protect an object that it is wrapped around. Using a perforation blade 11, a perforation line 14 can be added to the endless paper. Cutting of individual sheets can also take place here.

[0047] This processing is particularly shown once again in FIG. 3. The endless paper 13 has such perforation lines 14, on both sides, in a section that is pressed between the embossing plates (matrix 7 and patrix 8), and between these lines is alternately provided with convexities 15 and concavities 16. If the liquid used is ink, the endless paper 13 furthermore has a full-area imprint or a surface pattern, which additionally upgrades the endless paper 13.

[0048] What have been described above are therefore a method and an apparatus for the production of a planar cushioning material, which simplifies wetting of the paper and additionally upgrades the cushioning material, as well as the use of an application mechanism for the production of such a cushioning material, and the resulting cushioning material in this regard.

[0049] Although only a few embodiments of the present invention have been shown and described, it is to be understood that many changes and modifications may be made thereunto without departing from the spirit and scope of the invention.

REFERENCE SYMBOL LIST

[0050] 1 paper drum [0051] 2 crumpling mechanism [0052] 3 application mechanism [0053] 4 line [0054] 5 liquid tank [0055] 6 embossing press [0056] 7 matrix [0057] 8 patrix [0058] 9 spherical calotte [0059] 10 spherical cavity [0060] 11 perforation blade [0061] 12 heating element [0062] 13 endless paper [0063] 14 perforation line [0064] 15 convexity [0065] 16 concavity