A MULTIPLE ROLLER EMBOSSER AND METHOD FOR SELECTING AN EMBOSSING ROLLER

Abstract

The embosser includes two load-bearing structures that are mutually movable to approach and move away from each other. The first load-bearing structure supports a plurality of first embossing rollers that can be selectively brought to an operating position, in which they cooperate with a first pressure roller. The second load-bearing structure supports one or more second embossing rollers cooperating with a second pressure roller. The two support structures can be moved away from each other to allow the selection movement of the first embossing rollers.

Claims

1-17. (canceled)

18. An embosser comprising: a first load-bearing structure, on which a plurality of first embossing rollers is supported, each first embossing roller of said first embossing rollers having a respective rotation axis, wherein the first embossing rollers are rotatably mounted on a movable support, the movable support being movable with respect to the first load-bearing structure; and wherein the movable support is provided with a selection movement with respect to the first load-bearing structure, to selectively arrange in an operating position one of said first embossing rollers mounted on the movable support; a first pressure roller adapted to form a first embossing nip with the one of the first embossing rollers which is in the operating position; wherein the first pressure roller is supported on the first load-bearing structure; a first path for a first ply of web material, said first path extending through the first embossing nip; a second load-bearing structure, on which at least a second embossing roller is rotatably supported; a second pressure roller adapted to form, with said at least a second embossing roller, a second embossing nip; wherein the second pressure roller is supported on the second load-bearing structure; a second path for a second ply of web material extending around the second pressure roller; wherein the first load-bearing structure and the second load-bearing structure are movable relative to each other to take a position of mutual approach and a position of mutual distancing; wherein the position of mutual distancing is such that the first embossing rollers can be moved relative to the first load-bearing structure to perform the selection movement of the movable support.

19. The embosser of claim 18, wherein the movable support includes a carriage translatable orthogonally to the respective rotation axis of each of the first embossing rollers along the first load-bearing structure.

20. The embosser of claim 18, wherein the first embossing rollers are mounted on the movable support overlapping each other, with each of the respective rotation axis of each of the first embossing rollers lying in a vertical plane, and in which the movable support is provided with a movement parallel to said plane.

21. The embosser of claim 18, wherein the first pressure roller is movable, relative to the first load-bearing structure, between a non-operating position and an operating position, to approach and move away from the one of the first embossing rollers in the operating position; and wherein in use, the first pressure roller and the one of the first embossing rollers in the operating position is pressed against each other.

22. The embosser of claim 18, wherein the second pressure roller is movable relative to the second load-bearing structure, to approach or move away from the at least a second embossing roller.

23. The embosser of claim 18, wherein on the second load-bearing structure, at least an additional second embossing roller is rotatably supported.

24. The embosser of claim 23, wherein the second pressure roller is movable to define the second embossing nip selectively with the at least a second embossing roller or with the at least an additional second embossing roller.

25. The embosser of claim 24, wherein the at least a second embossing roller, the at least an additional second embossing roller and the second pressure roller are arranged such that the second pressure roller cooperates with the at least a second embossing roller and the at least an additional second embossing roller, the second pressure roller being supported on movable members which pivot relative to the second load-bearing structure and being arranged between the at least a second embossing roller and the at least an additional second embossing roller.

26. The embosser of claim 25, wherein the second pressure roller is arranged in an intermediate position between the at least a second embossing roller and the at least an additional second embossing roller.

27. The embosser of claim 23, further comprising guide rollers arranged to define the second path of the second ply of web material such that said second path extends alternately around the at least a second embossing roller or the at least an additional second embossing roller.

28. The embosser of claim 18, wherein the first load-bearing structure and the second load-bearing structure are movable relative to each other in a direction orthogonal to rotation axes of the first embossing rollers.

29. The embosser of claim 18, wherein the first load-bearing structure is fixed to a base, and wherein the second load-bearing structure is movable along the base relative to the first load-bearing structure.

30. The embosser of claim 18, further comprising a functional fluid dispenser adapted to cooperate with the one of the first embossing rollers which is in the operating position, to apply a functional fluid to a ply of web material guided around the one of the first embossing rollers which is in the operating position; wherein the functional fluid dispenser is supported by the first load-bearing structure; and wherein the functional fluid dispenser is movable relative to the first load-bearing structure to approach and move away with respect to the one of the first embossing rollers which is in the operating position.

31. The embosser of claim 18, further comprising a laminating roller supported by the second load-bearing structure and adapted to cooperate with the one of the first embossing rollers which is in the operating position and defining with the one of the first embossing rollers which is in the operating position a laminating nip when the first load-bearing structure and the second load-bearing structure are in a position of mutual approach.

32. The embosser of claim 18, wherein in the position of mutual distancing, the first load-bearing structure and the second load-bearing structure form a space therebetween of sufficient width for an operator to pass through.

33. A method for selecting an embossing roller in an embosser, comprising steps of: stopping the embosser; moving a first load-bearing structure and a second load-bearing structure away from each other; moving a movable support, on which a set of first embossing rollers are rotatably mounted, away from the first load bearing structure to remove one of said first embossing rollers from an operating position and bring another one of said first embossing rollers into the operating position; bringing the second load-bearing structure and the first load-bearing structure back together again after bringing said another one of said first embossing rollers into the operating position; restarting the embosser.

34. The method of claim 33, further comprising before moving said one of said first embossing rollers away from the operating position and bringing said another one of said first embossing rollers into the operating position, moving a functional fluid dispenser away from the one of the first embossing rollers which is in the operating position; after bringing the another one of said first embossing rollers into the operating position, bringing the functional fluid dispenser closer to said another one of said first embossing rollers.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The invention will be better understood by following the description and the accompanying drawings, which illustrate an exemplary and non-limiting embodiment of the invention. More particularly, the drawings show:

[0025] FIG. 1 a schematic side view of an embodiment of an embosser in a possible working position;

[0026] FIGS. 1A and 1B enlarged schematic details of portions of a first embossing roller and a second embossing roller of the embosser of FIG. 1;

[0027] FIG. 2 a view similar to the view of FIG. 1 with the embosser in the non-working position;

[0028] FIG. 3 a view similar to the view of FIG. 2, with a different position of the embossing rollers; and

[0029] FIG. 4 a view similar to the view of FIG. 1, with a different position of the embossing rollers and paths of the plies of web material.

DETAILED DESCRIPTION

[0030] FIG. 1 shows a schematic side view of an embodiment of an embosser in one of the several possible operating positions. The embosser, overall indicated with reference numeral 1, comprises a first load-bearing structure 3 and a second load-bearing structure 5, which are movable relative to each other in the manner described below. In the illustrated embodiment, the embosser 1 also has a base 7. In the embodiment shown in the accompanying drawings, the first load-bearing structure 3 is fixed relative to the base, which can be anchored to the ground, while the second supporting structure 5 is movable along the base according to the double arrow f5. The possibility of moving even or only the first load-bearing structure 3 is not excluded. However, the second load-bearing structure 5 is lighter and therefore it is easier to move the latter than the first load-bearing structure 3.

[0031] In the illustrated embodiment, a guide 8 is fixed on the base 7, which can comprise two tracks, one for each of the two sides that form the second load-bearing structure 5. The guide 8 can be associated with a rack with which a toothed wheel 10 meshes, driven by a motor 12, to control the movement according to f5, of reciprocal approaching and distancing between the second load-bearing structure 5 and the first load-bearing structure 3. In other embodiments, other types of actuators may be provided, for example one or more cylinder-piston actuators, or a fixed motor with a threaded rod which engages with a nut screw integral with the second load-bearing structure 5, or other mechanisms adapted to impart the motion according to the double arrow f5.

[0032] As visible in FIGS. 2 and 3, in the embodiment shown, the two supporting structures 3 and 5 can be spaced by forming a space S between them, the size of which can be such as to allow easy passage of an operator between the two load-bearing structures 3, 5, for the purpose of performing maintenance, repair or other operations, for instance.

[0033] In practice, each of the two load-bearing structures 3 and 5 comprises two vertical sidewalls aligned with each other orthogonally to the plane of the figures. Therefore, only one of the sidewalls of each load-bearing structure 3, 5 is visible in the drawings. The other sidewall is removed to show the members that are housed between the two sidewalls.

[0034] As will be described later, various embosser members, and in particular embossing rollers, pressure rollers, laminating rollers, guide rollers, dispensers of adhesive or other functional liquids, and the like, are arranged between the two sidewalls of each load-bearing structure 3, 5.

[0035] In other embodiments, the maximum distance between the two load-bearing structures 3, 5 can be less than that shown in the accompanying drawing.

[0036] A guide 13 is arranged on the first load-bearing structure 3, which may include two guide rails, one for each sidewall forming the first load-bearing structure 3. A carriage or slide 9 forming part of a movable support 11 is sliding along the guide 13. The movable support 11 has a lifting and lowering movement along the guide 13 according to the double arrow f11 (FIG. 2) for the purposes clarified below. The movement according to f11 can be controlled by a motor 15 or a pair of motors 15, one for each sidewall of the first load-bearing structure 3. The motion according to f11 is parallel to a vertical plane on which the rotation axes of first embossing rollers 21 lie, which are mounted overlapping each other on the movable support 11.

[0037] By way of example only, in the illustrated embodiment, motion is transmitted from the motor 15 to the movable support 11 via a threaded rod or a pair of threaded rods 17, one for each sidewall of the fixed structure 3. This does not exclude the possibility of other configurations of the actuator device to move the movable support 11 according to f11. For example, a motor may be arranged on the carriage 9 to drive a pinion, or a pair of pinions, each meshing with a rack, parallel to the respective guide 13, integral with a respective sidewall of the load-bearing structure 3, such that rotation of the motor causes the carriage or slide 9 of the movable support 11 to slide up or down.

[0038] A plurality of seats 19 is arranged on the movable support 11, each of which supports a respective embossing roller 21. Thus, a plurality of first embossing rollers 21 is supported on the movable support 11, and more specifically on the slide or carriage 9 Each embossing roller 21 has its own rotation axis around which it can rotate while being supported by the movable support 11.

[0039] By moving the carriage or slide 9 according to arrow f11, it is possible to selectively bring one or the other of the first embossing rollers 21 into a working position, also referred to in the following as an operating position. The first embossing rollers 21 can be placed in a space between two planes containing the two sidewalls of the first load-bearing structure 3.

[0040] Each first 21 embossing roller comprises a plurality of 21P embossing protuberances on its cylindrical surface, as schematically shown in the enlargement of FIG. 1A.

[0041] By way of example only, three first embossing rollers 21 are provided in the example shown. The number of first embossing rollers 21 may be different and will be at least two. The total number of first embossing rollers 21 may depend, for example, on the height of the first load-bearing structure 3, taking into account that the carriage or slide 9 must move along the structure first load-bearing in such a way that each of the first embossing rollers can be selectively arranged in the operating position.

[0042] In the operating condition of FIG. 1, the first central embossing roller 21 is in the working position, i.e., in the operating position, while the upper embossing roller 21 and the lower embossing roller 21 are in the non-operating position. The embossing roller 21, which is in the operating position, is interfaced with a motorization that brings it into rotation. The motorization, not shown, may include, for example, a motor on axis with the embossing roller 21 in the operating position, to which it is connected via a front coupling. In other embodiments, an off-axis motor may be provided with a belt or gear system, which transmits motion from the motor to the embossing roller 21 that is in the operating position.

[0043] A first pressure roller 23 is also arranged on the first load-bearing structure 3. The first pressure roller 23 is positioned between the two sidewalls of the first load-bearing structure 3.

[0044] The first pressure roller 23 is supported on the first load-bearing structure in such a way that it can move relative to the first embossing roller 21 that is in the operating position. For this purpose, in the illustrated embodiment, the first pressure roller 23 is supported by a pair of movable arms 25, e.g., hinged to the load-bearing structure 3 so as to swing around an oscillation axis 25a. The swinging motion of the first pressure roller 23 can be controlled by an actuator, such as a cylinder-piston 27 or a pair of cylinder-piston actuators, arranged on the two sidewalls of the first load-bearing structure 3. The first pressure roller 23 forms, with the first embossing roller 21 in operating position, a first embossing nip 29.

[0045] One or more guide rollers adapted to define a first path for a first ply of web material V1 are also supported on the first load-bearing structure 3. Specifically, a guide roller is indicated with 31. The first path for a first ply of web material V1 extends through the first embossing nip (29);

[0046] The first pressure roller 23 may have a cylindrical surface coated with a layer of elastically yielding material, such as natural or synthetic rubber, or other suitable material. Thus, pressing the pressure roller 23 against the cylindrical surface of the first embossing roller 21 in the operating position results in the embossing of the first ply of web material V1 passing through the first embossing nip 29, while the first embossing roller 21 in the operating position and the first pressure roller 23 rotate in opposite directions. The first pressure roller 23 may be provided with its own motor. In other currently preferred embodiments, the first pressure roller is drawn into rotation by pressure contact against the first embossing roller 21, which is in the operating position.

[0047] On the first load-bearing structure 3 is additionally mounted a functional fluid dispenser 33. The functional fluid may be, for example, glue, or water or any other liquid adapted to cause, favour or promote the mutual adhesion of several plies of web material fed to the embosser 1.

[0048] In the illustrated exemplary embodiment, the functional fluid dispenser 33 comprises a functional fluid tank 35, an screen roller, also called anilox roller 37, and a cliche roller 39. The screen roller 37 draws functional fluid from the tank 35 and transfers it to the cliche roller 39, which applies it to the first ply of web material V1 at embossing protuberances 1P of the first embossing roller 21 that is in the operating position.

[0049] The tank 35, the anilox roller 37 and the clich roller 39 may be supported on a slide or carriage 41, moving according to the double arrow f41 along guides 43 integral with the first load-bearing structure 3. The movement according to f41 allows the cliche roller 39 to be moved closer to and further away from the embossing roller 21 that is in the operating position.

[0050] On the second load-bearing structure 5, and more precisely between the two sidewalls thereof, a second embossing roller 51 is rotatably supported. The second embossing roller 51 is provided with embossing protuberances 51P, as schematically shown in the enlargement of FIG. 1B. The second embossing roller 51 can be connected to a motorization that brings the second embossing roller 51 into rotation. In some embodiments, the same motorization can bring the first embossing roller 21 that is in the operating position and the second embossing roller 51 into rotation. For example, motion may be transmitted by a gear train, a system of belts and pulleys, or a combination thereof. In other embodiments, separate motors may be provided for the first embossing roller 21 and the second embossing roller 51.

[0051] A second pressure roller 53 supported by the second load-bearing structure 5 can cooperate with the second embossing roller 51. The second pressure roller 53 may be movable with respect to the second load-bearing structure 5. For this purpose, the second pressure roller 53 may be supported by movable arms 55, for example. The arms 55 may be pivoting arms pivoting around an oscillation axis 55a. The swinging motion of the arms 55 can be controlled by a cylinder-piston actuator 57 or a pair of cylinder-piston actuators 57.

[0052] The second pressure roller 53 may be provided with a cylindrical surface coated with elastically yielding material, e.g., natural or synthetic rubber, or other suitable material, to emboss a second ply of web material V2 fed along a second feeding path through an embossing nip formed between the second pressure roller 53 and a second embossing roller as further described below.

[0053] In the embodiment shown, the structure of the embosser 1 is such that the second path of the second ply V2 of web material can extend differently depending on the specific operating condition of the embosser 1, as described below. In the operating condition of FIG. 1, the second path of the second ply of web material V2 extends through a second embossing nip 59 defined between the second embossing roller 51 and the second pressure roller 53.

[0054] In the illustrated embodiment, in addition to the second embossing roller 51 an additional second embossing roller 61 is supported on the second load-bearing structure 5, which may define an additional second embossing nip 62 with the second pressure roller 53. The additional second embossing roller 61 may be provided with embossing protuberances similar to the embossing protuberances 21P and 51P of the first embossing rollers 21 and the second embossing roller 51.

[0055] Advantageously, according to the illustrated embodiment, the second pressure roller 53 is arranged in an intermediate position between the second embossing roller 51 and the further second embossing roller 61. In this way, as will become apparent from the following description, it is possible to selectively bring one or the other of the two embossing rollers 51, 61 to work by simply moving the second pressure roller 53, without the need to move the second embossing roller 51 and the additional second embossing roller 61.

[0056] To achieve high production flexibility, the various embossing rollers in embosser 1 have different embossing patterns, each defined by the arrangement of their respective embossing protuberances. Thus, by appropriately selecting the operating embossing rollers, different embossed products can be produced without disassembling and reassembling the embossing rollers.

[0057] In FIG. 1, the second ply of web material V2 passes along the second path through the second embossing nip 59 between the second pressure roller 53 and the second embossing roller 51.

[0058] Conversely, in the operating condition of FIG. 4, the second ply of web material V2 passes through the additional second embossing nip 62, between the second pressure roller 53 and the additional second embossing roller 61.

[0059] In FIG. 1 the second pressure roller 53 is pressed by the actuator 57 against the second embossing roller 51, while in the condition of FIG. 4, the second pressure roller 53 is pressed by the actuator 57 against the additional second embossing roller 61.

[0060] To enable the feed path of the second ply of web material V2 to be changed, guide rollers indicated by 63, 65, 67 and 69 are supported on the second load-bearing structure. In the operating condition of FIG. 1, the feed path of the second ply of web material V2 is defined by guide rollers 63, 65, while in the operating condition of FIG. 4, the feed path of the second ply of web material V2 is defined by guide rollers 63, 69, 67.

[0061] With the system described so far, it is possible to emboss two plies of web material V1 and V2 and apply a functional liquid to ply V1. A laminating roller 71 can be provided, which can be carried by the second load-bearing structure 5, to bond the two plies of web material V1 and V2. The laminating roller 71 is advantageously movable with respect to the first embossing roller 21 which is in the operating position. For this purpose, in the illustrated embodiment, the laminating roller 71 is supported by arms 73 pivoting about an oscillation axis 73a. The motion is imparted by an actuator or pair of actuators 75. In the illustrated embodiment, the actuator which moves the arms 73 consists of a cylinder-piston actuator.

[0062] The laminating roller 71 can thus be pressed against the first embossing roller 21 which is in the operating position, thereby defining a laminating nip 77 therewith. The path of the first ply of web material V1 and the path of the second ply of web material V2 join in the lamination nip 77 so that the pressure exerted by the laminating roller 71 against the first embossing roller 21 in the operating position causes the plies of web material V1 and V2 to join, thus forming the embossed multi-ply web material N that exits the embosser 1.

[0063] In other embodiments, the laminating roller 71 can be omitted, or made inoperative, and the additional second embossing roller 61 can be pressed against the first embossing roller 21 that is in the operating position, such as by bringing the embossing protuberances of two embossing rollers to press against each other or at a distance less than the thickness of the web materials V1 and V2, to cause the plies of web materials V1 and V2 to adhere to each other, in an arrangement known in the art as tip-to-tip.

[0064] As can be easily understood from the accompanying drawings and the above, the structure of embosser 1 allows for the selection of one or the other of first embossing rollers 21, bringing the desired one to the operating position, or working position. By way of example, in FIG. 1 the first embossing roller 21, which is in the intermediate position (i.e., center roller 21) is in working position. In FIG. 4 the topmost embossing roller 21 is in working position. Similarly, in the illustrated embodiment it is possible to select either one or the other of the second embossing rollers 51, 61. In FIG. 1 the second embossing roller 51 is in operation. In FIG. 4 the further second embossing roller 61 is in operation.

[0065] To change the operating condition of the embosser 1, for example, to change embossing roller 21 which is in the working position, it is sufficient to move the second load-bearing structure 5 away from the first load-bearing structure 3, as shown in the passage from FIG. 1 to FIG. 2. In addition, the functional liquid dispenser 33 is moved away from the embossing roller 21 that is in the working position, and the first pressure roller 23 and the laminating roller 71 can be moved away from the first embossing roller 21 that is temporarily in the working position. Once this condition has been reached (FIG. 2), it is possible to translate the movable support 11 to change the first embossing roller 21. In the example shown, moving from FIG. 2 to FIG. 3 the first embossing roller 21, which is in the highest seat on the movable support 11, is brought to the operating position by moving the movable support downward. The path of the first ply of web material V1 is also changed.

[0066] In the example shown, moving from the operating condition in FIG. 1 to the operating condition in FIG. 4, also the path of the second ply of web material V2 has been changed, so as to bring the embossing roller 61 to work in place of embossing roller 51. This modification requires the movement of the second pressure roller 53.

[0067] The embosser 1 is then brought back to work by bringing the first load-bearing structure 3 and the second load-bearing structure 5 closer together again.

[0068] Embodiment have been described herein and illustrated in the accompanying drawings for illustrative purposes. Those skilled in the art will understand that various modifications, omissions or additions may be contemplated with respect to what is specifically described herein, without departing from the scope of the invention as defined in the following claims.

[0069] For example, in the embodiment shown, it is provided that the second load-bearing structure 5 supports two second embossing rollers 51 and 61. This is particularly advantageous, because it greatly increases the possible working configurations of the embosser 1. In currently less preferred, but simpler and more cost-effective embodiments, only one second embossing roller may be provided.

[0070] As another example, it is possible to support the tank 35, the anilox roller 37, and the clich roller 39 no longer on a movable structure along guides 43, but by means of a pivoting structure hinged to the load-bearing structure 3, the pivoting movement of which allows the cliche roller 39 to be moved closer to and further away from the embossing roller 21 that is in the operating position.

[0071] Additionally, when one of the first embossing rollers 21 is to be selected and thus the carriage or slide 9 is to be moved according to arrow f11, it is not necessary to distance the two load-bearing structures 3 and 5 to form a space S between them large enough for an operator to pass through, but it is possible to just move the two load-bearing structures 3 and 5 by a space S sufficient for moving the carriage or slide 9. On the other hand, it is possible to space the two load-bearing structures 3 and 5 by a space S even just to carry out maintenance without selecting one of the first embossing rollers 21.