Embossing machine-mounting machine unit with functional liquid applicator and method

Abstract

The embossing machine-mounting machine unit comprises: an embossing roller (21) which is supported on a stationary support structure (45); and an applicator roller (61) adapted to apply glue on the embossed web-like material conveyed around the embossing roller (21). The applicator roller (61) is carried by a slide (41) which is movable relative to the support structure (45) to move towards and away from the embossing roller (21). The embossing machine-mounting machine further comprises: an actuation mechanism (51, 67) adapted to command side-by-side adjacent and distant movement of the slider (41) and the applicator roller (61) relative to the embossing roller (21); and position detection means (69) adapted to detect a relative position between the slider and the stationary support structure. The detection device (75) is adapted to detect a contact state between the applicator roller (61) and the embossing roller (21). A method for positioning the applicator roller (61) relative to the embossing roller (21) is also described.

Description

Embossing Machine-Mounting Machine Unit and Method with Functional Liquid Applicator Technical Field

[0001] This disclosure relates to the field of machinery for converting web-type materials. The embodiments disclosed herein particularly relate to paper conversion machines, and especially to machines for converting tissue paper, kitchen paper, facial tissues, napkins, and similar products.

[0002] Specifically, this paper discloses improvements to embossing machines or embosser-laminator units for processing multi-layer web materials, especially multi-layer web materials made of thin paper. Background Technology

[0003] Products made of cellulose materials (e.g., toilet paper rolls, kitchen paper, facial tissues, and napkins) are produced using cellulose web materials, which are typically thin paper, supplied from one or more master rolls from a continuous production machine.

[0004] In some cases, the master roll is unwound and rewound into a roll or spool with a smaller diameter and / or axial dimension, and then fed into a so-called slitting rewinder or rewinder.

[0005] Rolls from continuous paper machines or slitting and rewinding machines are intended to be fed to conversion lines for the production of consumer goods, such as rolls of napkins, facial tissues, toilet paper, kitchen paper, and similar products.

[0006] This conversion line typically includes an unwinding station adapted to unwind one or more rolls of cellulose web material. One or more layers of the cellulose web material are fed along the same path or along separate paths to a machine located downstream of the unwinding station along the conversion line to undergo one or more conversion operations in order to ultimately obtain a product intended for sale and consumption.

[0007] Typically, the conversion line includes at least one embossing unit downstream of the unwinding station, which performs an embossing operation on one or more layers forming a continuous cellulose web-like material. Embossing consists of permanently deforming the cellulose web-like material by passing it through an embossing clamp defined between an embossing roller and a pressure roller, both of which have embossing protrusions. The embossing roller is typically made entirely of steel, or at least its outer sheath is made of steel or other hard material and has the embossing protrusions. The pressure roller is a roller that may have a hard, engraved outer surface, wherein the engravings are complementary to the embossing protrusions of the embossing roller. In a more general embodiment, the pressure roller has a smooth outer surface, where smooth means generally free of engravings or protrusions formed by a yield layer, preferably of an elastically yielding material.

[0008] In use, the pressure roller and the embossing roller press against each other at the embossing clamping section. If the pressure roller is coated with a yielding material, the pressure between the embossing roller and the pressure roller causes the embossing protrusions of the embossing roller to penetrate at least partially into the yielding coating of the pressure roller. Simultaneously, the embossing roller and the pressure roller rotate in opposite directions at substantially equal circumferential speeds. This causes permanent deformation of the web-like material, which is fed through the embossing clamping section at a forward speed substantially equal to the circumferential speeds of the embossing roller and the pressure roller.

[0009] In some cases, the conversion line may include an embossing machine unit having a single embossing roller and a single pressure roller forming a clamping portion through which web-like material passes, the web-like material being composed of one or more layers of cellulose fibers.

[0010] More commonly, the conversion line may include an embossing machine unit with more than one embossing roller, each of which engages with a corresponding pressure roller to emboss two layers of cellulose fibers, each of which may be made of one or more layers of cellulose fibers. This type of embossing machine unit is more specifically referred to as an "embossing-mounting machine unit" because it includes a mounting system at which two (or more) individually embossed layers are bonded together by applying a functional fluid, by means of mechanical interlayer bonding, or otherwise. This mounting system may, for example, include a clamping portion defined between two opposing and counter-rotating embossing rollers or between the embossing roller and the mounting roller. The result is the formation of a multilayered embossed cellulose web material.

[0011] In some embodiments, the layer bonding in the embossing-mounting unit occurs using an adhesive, which may be in the form of an aqueous suspension. More generally, a functional fluid, typically a functional liquid, may be used. In some cases, the functional fluid may simply be water, without the addition of additional adhesive. This functional fluid has the function of promoting the formation of hydrogen bonds between the fibers of the cellulose layer. Therefore, in this context, "functional fluid" refers to a general fluid that, when applied as described below, facilitates the bonding of the layers. In this sense, the functional fluid is an adhesive, and therefore (unless otherwise stated) the term adhesive in this specification and claims refers to a fluid that is generally liquid, acting as a functional fluid adapted to achieve, assist in, or promote the bonding of the cellulose layers.

[0012] The embossed cellulose web material exiting the embossing unit undergoes further processing in a conversion station downstream of the embossing unit. For example, it is wound into logs, i.e., logs with a diameter equal to the diameter of the finished roll and an axial length that is a multiple of the axial dimension of the finished roll. These logs are then cut into individual rolls, which are subsequently packaged for transport and distribution. In this case, a rewinding machine is located in the conversion station.

[0013] In other conversion lines, the conversion station is located downstream of the embossing unit. The conversion station includes an interfolding machine or a cutting and folding machine to produce paper towels, napkins, or kitchen paper that can be interfolded together (in the case of an interfolding machine).

[0014] Downstream of the embossing clamp formed by the embossing roller and the corresponding pressure roller, a functional fluid is typically applied to the cellulose layer after it has been embossed and while still in contact with the corresponding embossing roller. The application of adhesive or more generally, the functional fluid, is achieved via an applicator roller, which may have interchangeable plates adapted to allow the functional fluid to be applied, for example, according to a given pattern, onto the embossed layer and, more precisely, onto at least some of the embossed protrusions of the layer. The functional fluid is typically dispensed onto the applicator roller by a metering roller (e.g., an anilox roller), which is wetted by the functional fluid through continuous rotational contact with the applicator roller and by drawing functional fluid from a reservoir.

[0015] To optimize the application of the functional fluid, it is recommended to maintain a precise and consistently defined distance between the applicator roller and the embossing roller, specifically the embossing protrusions that mate with the applicator roller. To this end, a functional fluid application clamping portion or adhesive clamping portion is defined between the applicator roller and the embossing roller. The size of this clamping portion is equal to or slightly smaller than the thickness of the cellulose material layer at the embossing protrusions, in order to ensure minimal pressure contact between the applicator roller and the embossed layer.

[0016] When the embossing roller, the applicator roller, or a portion thereof (e.g., a plate) is replaced, the relative distance between the envelope surface of the embossing protrusions of the embossing roller and the envelope surface of the applicator roller needs to be precisely adjusted.

[0017] EP-A-2815815 discloses an embossing machine-mounting machine with an adhesive applicator unit. This adhesive applicator unit includes an actuator that pushes an adhesive applicator roller against an embossing roller, driving a cellulose layer around the embossing roller. This known device is configured to continuously control the pressure applied by the adhesive applicator roller to the embossing roller during the processing of cellulose web-like materials.

[0018] The purpose of the subject matter disclosed herein is to provide an embossing machine-mounting unit and an adjustment method that allows for simple and automatic adjustment of the relative positions between the applicator roller and the embossing roller to optimize the operation of the embossing machine-mounting unit in terms of the correct application of adhesive or functional fluid. Summary of the Invention

[0019] According to one aspect, this document discloses an embossing machine-mounting unit (hereinafter referred to as the "embossing machine unit") comprising an embossing roller supported on a stationary support structure and a dispenser for applying a functional fluid to a web-like material guided around the embossing roller. The dispenser includes an applicator roller adapted to apply a functional fluid (e.g., adhesive) to the embossed web-like material guided around the embossing roller. The applicator roller is carried by a slider movable on a guide defining a prism or rotational joint to allow movement of the slider relative to the support structure, thereby moving the applicator roller toward and away from the embossing roller. The embossing machine further includes: an actuation mechanism adapted to command the approach and away movements of the slider and the applicator roller relative to the embossing roller; and a position detection device adapted to detect the relative position between the slider and the stationary support structure. The detection device is adapted to detect the contact state between the applicator roller and the embossing roller.

[0020] An embossing machine or embossing machine-mounting unit configured in this way can perform a positioning cycle of the applicator roller relative to the embossing roller, in which a zero position, i.e., a reference position, is determined, which is typically the position where the applicator roller and the embossing roller are in contact with each other. Before starting the embossing machine, the applicator roller is brought from this position to a position at a predetermined distance from the embossing roller by means of an actuator.

[0021] In some embodiments, the position detection device is carried by a slider or a stationary support structure. In this case, the embossing machine unit includes a first stop that is fixed relative to the stationary structure or slider. The position detection device is adapted to cooperate with the first stop to measure the relative movement between the slider and the stationary support structure. In other embodiments, the position detection device may be integrated into a first actuator. In other embodiments, the position detection device may be an optical device, wherein a light source generates a light beam that strikes a detector, and the detector generates a photocurrent based on the location where the light beam strikes the detector. In other embodiments, the position detection device may include a laser device or a camera.

[0022] The embossing machine unit may also include a control unit functionally connected to the first actuator, the position detection device, and the detection equipment. Functional connection means that the control unit receives signals from the detector or transducer device and sends commands to the actuator. This control unit can be programmed to command the slider to begin moving away from the embossing roller from a zero position (i.e., a reference position), the zero position being defined as the position where the applicator roller and the embossing roller are in contact.

[0023] In some embodiments, the detection device for detecting the contact state between the applicator roller and the embossing roller may include at least one force gauge adapted to detect the force applied to the applicator roller by the contact between the applicator roller and the embossing roller. Preferably, two force gauges are provided, which are associated with, for example, a bearing supporting the applicator roller.

[0024] In other embodiments, the detection device for detecting the contact state between the applicator roller and the embossing roller may include a detector that causes the applicator roller to stop moving toward the embossing roller when the actuator is activated to command the movement of the slider carrying the applicator roller toward the embossing roller.

[0025] In a particularly simplified embodiment, the actuation mechanism may include a single actuator that performs all approach and departure movements between the applicator roller (and the slide carrying it) and the embossing roller. In this case, an electric actuator may be used, for example. In this case, the position detection device may be integrated into the single actuator.

[0026] In a more efficient embodiment, the actuation mechanism of the embossing machine-mounting unit may include a first actuator, for example configured as a thrust actuator, adapted to bring a slider into a position close to the embossing roller. The actuation mechanism also includes a second actuator adapted to command controlled movement of the slider, and thus the applicator roller, relative to the embossing roller. In practice, in this case, the embossing machine-mounting unit includes two actuators. The first actuator (thrust actuator) commands movement of the slider toward and away from the embossing roller to push the slider to and hold it in a stop position. The away movement actuated by the first actuator can, for example, be used to completely move the functional fluid dispenser away from the first embossing roller. The second actuator is used to apply controlled approach and away movement of the slider, and thus the applicator roller, relative to the embossing roller, which begins from the approach position reached by the first actuator.

[0027] In this embodiment, a second stop may be provided, which is supported by a sliding member or a stationary support structure and cooperates with a third stop, which is also supported by a stationary structure or a sliding member. A second actuator is adapted to command the movement of the second stop, which causes the sliding member to move relative to the stationary support structure when the second stop contacts the third stop.

[0028] The second actuator can be functionally connected to the control unit, and the control unit is programmed to command the slider to move away from the embossing roller in a controlled manner by means of the second actuator. The controlled away movement starts from a zero position (i.e., a reference position), which can be determined by the previous step of the second actuator commanding the applicator roller to move towards the embossing roller in a controlled manner.

[0029] Other advantages and embodiments of the embossing machine unit disclosed herein are set forth in the appended claims and will be described in detail below with reference to the accompanying drawings.

[0030] Depending on the aspect, this document also discloses a method for adjusting the relative position between an embossing roller and an applicator roller in an embossing machine-mounting machine, wherein the embossing roller is supported by a stationary support structure and the applicator roller is supported by a sliding member capable of moving relative to the stationary support structure. The method includes the following steps: bringing the applicator roller close to the embossing roller until the applicator roller contacts the embossing roller; detecting the contact by means of a detection device and setting the position of the applicator roller when it contacts the embossing roller as a reference position; moving the applicator roller away from the embossing roller and measuring the movement by means of a position detection device; and stopping the applicator roller when the position detection device detects that a predetermined distance from the reference position has been reached.

[0031] The contact between the embossing roller and the applicator roller can be detected by at least one force gauge or by a position detection device (i.e., an encoder), the signal of which allows identification of when the movement of the applicator roller toward the embossing roller stops due to the mutual contact between the two. Attached Figure Description

[0032] An embodiment is shown in the accompanying drawings, wherein:

[0033] Figure 1 shows the embossing machine-mounting machine unit;

[0034] Figure 1A shows an enlarged schematic diagram of the details marked A in Figure 1;

[0035] Figure 1B shows an enlarged schematic diagram of the details marked B in Figure 1;

[0036] Figure 2A shows details of the embossing roller and functional fluid distributor in the first position; and

[0037] Figure 2B shows details of the embossing roller and the functional fluid distributor in the second position. Detailed Implementation

[0038] In the embodiment shown in Figure 1, an embossing machine-mounting machine unit 5 (hereinafter referred to as the "embossing machine unit") is illustrated. The embossing machine-mounting machine unit includes a first embossing roller 21, which has embossing protrusions 21P (Figure 1A) and cooperates with a first pressure roller 23. The first pressure roller may have an outer surface 23A made of a coating of a yielding material, particularly an elastic yielding material such as rubber. The embossing machine-mounting machine unit 5 also includes a second embossing roller 25, which has embossing protrusions 25P (Figure 1B) and cooperates with a second pressure roller 27. The second pressure roller may have an outer surface 27A made of a coating of a yielding material, particularly an elastic yielding material such as rubber.

[0039] In the illustrated embodiment, the first pressure roller 23 is supported at its end by a corresponding pivot arm 20, which is hinged to a fixed support structure 45 via a hinge 22. An actuator 24 (e.g., a pair of pneumatic or hydraulic cylinder-piston actuators) acts on the pivot arm 20 to press the pressure roller 23 against the embossing roller 21.

[0040] Similarly, in the illustrated embodiment, the second pressure roller 27 is supported at its end by a corresponding pivot arm 26, which is hinged to a fixed support structure 45 via a hinge 28. An actuator 30, such as a pair of pneumatic or hydraulic cylinder-piston actuators, acts on the pivot arm 26 to press the pressure roller 27 against the embossing roller 23.

[0041] A first embossing clamping portion 31 is formed between the first embossing roller 21 and the first pressure roller 23, into which the first layer V1 is fed. A second embossing clamping portion 33 is formed between the second embossing roller 25 and the second pressure roller 27, into which the second layer V2 is fed. The two embossed layers are bonded together in a mounting clamping portion, which can be formed between the first embossing roller 21 and the second embossing roller 25, for example, in the case of a so-called tip-to-tip embossing unit. Alternatively, as shown in FIG1, the embossed layer V2 can be detached from the second embossing roller 25 and guided around the first embossing roller 21 so as to pass together with layer V1 through the mounting clamping portion 36 formed between the first embossing roller 21 and the mounting roller 35.

[0042] In the illustrated embodiment, the mounting roller 35 is supported at its end by a corresponding pivot arm 34, which is hinged to a fixed support structure 45 via a hinge 38. An actuator 40 (e.g., a pair of pneumatic or hydraulic cylinder-piston actuators) acts on the pivot arm 34 to press the mounting roller 35 against the embossing roller 21.

[0043] To bond the two layers V1 and V2 together, a functional liquid (e.g., glue) can be used. The functional liquid is applied to layer V1 while layer V1 is being guided around the first embossing roller 21 and after undergoing permanent deformation in the embossing clamping portion 31, it is bonded to the first embossing roller, such that embossed protrusions are formed in layer V1 and the embossed protrusions are attached to the embossed protrusions 21P of the first embossing roller 21.

[0044] To apply the functional liquid, a dispensing unit is provided for dispensing adhesives or other functional liquids (e.g., water alone). In the following text, the dispensing unit for adhesives or other functional fluids will be simply referred to as a “dispenser” or “dispensing unit” and is generally designated 37 in Figure 1.

[0045] The main components of the dispenser 37 are shown in more detail in Figures 2A and 2B.

[0046] In the embodiments described herein, the dispenser 37 includes a slider 41 guided along a guide 43, which can be integrated with a stationary support structure 45 supporting the embossing machine-mounting machine unit 5. The slider 41 can engage with the guide 43 via a skid 47. In other embodiments, the dispenser assembly 37 can also be constrained to the stationary support structure 45 via a rotating joint, so that the dispenser unit 37 can rotate about a rotation axis and move toward and away from the first embossing roller 21.

[0047] In the illustrated embodiment, the slider 41 is divided into two slider parts, more precisely, a first slider part 41A and a second slider part 41B, the purpose of which will become clear below. In other embodiments not shown, the slider 41 may be integral. The mutual distance between the first slider part 41A and the second slider part 41B can be adjusted by stops 49A and 49B. One of these stops is mounted on one of the two slider parts 41A and 41B and can be fixed relative to that slider part. The other stop is carried by the other slider part and can be adjusted relative to the slider part on which the stop is mounted. The mutual distance between the two slider parts 41A and 41B can be adjusted by acting on the adjustable stop (stop 49A in the illustrated example).

[0048] In the illustrated embodiment, two sliding portions 41A, 41B are pushed toward embossing rollers 21, 25 by means of a first actuator. In this embodiment, the first actuator may include a linear actuator or a pair of linear actuators, i.e., linear actuators are located on each side of the sliding portion 41. Each linear actuator is designated 51. For example, the linear actuator or each linear actuator 51 may be a cylinder-piston actuator. Each linear actuator 51 may be constrained to the sliding portion 41A and a point 53 integrated with the stationary support structure 45. By acting on the linear actuator 51 and commanding its retraction, the sliding portion 41 is pushed toward the embossing rollers 21, 25, reaching a position defined as described below. In the example shown, if the slider 41 is divided into two parts 41A and 41B and one or more actuators 51 are anchored to the slider part 41A that is furthest from the embossing rollers 21 and 25, the two slider parts 41A and 41B can be moved to the position closest to the embossing rollers 21 and 25, while the slider part 41A is pushed against the slider part 41B due to the action of the stops 49A and 49B.

[0049] Dispenser 37 may include a metering roller (hereinafter referred to as an anilox roller, denoted as 57) that draws functional liquid (e.g., adhesive) from a storage tank or other functional liquid source (denoted as 59). Anilox roller 57 transfers the functional liquid to applicator roller 61, which may be equipped with interchangeable plates (not shown in detail). Applicator roller (or plate roller) 61 is configured to transfer the functional liquid received from anilox roller 57 to an embossed layer V1, and more precisely, to at least some of the embossed protrusions of this layer V1 that engage with the embossed protrusions 21P of the first embossing roller 21. For this purpose, applicator roller 61 is positioned such that its outer surface is at a distance from the head of the embossed protrusion 21P, said distance being equal to or preferably less than the thickness of layer V1 at the embossed protrusion 21P, to which anilox roller 57 meterly applies the functional liquid. This distance is adjusted as described below.

[0050] The system, which includes two sliding parts 41A and 41B and stops 49A and 49B, combined with a linear actuator 51, allows adjustment of the distance between the axis 61A of the applicator roller 61 and the axis 57A of the anilox roller 57 (acting on the adjustable stop 49A). Thus, by acting on the stop 49A, the amount of functional liquid transferred from the anilox roller 57 to the applicator roller 61 can be quantified.

[0051] In other embodiments not shown, the slider 41 may be integral and the distance between axes 57A and 61A may be adjusted, for example, by assuming that the anilox roller 57 is supported by a support that is adjustable relative to the slider 41.

[0052] To set the correct position of the applicator roller 61 relative to the embossing roller 21, a second actuator can be provided. This second actuator adjusts the position of a movable stop that engages with a corresponding fixed stop. By bringing these movable and fixed stops into contact and moving the movable stops, the distance between the applicator roller 61 and the first embossing roller 21 is adjusted, thereby ensuring that one of the two stops is integrated with the sliding member 41 (more precisely, the sliding member portion 41B), while the other stop is integrated with the stationary support structure 45.

[0053] In the illustrated embodiment, a fixed stop 63 is envisioned, which is integrated with the stationary support structure 45 and cooperates with a movable stop 65, which is supported by a slider 41, or more precisely by a portion 41B of the slider 41.

[0054] In the illustrated embodiment, the movable slider 65 is controlled by a second actuator 67. In some embodiments, the second actuator 67 may be an electric actuator. The double-headed arrow f65 indicates the movement applied by the actuator 67 to the stop 65. The arrangement of the actuator 67 and the stops 63, 65 may be dual, with one set on each side of the slider 41. In other embodiments, a single actuator 67 and a single stop 63, 65 are provided.

[0055] The arrangement of the stop and the actuator can also be interchanged. In this case, the fixed stop is integrated with the slider 41 and more precisely with the slider portion 41B, and is "fixed" in the sense that the fixed stop does not move relative to the slider that carries it. The movable slider can be carried by the stationary support structure 45 and is "movable" in the sense that it moves relative to the stationary support structure 45 under the command of the actuator 67.

[0056] In both cases, as long as the movable stop 65 and the fixed stop 63 remain in contact and an actuator connected to the movable stop is applied, the sliding member 41 (more precisely, the sliding member portion 41B) can be moved in a controlled manner relative to the stationary support structure 45 and therefore relative to the first embossing roller 21. Because the axis 61A of the applicator roller 61 is in a fixed position relative to the sliding member 41 (more precisely, relative to the sliding member portion 41B), the distance between the cylindrical surface of the applicator roller 61 and the cylindrical surface of the first embossing roller 21 can be adjusted by means of the actuator 67. The cylindrical surface of the first embossing roller 21 is actually the surface that envelops the embossing protrusions 21P. If the heights of the embossing protrusions 21P are not the same, the cylindrical surface of the first embossing roller 21 should be understood as the enveloping surface of the taller embossing protrusion.

[0057] The above arrangement can be associated with a detection device that detects the relative position between the slider 41 (more specifically the slider portion 41B) and the embossing roller 21, that is, the relative position between the slider 41 and the stationary support structure 45.

[0058] In the illustrated embodiment, the position detection device includes an encoder. The encoder may be associated with actuator 67, for example, the encoder may be integrated into the actuator. Conversely, in the illustrated embodiment, encoder 69 is disposed outside actuator 67 and carried by slider 41, and more precisely, the encoder is integrated with slider portion 41B. In some embodiments, encoder 69 may cooperate with fixed stop 71. In this embodiment, fixed stop 71 is integrated with stationary support structure 45. For example, stop 71 may be integrated with or formed integrally with stop 63. In other embodiments, the position detection device may include a sensor or transducer adapted to measure distance, even without contact, such as a capacitive or eddy current system.

[0059] In other embodiments, the encoder 69 may be carried by a stationary support structure 45, while the stop 71 may be integrated with the slider 41 (more precisely, integrated with the slider portion 41B).

[0060] Using an encoder integrated into actuator 67 or located externally to actuator 67 and cooperating with the corresponding stop 71 can have significant advantages, as this constitutes a simple device for detecting the position of slider 41 and applicator roller 61 relative to the first embossing roller 21. However, other position detection devices or transducers can also be used. For example, a capacitive sensor can be provided. In some embodiments, a laser device can be provided, wherein the transmitter / receiver is integrated with slider portion 41B and the reflective surface is integrated with the stationary support structure 47, or vice versa. In a further embodiment, the mutual distance between slider 41 (or slider portion 41B) and the first embossing roller 21 can be detected by a camera and an image processing system.

[0061] Another type of encoder can be used instead of the contact encoder shown in the figure, for example, an encoder that uses an optical emitter in conjunction with a detector, which generates a photocurrent based on the position of the light spot produced by the optical emitter on the detectable surface of the detector.

[0062] In some embodiments, one or more force sensors are associated with the applicator roller 61; for simplicity, these force sensors are referred to herein as force gauges. This term refers to any transducer device suitable for detecting force and emitting a signal (typically an electrical signal) based on the detected force. At least one force gauge is associated with the applicator roller 61 to detect the force exchanged between the applicator roller 61 and the first embossing roller 21 when the applicator roller 61 is in contact with the first embossing roller 21.

[0063] For more accurate measurements, two force gauges can be installed, one on each support member, which are used to bring the applicator roller 61 to the slider 41, i.e., the applicator roller 61 is brought to the slider 41 via the slider portion 41B. In Figures 2A and 2B, only a single force gauge 75 is schematically shown.

[0064] Figure 2A schematically illustrates a control unit 77, which is functionally connected to an encoder 69 (or other general position detection device) (see connection C) and to one or more force gauges 75 (see connection D) to receive signals relating to the relative position between the slider 41 (and therefore the applicator roller 61) and the first embossing roller 21, as well as signals relating to the contact force between the applicator roller 61 and the first embossing roller 21. Furthermore, the control unit 77 is also connected to an actuator 67 (connection E).

[0065] The set of devices and components described so far are used to adjust the position of the applicator roller 61 relative to the first embossing roller 21 using the following procedure, which can be performed at any time when the position needs to be adjusted, such as after changing the plate fixed to the applicator roller 61, after changing the first embossing roller 21, or when adjustment is required for any other reason.

[0066] In the first step, the movable stop 65 is pulled out by the actuator 67, and the actuator 51 causes the slider 41 to move toward the embossing rollers 21, 25 until the movable stop 65 comes into contact with the fixed stop 63.

[0067] At this point, actuator 51 remains active, in a sense continuing to hold slider 41 in the closest approach position to embossing rollers 21, 25 as permitted by the presence of a pair of stops 63, 65. Subsequently, actuator 67 is activated, which begins to cause stops 65 to gradually retract. If actuator 67 and stops 65, 63 are dual-set, control unit 77 sends commands to both actuators 67 simultaneously.

[0068] The retraction of the stop 65 causes the cylindrical surface of the applicator roller 61 to gradually approach the cylindrical surface of the first embossing roller 21. This gradual approaching motion is achieved in the same way, even though the movable stop 65 is supported by the stationary support structure 45 and the fixed stop 63 is integrated with the slider 41 (i.e., with the slider portion 41B).

[0069] This movement continues until the control unit 77 detects contact between the cylindrical surface of the applicator roller 61 and the cylindrical surface of the first embossing roller 21. In the illustrated embodiment, this contact can be detected by means of a signal (signal D) generated by one or more force gauges 75. In fact, the contact between the first embossing roller 21 and the applicator roller 61 generates a force on each support of the applicator roller 61, which is detected by the force gauge 75.

[0070] In other embodiments, this contact can also be detected indirectly. In fact, when the applicator roller 61 contacts the first embossing roller 21, this contact prevents the slider 41 from advancing further along the guide 43 toward the embossing rollers 21, 25. This stop can be detected by the encoder 69, or other position detection devices as described above.

[0071] For this purpose, the system can operate as follows: The movable stop 65 is withdrawn and comes into contact with the stop 63, and the encoder 69 is brought into contact with the stop 71. The control unit 77 issues a command to gradually retract the movable stop 65. Until the applicator roller 61 touches the first embossing roller 21, the encoder generates a time-varying motion (or position) signal, which corresponds to the retraction movement of the movable stop 65. In other words, each movement of the movable stop 63 corresponds to a movement detected by the encoder 69 (or other device suitable for this function).

[0072] When the applicator roller 61 contacts the first embossing roller, the retraction movement of the movable stop 65 continues, but the position detection device (i.e., the encoder 69 or other device) will no longer detect a change in the relative position between the applicator roller 61 and the first embossing roller 21, or will only detect a smaller change, for example, due to yielding of the outer surface of the applicator roller 61. This state indicates that contact has occurred between the applicator roller 61 and the first embossing roller 21.

[0073] In both embodiments, the embossing machine-mounting machine typically includes a detection device adapted to detect the contact state between the applicator roller 61 and the first embossing roller 21.

[0074] Regardless of the technology used, the control unit 77 detects the moment when the first embossing roller 21 comes into contact with the applicator roller 61. This position is detected by the encoder 69 or other position detection device and set to zero.

[0075] The working position of the applicator roller 61 cannot be this contact position because the applicator roller would apply excessive pressure to the first embossing roller 21. The working position is set at this point by moving the slider 41 (or more precisely, slider portion 41b) backward by a certain amount from the zero position defined above, the amount being equal to the desired distance between the cylindrical surfaces of the applicator roller 61 and the first embossing roller 21. This backward movement is commanded by the control unit 77, which activates the actuator 67, thereby reversing its movement from the zero position achieved as described above. Movement in the remote direction is detected by means of the encoder 69 and this data is transmitted to the control unit 77, which stops the actuator 67 when a movement equal to the desired mutual distance between the applicator roller 61 and the first embossing roller 21 is implemented. Typically, this retraction stroke will be equal to or slightly less than the thickness of layer V1.

[0076] The above process is summarized in Figures 2A and 2B: In Figure 2A, the slider 41 is spaced apart from the embossing rollers 21 and 25, the movable stop 65 is withdrawn, and the applicator roller 61 is spaced apart from the first embossing roller 21. Figure 2B shows the instant (i.e., zero point) when the applicator roller 61 and the first embossing roller 21 make contact. From this moment on, the movable stop 65, which has been retracted from Figure 2A to Figure 2B, begins to be withdrawn until the desired distance is reached between the cylindrical surface of the applicator roller 61 and the cylindrical surface of the first embossing roller 21.

[0077] In the embodiment described, two actuators (or a pair of actuators) 51 and 67 are provided: the first actuator 51 keeps the stop 65 in contact with the stop 63; the second actuator moves the stop 65 so that the slider 41 first moves toward the first embossing roller 21 and then away from the first embossing roller 21. By using a thrust actuator (e.g., hydraulic or pneumatic cylinder-piston type) for the first actuator 51 and an electronically controlled electric actuator for the second actuator, extremely precise control is achieved within a limited cost structure.

[0078] Theoretically, a single actuator or a pair of actuators 51 can be used in conjunction with a detection device that detects the relative position between the stationary support structure 45 (and therefore the first embossing roller 21) and the slider 41, and particularly the slider portion 41B, and further in conjunction with a contact state detection device adapted to detect the contact state between the applicator roller 61 and the first embossing roller 21. The single actuator 51 brings the slider 41, and therefore also the applicator roller 61, closer until it contacts the first embossing roller 21. Once this position is reached, which is assumed to be zero by the control unit 77, the actuator will then controllably move the slider 41 (slider portion 41B), and therefore also the applicator roller 61, away from the first embossing roller 21 by a predetermined amount, the predetermined amount corresponding to a desired distance between the cylindrical surfaces of the applicator roller 61 and the first embossing roller 21.

[0079] Thus, the mutual positioning between the applicator roller 61 and the embossing roller 21 is achieved. From this point on, the operator can modify the mutual positioning through the human-machine interface (HMI) schematically indicated by 78 in Figure 2A, or the control unit 77 can automatically change the mutual positioning according to the type of product to be manufactured or according to the quality of the product being manufactured at this time.

Claims

1. An embossing machine-mounting machine unit (5), the embossing machine-mounting machine unit comprising: The first embossing roller (21) is supported on a static support structure (45); A first pressure roller (23), supported on the static support structure (45), the first pressure roller cooperating with the first embossing roller and defining a first embossing clamping portion (31) for the first web-like material (V1) with the first embossing roller (21); a dispenser (37) adapted to dispense functional fluid, the dispenser having an applicator roller (61) adapted to apply the functional fluid to the embossed first web-like material (V1) guided around the first embossing roller (21); wherein the applicator roller (61) is carried by a slider (41) capable of... The sliding member (41) and the applicator roller (61) are movable relative to the support structure (45) to move toward and away from the first embossing roller (21); the actuation mechanism (51, 67) is adapted to command the sliding member (41) and the applicator roller (61) to move toward and away from the first embossing roller (21); the position detection device (69) is adapted to detect the relative position between the sliding member (41) and the stationary support structure (45); and the contact state detection device (75) is adapted to detect the contact state between the applicator roller (61) and the first embossing roller (21).

2. An embossing machine-mounting machine unit (5), the embossing machine-mounting machine unit comprising: The second embossing roller (25) is supported on a static support structure (45); And a second pressure roller (27), which is supported on the static support structure (45), the second pressure roller cooperates with the second embossing roller (25) and defines a second embossing clamping portion (33) for the second web material (V2).

3. The embossing machine-mounting unit (5) according to claim 1 or 2, wherein the embossing machine-mounting unit comprises at least one of the following features: each pressure roller (23, 27) is supported by a corresponding pair of pivot arms, the pivot arms being hinged to the support structure and operated by a corresponding actuator to press the pressure roller against the corresponding embossing roller; each pressure roller (23, 27) is coated with an elastic yielding material such that the pressure between the embossing roller (21, 25) and the corresponding pressure roller (23, 27) causes the embossing protrusions (21P; 25P) of the corresponding embossing roller (21, 25) to at least partially penetrate the corresponding pressure roller while the embossing roller (21, 25) and the pressure roller (23, 27) rotate in opposite directions at substantially equal circumferential speeds. In the elastic yield coating of (23, 27); the mounting roller (35) cooperates with the first embossing roller (21) to define a mounting clamping portion (36) with the first embossing roller (23), through which the first web material (V2) and the second web material (V2) pass; and the first embossing roller (21) cooperates with the second embossing roller (25) to define a mounting clamping portion between the first embossing roller and the second embossing roller, through which the first web material (V1) embossed between the first embossing roller (21) and the first pressure roller (23) passes, and through which the second web material (V2) embossed between the second embossing roller (25) and the second pressure roller (27) passes.

4. The embossing machine-mounting machine unit (5) according to any one of the preceding claims, wherein, The position detection device (69) is carried by one of the slider (41) and the stationary support structure (45) and is adapted to cooperate with a fixed reference, which is stationary relative to the other of the slider (41) and the stationary support structure (45), to measure the relative motion between the slider (41) and the stationary support structure (45).

5. The embossing machine-mounting machine unit (5) according to claim 4, wherein, The fixed reference is the stop (71), and the position detection device (69) is in contact with the stop.

6. The embossing machine-mounting machine unit (5) according to claim 4 or 5, wherein, The position detection device (69) is carried by the sliding member (41) and the first stop (71) is fixed relative to the static support structure (45).

7. The embossing machine-mounting machine unit (5) according to one or more of the preceding claims, wherein the embossing machine-mounting machine unit further comprises a control unit (77), the control unit being functionally connected to the actuation mechanism (51, 67), the position detection device (69), and the contact state detection device (75); wherein, The control unit (77) is programmed and configured to command the slider (41) to move away from the first embossing roller (21) via the actuation mechanism (51, 67), the controlled movement starting at a zero position defined by the position where the applicator roller (61) comes into contact with the first embossing roller (21).

8. The embossing machine-mounting machine unit (5) according to claim 7, wherein, The control unit (77) is configured to perform the following steps: by means of the actuation mechanism (51, 67) to bring the applicator roller (61) closer to the first embossing roller (12) until the applicator roller (61) contacts the first embossing roller (21); by means of the contact state detection device (75) to detect the contact and set the position of the applicator roller (61) when it contacts the first embossing roller (21) as a reference position; by means of the actuation mechanism (51, 67) to move the applicator roller (61) away from the first embossing roller (21) and to measure the movement by means of the position detection device (69); when the position detection device (69) detects that a predetermined distance from the reference position has been reached, the applicator roller (61) is stopped.

9. The embossing machine-mounting machine unit (5) according to any one of the preceding claims, wherein, The contact state detection device (75) includes at least one force gauge adapted to detect the force applied by the first embossing roller (21) to the applicator roller (61).

10. The embossing machine-mounting machine unit (5) according to claim 9, comprising two force gauges (75), each force gauge being associated with a corresponding support of the applicator roller (61).

11. The embossing machine-mounting machine unit (5) according to any one of the preceding claims, wherein, The actuation mechanism includes at least one actuator (51) adapted to bring the first embossing roller (21) and the slider (41) with the applicator roller (61) closer to or further away from each other in a controlled manner.

12. The embossing machine-mounting machine unit (5) according to any one of claims 1 to 11, wherein, The actuation mechanism includes: a first thrust actuator (51) adapted to push the slider (41) toward a position close to the first embossing roller (21); and a second actuator (67) adapted to command the slider (41) to move toward and away from the first embossing roller (21) in a controlled manner.

13. The embossing machine-mounting machine unit (5) according to claim 12, comprising a second stop (65) supported by one of the sliding member (41) and the stationary support structure (45) and cooperating with a third stop (63) supported by the other of the sliding member (41) and the stationary structure (45), wherein the second actuator (67) is adapted to command movement of the second stop (65); wherein, When the second stop (65) contacts the third stop (61), the movement of the second stop (65) will cause the sliding member (41) to move relative to the stationary support structure (45).

14. The embossing machine-mounting machine unit (5) according to claim 13, wherein, The third stop (63) is carried by the static support structure (45); and the second stop (65) and the second actuator (67) are carried by the slider (41).

15. The embossing machine-mounting machine unit (5) according to claim 12, 13 or 14 when at least dependent on claim 7, wherein, The second actuator (67) is functionally connected to the control unit (77), and the control unit (77) is programmed to command the slider (41) to move toward and away from the first embossing roller (21) by means of the second actuator (67).

16. The embossing machine-mounting machine unit (5) according to any one of claims 12 to 15, wherein, The position detection device is integrated within the second actuator (67).

17. The embossing machine-mounting machine unit (5) according to any one of claims 12 to 16, wherein, The second actuator (67) is an electric actuator.

18. The embossing machine-mounting machine unit (5) according to any one of claims 13 to 17, wherein, The first stop (71) and the third stop (63) are integrated with each other.

19. The embossing machine-mounting machine unit (5) according to claim 11, wherein, The position detection device is integrated in the at least one actuator (51).

20. A method for adjusting the relative position between a first embossing roller (21) and an applicator roller (61) in an embossing machine-mounting machine (5), the first embossing roller being supported by a stationary support structure (45), the applicator roller (61) being supported by a slider (41) movable relative to the stationary support structure (45) and adapted to apply a functional fluid to an embossed web-like material guided around the first embossing roller (21), wherein, The method includes the following steps: moving the applicator roller (61) closer to the first embossing roller (21) until the applicator roller (61) contacts the first embossing roller (21), detecting the contact by means of a contact detection device (75), and setting the position of the applicator roller (61) when it contacts the first embossing roller (21) as a reference position; moving the applicator roller (61) away from the first embossing roller (21), measuring the movement by means of a position detection device (69); and stopping the applicator roller (61) when the position detection device (69) detects that a predetermined distance from the reference position has been reached.

21. The method according to claim 20, wherein, The contact between the first embossing roller (21) and the applicator roller (61) is detected by means of at least one force gauge (75).

22. The method according to claim 21, wherein, The force gauge is associated with at least one support of the applicator roller (61).

23. The method according to claim 20, 21 or 22, wherein, The position detection device (69) is mounted on the sliding member (41) or the static support structure (45) and cooperates with the stop member (71) mounted on the static support structure (45) or the sliding member (41).

24. The method according to any one of claims 20 to 23, the method comprising the following steps: The slider (41) is pushed toward the first embossing roller (21) by means of a first actuator (51), the first actuator keeping the slider and the stop (63) integrated into the stationary load-bearing structure (45) side by side; the applicator roller (61) is moved closer to the first embossing roller (21) by means of a second actuator (67) until the applicator roller (61) contacts the first embossing roller (21); When the contact between the applicator roller (61) and the first embossing roller (21) is detected, the slider (41) and the applicator roller (61) are moved away from the first embossing roller (21) by means of the second actuator (67) until a preset distance is reached between the applicator roller (61) and the first embossing roller (21).

25. The method according to claim 24, wherein, The second actuator (67) causes the movable stop (65) carried by the slider (41) or the stationary support structure (45) to move, and the movable stop cooperates with the fixed stop (63) carried by the stationary support structure (45) or the slider (41).

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