Quickly adjustable rollers for crimpers for sheet materials

Abstract

An adjustable roller (20) for a crimper for sheet material, the adjustable roller comprising a substantially cylindrical outer portion (21) having a first end (22) and a second end (23) with a longitudinal axis of rotation (30) extending between the first end (22) and the second end (23), a first bushing (26) mounted inside the first end (22) of the roller, and a second bushing (126) mounted inside the second end (23) of the roller, the first bushing (26) and the second bushing (126) each having a respective cylindrical bore (28, 128) having an axis parallel to the longitudinal axis of rotation. At least one of the first bushing (26) and the second bushing (126) is adjustably mounted inside each end (22, 23) of the roller such that the axis of at least one of the first bushing (26) and the second bushing (126) is displaceable relative to the longitudinal axis of rotation (30).

Description

[Technical field]

[0001] The present disclosure relates to adjustable rollers, particularly, but not exclusively, to adjustable rollers for crimping machines, for example, tobacco sheets, polymer sheets, or paper sheets, and to adjustable bushings for rollers such as crimping rollers. [Background technology]

[0002] Equipment in the tobacco industry, like any equipment, is subject to maintenance. Downtime means financial loss, so it is important to get the equipment up and running again as soon as possible. After maintenance or troubleshooting, where parts are disassembled and reassembled, the equipment parts need to be adjusted relative to each other. Production lines for tobacco products, including heated non-combustion aerosol generating products, often include a unit in which a sheet of material passes between at least two rollers. The sheet of material may be unwound from a bobbin for feeding to the rollers. A particular example is a crimping unit in which first and second substantially cylindrical crimping rollers, each having a longitudinal axis of rotation and each provided with a plurality of substantially parallel circumferential ridges about the outer surface of the cylindrical crimping roller, are disposed substantially parallel to and adjacent to each other with the first roller such that the ridges of the first roller alternate with the ridges of the second roller along the closest tangential plane of the outer surfaces of the first and second rollers. A sheet of material, for example a sheet of polymeric material or a sheet of homogenized tobacco material, passes between the first and second rollers and is crimped by the alternating circumferential ridges. Naturally, the cylindrical crimping rollers need to be adjusted in the micrometer range to ensure that the spacing between the outer surfaces of the rollers in the tangential plane is substantially uniform in a direction parallel to the longitudinal axis of the rollers and that the ridges are precisely alternating to define the desired crimp amplitude. If the spacing is too narrow, the ridges may cut the sheet of material, and if the spacing is too wide, the sheet of material may not be precisely crimped. Furthermore, if the spacing is not substantially uniform along the length of the first and second rollers, the sheet of material may not be uniformly crimped across its width. Adjusting the rollers is particularly time consuming and requires skilled maintenance personnel, as tolerances may otherwise be unintentionally exceeded, reducing the overall quality of the product being manufactured. The tolerances are typically on the micrometer scale, requiring a high level of precision in adjusting the crimping rollers.

[0003] FIG. 1 shows a prior art crimping unit with first and second crimping rollers, for example as disclosed in U.S. Pat. No. 10,888,118, the entire disclosure of which is incorporated herein by reference. A continuous sheet of material is fed into the crimping unit between the first and second crimping rollers. The two crimping rollers are mainly tubular in shape, with two flanges mounted on the outer ends of the crimping rollers. A shaft is mounted along the longitudinal axis of each crimping roller as well as the axis of the mounting flange, and the crimping rollers can be driven, for example by an electric motor, by rotating the shaft. The shaft is mounted on a support frame. This design of several assembled parts, as with any system, results in the accumulation of tolerances that must be realigned by maintenance personnel. The adjustment of the crimping rollers relative to each other is time-consuming and needs to be performed with the utmost precision. Moreover, the adjustment of the crimping rollers is a highly skilled task that can take a significant amount of time. Summary of the Invention

[0004] According to a first aspect of the present invention, there is provided an adjustable roller for a crimper for sheet material, comprising: a substantially cylindrical outer portion having a first end and a second end, with a longitudinal axis of rotation extending between the first end and the second end; a first bushing mounted on the inside of a first end of the roller, and a second bushing mounted on the inside of a second end of the roller; the first bushing and the second bushing each have a respective cylindrical bore having an axis parallel to the longitudinal axis of rotation; An adjustable roller is provided, where at least one of the first bushing and the second bushing is adjustably mounted inside each end of the roller such that an axis of at least one of the first bushing and the second bushing is displaceable relative to the longitudinal axis of rotation.

[0005] If rollers are mounted on shafts extending through cylindrical holes in the first and second bushings, and the shafts are supported by an external frame, axial displacement of one or the other or both bushings makes it possible to achieve fine tuning of the orientation of the longitudinal axis of rotation of the cylindrical external portion without the need to adjust the external frame, in this context fine tuning means tuning on a sub-millimeter scale, in the range of a few hundred micrometers or less.

[0006] In certain embodiments, gross adjustment of the longitudinal axis of rotation orientation is obtained by adjusting the supports of the external frame, and fine adjustment of the longitudinal axis of rotation orientation is obtained by subsequent adjustment of one or the other or both of the bushings. [Brief description of the drawings]

[0007] [Figure 1] FIG. 2 shows a perspective view of the arrangement of two crimping rollers in the crimping unit. [Diagram 2] FIG. 2 shows a more detailed view of the alternating corrugations of the crimping rollers of FIG. 1, where the crimping rollers are imperfectly aligned. [Diagram 3] 1 illustrates a longitudinal cross section through an adjustable roller of the present disclosure in a first rotational position. [Figure 4] FIG. 4 shows an end elevation view of the left end of the adjustable roller of FIG. 3. [Diagram 5] 4 shows a longitudinal cross section through the adjustable roller of FIG. 3 in a second rotational position. [Figure 6] 6 shows an axial section through the left end of the adjustable roller of FIG. 5. [Figure 7] FIG. 1 illustrates a perspective view of an alternative adjustable roller of the present disclosure. [Figure 8] 8 shows a longitudinal cross section through the adjustable roller of FIG. 7. [Figure 9] FIG. 8 shows an end elevation view of the left end of the adjustable roller of FIG. 7. [Figure 10] 8 shows three stages in the adjustment of the adjustable roller of FIG. 7. [Figure 11]8 shows three stages in the adjustment of the adjustable roller of FIG. 7. [Figure 12] 8 shows three stages in the adjustment of the adjustable roller of FIG. 7. [Figure 13] 8 shows longitudinal cross sections through the right end of the adjustable roller of FIG. 7 mounted on a shaft at two different adjustments. [Figure 14] 8 shows longitudinal cross sections through the right end of the adjustable roller of FIG. 7 mounted on a shaft at two different adjustments. [Figure 15] FIG. 2 illustrates a front elevation view of a flange portion of the adjustable roller of the present disclosure. [Figure 16] FIG. 2 illustrates a side elevation view of a flange portion of the adjustable roller of the present disclosure. [Figure 17] FIG. 2 illustrates a rear elevation view of a flange portion of the adjustable roller of the present disclosure. [Figure 18] 14 illustrates a front view of an alternative flange portion of the adjustable roller of the present disclosure. [Figure 19] FIG. 2 illustrates a front elevation view of an adjustable roller bushing of the present disclosure. [Figure 20] FIG. 2 illustrates a side elevation view of an adjustable roller bushing of the present disclosure. [Figure 21] FIG. 2 illustrates a rear elevation view of the adjustable roller bushing of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] The embodiments will now be further described with reference to the figures.

[0009] 1 shows a crimping unit 1 comprising a first crimping roller 2 and a second crimping roller 102 mounted in a generally parallel and adjacent arrangement. Each of the first crimping roller 2 and the second crimping roller 102 comprises a substantially cylindrical outer portion 3, 103 having a first end 4, 104 and a second end 5, 105, with a longitudinal axis of rotation 6, 106 extending between the first end 4, 104 and the second end 5, 105. Each of the first crimping roller 2 and the second crimping roller 102 also comprises a first bushing 7, 107 at the first end 4, 104 and a second bushing 8, 108 at the second end 5, 105. The first bushing 7, 107 and the second bushing 8, 108 are fixedly mounted inside the respective substantially cylindrical outer portion 3, 103. Each of the first bushing 7, 107 and the second bushing 8, 108 has a central hole (not shown) configured to receive a shaft (not shown) such that the first shaft (not shown) passes through the first bushing 7 and the second bushing 8 and the second shaft (not shown) passes through the first bushing 107 and the second bushing 108. The crimping unit 1 is mounted in a frame (not shown) and the first shaft and the second shaft can be driven by a motor to rotate the first crimping roller 2 and the second crimping roller 102 in opposite rotational directions. The cylindrical outer portion 3, 103 of each of the first roller 2 and the second roller 102 is provided with circumferential corrugations 9, 109 which can be arranged alternately with each other along a tangential plane between the cylindrical outer portions 3, 103 when the first roller 2 is positioned adjacent to the second roller 102, as shown more clearly in FIG. 2. A sheet of material 10, for example a tobacco sheet or a polymer sheet, may be fed between a first roller 2 and a second roller 102 to crimp the sheet 10 by imparting a corrugated profile to the sheet 10 by alternating circumferential corrugations 9, 109.

[0010] In the illustrated embodiment, the central bores of the first bushing 7 and the second bushing 8 are concentric with the longitudinal axis of rotation 6 of the cylindrical outer part 3 of the first roller 2. Similarly, the central bores of the first bushing 107 and the second bushing 108 are concentric with the longitudinal axis of rotation 106 of the cylindrical outer part 103 of the second roller 102. This means that the first shaft coincides with the longitudinal axis of rotation 6 and the second shaft coincides with the longitudinal axis of rotation 106. As a result, the only way to adjust the longitudinal axes of rotation 6, 106 is to adjust the mounting of the first and second shafts in the frame, which can be a complex and time-consuming procedure.

[0011] 2, if the longitudinal axes of rotation 6, 106 are imperfectly parallel aligned, the circumferential corrugations 9, 109 may not alternate consistently along the length of the cylindrical outer portion 3, 103, and may not alternate at all toward one of the tangential ends. As a result, the sheet 10 passing between the first roller 2 and the second roller 102 may not be crimped consistently across the width of the sheet 10.

[0012] FIG. 3 shows a longitudinal section through an adjustable roller 20 of an embodiment of the present disclosure in a first rotational position. The adjustable roller 20 comprises a substantially cylindrical outer portion 21 having a first end 22 and a second end 23 and a longitudinal axis of rotation 30. The circumferential corrugations are not visible because the structural height of the corrugations is below the resolution of the drawing. FIG. 4 shows an end elevation view of the first end 22 of the adjustable roller 20 of FIG. 3. The first flange portion 24 is fitted inside the first end 22 of the cylindrical outer portion 21 by bolts 25. Similarly, the second flange portion 124 is fitted inside the first end 23 of the cylindrical outer portion 21 by bolts 125. The first bushing 26 can be secured to the first flange portion 24 at the first end 22 by bolts 27. Similarly, the second bushing 126 can be secured to the second flange portion 124 at the second end 23 by bolts 127. The first bushing 26 has a central bore 28. The second bushing 126 has a central bore 128. The central bore 26, 126 is configured to receive a shaft (not shown) that can be rotated by a motor to rotate the roller 20. Importantly, at least one of the first bushing 26 and the second bushing 126 is axially displaceable (when the bolts 27, 127 are loosened) relative to the respective flange portion 24, 124, and thus relative to the cylindrical outer portion 21 and the longitudinal axis of rotation 30. The axial displaceability is made possible by providing a predetermined amount of play between at least one of the first bushing 26 and the second bushing 126 and the respective flange portion 24, 124 in a plane perpendicular to the longitudinal axis of rotation 30. Each of the central holes 28, 128 (and therefore each of the first bushing 26 and the second bushing 126) has its own longitudinal axis of rotation, and the longitudinal axis of at least one of the central holes 28, 128 (and therefore at least one of the first bushing 26 and the second bushing 126) can be radially displaced by a small amount from the longitudinal axis of rotation 30 of the cylindrical outer portion 21.Displacing the longitudinal axis of rotation of at least one of the first bushing 26 and the second bushing 126 relative to the longitudinal axis of rotation 30 of the cylindrical outer portion 21 provides a fine degree of adjustment without having to adjust the mounting of the rollers 20 within an outer frame (not shown). The adjustment facilitates precise mutual alignment of the pair of rollers 20 when assembled into a crimping unit, as shown in FIG.

[0013] FIG. 5 shows longitudinal cross sections through the adjustable roller 20 of FIGS. 3 and 4 in different rotational positions. FIG. 6 shows axial cross sections AA through the second end 23 of the adjustable roller 20 of FIG. 5. FIGS. 5 and 6 show four adjustable fasteners in the form of set screws 31, 131 disposed in radially oriented threaded holes 32, 132 in at least one of the flange portions 24, 124. The set screws 31, 131 can be moved in both directions along the threaded holes 32, 132 by rotation. The threaded holes 32, 132 are accessible from the outer periphery of the flange portions 24, 124 to allow rotation and adjustment of the set screws 31, 131 using an appropriate tool. In the illustrated embodiment, the threaded holes 32, 132 are disposed at 90 degrees relative to one another around the circumference of the flange portion 24, 124, but it will be appreciated that three threaded holes 32, 132 spaced at 120 degrees apart are suitable, as well as other numbers of threaded holes 32, 132. It will be appreciated that very fine and controllable adjustment of the displacement of at least one of the first bushing 26 and the second bushing 126 relative to the longitudinal axis of rotation 30 of the cylindrical outer portion 21 can be obtained by adjusting set screws 31, 131 in the threaded holes 32, 132. The set screws 31, 131 each have an inner end that can protrude slightly beyond the inner circumference of the flange portion 24, 124 to adjust and hold at least one of the first bushing 26 and the second bushing 126. The set screws 31, 131 each have an outer end that can be engaged by a suitable tool (such as a hex key) to allow the set screws 31, 131 to rotate and therefore move in either direction along the threaded bores 32, 132. Thus, radial displacement of at least one of the first bushing 26 and the second bushing 126 relative to the longitudinal axis of rotation 30 of the cylindrical outer portion 21 can be achieved without having to adjust the mounting of the roller 20 within the outer frame (not shown).When the set screws 31, 131 and threaded holes 32, 132 are disposed at radially opposed positions around the circumference of the flange portion 24, it is possible to effect fine controlled displacement of at least one of the first bushing 26 and the second bushing 126 by making complementary adjustments of the opposed set screws 31, 131. The mechanical advantage gained by using the set screws 31, 131 with the threaded holes 32, 132 allows for controlled displacement of a heavy component such as the cylindrical outer portion 21 relative to at least one of the first bushing 26 and the second bushing 126. By providing multiple set screws 31, 131 and threaded holes 32, 132 around the circumference of the flange portion 24, 124, any radial displacement is possible.

[0014] Although it may be possible for at least one of the first bushing 26 and the second bushing 126 to be held in firm engagement with the respective flange portions 24, 124, it may be preferable that after at least one of the first bushing 26 and the second bushing 126 is correctly adjusted, the bushings 26, 126 are adjusted to be firmly engaged with the respective flange portions 24, 124 by the bolts 27, 127. The bolts 27, 127 may pass through bolt holes that have sufficient radial play for the bolts 27, 127 to accommodate radial displacement of the bushings 26, 126 relative to the flange portions 24, 124 before the bolts 27, 127 are tightened.

[0015] FIG. 7 shows a perspective view of an adjustable roller 20 of another embodiment of the present disclosure, FIG. 8 shows a longitudinal section through the adjustable roller 20 of FIG. 7, and FIG. 9 shows an end elevation view of the left end of the adjustable roller 20 of FIG. 7. As with the previous embodiment, the adjustable roller 20 of FIGS. 7-9 has a substantially cylindrical outer portion 21 having a first end 22 and a second end 23 and a longitudinal axis of rotation 30. A first flange portion 24 is fitted inside the first end 22 of the cylindrical outer portion 21 by bolts 25. Similarly, a second flange portion 124 is fitted inside the first end 23 of the cylindrical outer portion 21 by bolts 125. A first bushing 26 is securable to the first flange portion 24 at the first end 22 by bolts 27. Similarly, a second bushing 126 is securable to the second flange portion 124 at the second end 23 by bolts 127. The first bushing 26 has a central bore 28. The second bushing 126 has a central bore 128. The central bore 26, 126 is configured to receive a shaft (not shown) that can be rotated by a motor to rotate the roller 20. In this embodiment, the central bore 28, 128 of at least one of the first bushing 26 and the second bushing 126 has an axis that is slightly radially offset from the longitudinal axis of rotation 30 of the cylindrical outer portion 21. The radial offset may be provided by an eccentricity of the flange portion 24, 124, or an eccentricity of the bushing 26, 126, or an eccentricity of both the flange portion 24, 124 and the bushing 26, 126. Thus, by rotating the bushing 26, 126 relative to the flange portion 24, 124, the axis of the bushing 26, 126 may be moved along an orbital path about the longitudinal axis of rotation 30. The degree of rotation of the bushings 26, 126 relative to the flange portions 24, 124 is indicated by indicia 40 provided on the flange portions 24, 124 and markers 41 provided on the bushings 26, 126. To allow rotation of the bushings 26, 126 relative to the flange portions 24, 124, the bolts 27, 127 may be removed.Once the bushings 26, 126 are rotated to the desired position, as indicated by indicia 40 and markers 41, the bolts 27, 127 can be reinserted and tightened.

[0016] The bushing 26, 126 may be provided with recesses 42 configured to receive corresponding protrusions of a tool 43 designed to facilitate rotation of the bushing 26, 126 within the flange portion 24, 124, as shown in Figures 10-12. The indicia 40 may be in the form of a numerical scale to provide an easy to read indication of the degree of relative rotation. In Figure 10, the bushing 26 is in position "1". The bolt 27 is removed and the tool 43 is used to rotate the bushing 26 clockwise, as shown in Figure 11. In Figure 12, the bushing 26 is rotated to position "3" and the bolt 27 is reinserted and tightened. Moving the axis of the bushing 26 along an orbital path about the longitudinal axis of rotation 30 of the cylindrical outer portion 21 allows fine adjustment of the axis of rotation of the entire roller 20, allowing precise alignment of one roller 20 with respect to another roller in the crimping unit 1, as generally shown in Figure 1.

[0017] Naturally, the eccentricity of the bushing 26, 126 or the flange 24, 124 is relatively small, for example less than 1 mm, or less than 0.5 mm, or less than 0.1 mm, or less than 0.05 mm. Thus, even a relatively large rotational displacement of the bushing 26, 126 relative to the flange 24, 124 only has a small effect on the orientation of the rotation axis of the entire roller 20. As a result, accurate adjustments are easily performed, even by unskilled personnel.

[0018] Figures 13 and 14 show an adjustable roller 20 of the type shown in Figures 7-10 mounted on a shaft 50 driven by a motor (not shown) to rotate the roller 20. Features in Figures 18 and 14 are labeled as in Figures 7-10. In Figure 18, the bushing 26 is in a first rotational position relative to the flange portion 24 (e.g., position "1" in Figure 10), and in Figure 14, the bushing 26 is in a second rotational position relative to the flange portion 24 (e.g., position "3" in Figure 12). It can be seen how orbital rotation of the eccentric within the bushing 26 moves the axis of rotation of the shaft 50 relative to the longitudinal axis of rotation of the cylindrical outer portion 21 to allow fine adjustment of the orientation of the entire roller 20.

[0019] 15-17 show front, side, and rear elevation views, respectively, of the flange portion 24 of an adjustable roller 20 of an embodiment of the present disclosure. The flange portion 24 has an outer periphery 60 that fits within the end of the cylindrical outer portion 21 of the roller 20, with bolt holes 61 receiving bolts 25 that affix the flange portion 24 to the end 22 of the cylindrical outer portion 21 of the roller 20. The flange portion 24 has an inner periphery 62 that defines holes 64 for receiving bushings 26 (not shown in FIGS. 15 and 16). Bolt holes 63 are provided around the inner periphery 62 to receive bolts 27 that connect the bushings 26 to the flange portion 24. Indicia 40 in the form of a numerical scale are provided circumferentially around the flange portion 24. It can be seen that in this embodiment the bolt holes 63 are aligned with the indicia 40. In the illustrated embodiment, there are eighteen indicia 40 and eighteen corresponding bolt holes 63. This means that the bushing 26 can be bolted to the flange portion 24 in any one of 18 distinct rotational positions. The number of bolt holes 63 may be more or less than 18, but in any case, the number of bolt holes 63 defines the rotational positions available for securing the bushing 26 relative to the flange portion 24.

[0020] 18 shows a front elevational view of an alternative flange portion 24. Instead of eighteen individual bolt holes 63, this flange portion 24 has six arcuate cutouts 65 provided about the inner periphery 62. The number of arcuate cutouts 65 is not particularly significant. This arrangement allows the bushing 26 to be bolted to the flange portion 24 in a more continuously variable manner and provides for rotational position between the integral indicia 40.

[0021] 19-21 show front, side, and rear elevational views, respectively, of a bushing 26 of an adjustable roller 20 of an embodiment of the present disclosure. The bushing 26 has an outer periphery 70 and a central bore 28 that is eccentric relative to the outer periphery 70. An inner periphery 73 surrounds the central bore 28. The central bore 28 may have an axis that is skewed relative to the axis of the outer periphery 70. The central bore 28 may have an axis that is radially offset relative to the axis of the outer periphery 70. Thus, rotation of the bushing 26 relative to the flange portion 24 allows fine adjustment of the axis of rotation of the cylindrical outer portion 21 relative to the axis of rotation of the shaft 50, as shown in FIGS. 18 and 14. The front surface 71 of the bushing 26 is provided with a recess 42 configured to receive a corresponding protrusion of a tool 43, as shown in FIGS. 10-12. The front surface 71 of the bushing is also provided with a bolt hole 72 for receiving a bolt 27 that connects the bushing 26 to the flange portion 24. Markers 41 are provided on front surface 71 at outer periphery 70 to combine with indicia 40 on flange portion 24 to provide an easily readable indication of the rotational position of bushing 26 relative to flange portion 24 .

[0022] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like, should be understood in all instances as modified by the term "about." Also, all ranges include the maximum and minimum points disclosed, and include any intermediate ranges therein, which may or may not be specifically recited herein. Thus, in this context, the number A is understood as A±5%. Within this context, the number A may be considered to include a numerical value that is within the general standard error for the measurement of the property that the number A modifies. The number A may deviate by the percentages recited above, in some cases as used in the appended claims, provided that the amount by which A deviates does not materially affect the basic and novel properties of the claimed invention. Also, all ranges include the maximum and minimum points disclosed, and include any intermediate ranges therein, which may or may not be specifically recited herein.

[0023] The embodiments of the present disclosure allow for quick and easy adjustment of the longitudinal axis of rotation when the rollers are first assembled or when they are reassembled after being disassembled for maintenance. Naturally, each component of the mechanism has a given engineering tolerance. The engineering tolerances include, among other factors, the allowable size variations of the components, the allowable eccentricity of the axis of rotation, and the allowable diameter variations along the longitudinal axis. The various engineering tolerances in the system combine with each other in a complex tolerance stacking or stacking process, which means that small individual tolerances can end up with a much larger overall tolerance. The embodiments of the present disclosure provide a quick and easy mechanism to compensate for the stacked tolerances in a production environment. This is especially true when alternating crimping rollers, where the engineering tolerances during manufacturing can be on the micrometer scale.

[0024] At least one of the first bushing and the second bushing may be mounted inside each end of the roller with a predetermined amount of play in a plane perpendicular to the longitudinal axis such that at least one of the first bushing and the second bushing is adjustably securable to the each end of the roller by a plurality of adjustable fasteners.

[0025] The predetermined amount of play allows for displacement of at least one of the first bushing and the second bushing relative to a longitudinal axis of rotation of the substantially cylindrical outer portion, and the adjustable fastener allows for adjustably fixing at least one of the first bushing and the second bushing at a desired displacement.

[0026] The plurality of adjustable fasteners may be circumferentially disposed about at least one of the first bushing and the second bushing. The plurality of adjustable fasteners may be evenly spaced circumferentially about at least one of the first bushing and the second bushing. An adjustment of one of the adjustable fasteners may be made while simultaneously making a compensating adjustment of another of the adjustable fasteners, for example at an opposite circumferential portion of the circumference of the bushing, to allow the bushing to displace relative to a longitudinal axis of the substantially cylindrical outer portion without the bushing loosening within each end of the roller.

[0027] The plurality of adjustable fasteners may include a plurality of set screws. The substantially cylindrical outer portion may be provided with a plurality of radially oriented, circumferentially spaced threaded holes at the first end or the second end, or at both the first end and the second end. The plurality of set screws may be adjustably rotatable within the threaded holes to securely hold the respective first bushing or second bushing in a fixed position relative to the respective first end or second end at selectable different displacements of the bushing axis relative to the longitudinal axis of rotation.

[0028] The plurality of adjustable fixtures may include at least three adjustable fixtures. The plurality of adjustable fixtures may include at least four adjustable fixtures. The plurality of adjustable fixtures may include three adjustable fixtures. The plurality of adjustable fixtures may include four adjustable fixtures. If three adjustable fixtures are provided, they may be positioned at 120 degree circumferential positions relative to each other. If four adjustable fixtures are provided, they may be positioned at 90 degree circumferential positions relative to each other. Four adjustable fixtures provide a good balance between precise displacement and simplicity of adjustment.

[0029] In an alternative embodiment, at least one of the first bushing and the second bushing may be offset from or skewed relative to the longitudinal axis of rotation, and at least one of the first bushing and the second bushing may be rotatably adjustable relative to the cylindrical outer portion to allow an axis of the at least one of the first bushing and the second bushing to move along an orbital path about the longitudinal axis during adjustment.

[0030] At least one of the first and second bushings can be adjustably rotated relative to the cylindrical outer portion to move the shaft of at least one of the first and second bushings along an orbital path about the longitudinal axis of rotation of the substantially cylindrical portion. When rollers are mounted on shafts that extend through cylindrical bores in the first and second bushings, and the shafts are supported by an outer frame, rotation of one or the other, or both, of the bushings relative to the cylindrical outer portion allows fine adjustment of the orientation of the longitudinal axis of rotation to be achieved without the need to adjust the outer frame.

[0031] In certain embodiments, the displacement of the axis of at least one of the first bushing or the second bushing from the longitudinal axis of rotation may be up to 1 mm, optionally up to 0.5 mm, optionally up to 0.1 mm, optionally up to 0.05 mm. In currently preferred embodiments, the displacement is up to 0.1 mm, preferably up to 0.05 mm.

[0032] When adjustment is made by rotating the bushing relative to the substantially cylindrical outer portion, even large (up to 180 degrees) rotations of the bushing relative to the substantially cylindrical outer surface can have a relatively small effect on the orientation of the longitudinal axis of rotation, making it possible to achieve very fine adjustments of the orientation through relatively large rotational adjustments of the bushing, thereby facilitating adjustment by unskilled personnel.

[0033] In some embodiments, only one of the first bushing and the second bushing is adjustably mounted inside the respective end of the roller. In these embodiments, displacement of the bushing relative to the longitudinal axis of the cylindrical outer portion is only possible at one end of the roller. Alternatively, both the first bushing and the second bushing may be adjustably mounted inside the respective end of the roller to allow displacement of the bushing at both ends of the roller.

[0034] In embodiments in which the axes of the first and second bushings are offset from, skewed relative to, or both offset from and skewed relative to the longitudinal axis of rotation, the offset, skew, or offset and skew may be the same amount for both the first and second bushings. Alternatively, the axes of the first and second bushings may be offset from, skewed relative to, or offset from and skewed relative to the longitudinal axis of rotation by different amounts.

[0035] At least one end of the substantially cylindrical outer portion may be provided with a flange portion for receiving the respective first bushing or second bushing.

[0036] At least one of the first bushing and the second bushing may be releasably secured to the respective flange portion by a plurality of bolts.

[0037] At least one of the first bushing and the second bushing may be rotatably adjustable within its respective flange portion by loosening the plurality of bolts, rotating the bushing a predetermined amount, and then tightening the plurality of bolts.

[0038] At least one of the flange portion and the first and second bushings may each be provided with indicia to indicate the amount of relative rotation between the flange portion and the bushing. The indicia may include a numerical scale. The indicia may provide a useful indication to maintenance personnel as to the amount of rotation and thus the degree of adjustment of the first or second bushing.

[0039] At least one of the first bushing and the second bushing may be provided with a plurality of recesses or protrusions configured to receive or be received by a tool for rotatably adjusting the bushing. The tool may take the form of a wrench having protrusions or recesses complementary to the recesses or protrusions formed in at least one of the first bushing or the second bushing.

[0040] The axial offset or distortion of at least one of the first and second bushings from the longitudinal axis of rotation may be provided by eccentricity of the respective flange portions.

[0041] The axial offset or skew of at least one of the first and second bushings from the longitudinal axis of rotation may be provided by eccentricity of the bushings.

[0042] The axial offset of at least one of the first bushing and the second bushing from the longitudinal axis of rotation may be 1 mm or less, optionally 0.5 mm or less, optionally 0.1 mm or less, optionally 0.05 mm or less.

[0043] The substantially cylindrical outer portion may have a length along the longitudinal axis of from 200mm to 500mm, optionally a length along the longitudinal axis of from 300mm to 400mm.

[0044] The substantially cylindrical outer portion may have a diameter of from 100mm to 300mm, optionally from 150mm to 250mm.

[0045] The substantially cylindrical outer portion may be provided with a plurality of substantially parallel circumferential ridges, which may be configured to apply a desired crimp pattern, for example to a tobacco sheet, a polymer sheet, or a paper sheet.

[0046] The substantially cylindrical outer portion, the first bushing and the second bushing may be made of any suitable material. Exemplary materials include steel and stainless steel, optionally with a coating of manganese phosphate. The same or similar materials may be used to make the flange portion. The adjustable fastener or set screw may also be made of steel, or another metal or alloy as appropriate.

[0047] According to a second aspect of the present invention there is provided a roller unit for a crimper for sheet material comprising a first adjustable roller according to the first aspect in combination with a second roller, the second roller having a substantially cylindrical outer portion having a first end and a second end, a longitudinal axis of rotation extending between the first end and the second end, the longitudinal axis of the second roller being substantially parallel to the longitudinal axis of the first roller, and the first and second rollers being movable relative to each other to bring their cylindrical outer surfaces into approximation along a tangent plane between the cylindrical outer surfaces.

[0048] Fine adjustment of the longitudinal axis of rotation of the first roller relative to the longitudinal axis of rotation of the second roller is made possible by adjustable displacement of at least one of the first bushing or the second bushing of the first roller, so that good alignment of the cylindrical outer surface along the tangential plane can be obtained.

[0049] Fine tuning of the longitudinal axis of rotation of the substantially cylindrical outer portion of the first roller relative to the orientation of the longitudinal axis of rotation of the substantially cylindrical outer portion of the second roller may be obtained by displacing an axis of at least one of the first bushing and the second bushing relative to the longitudinal axis of rotation of the substantially cylindrical outer portion of the first roller.

[0050] Fine adjustment of the longitudinal axis of rotation of the substantially cylindrical outer portion of the first roller relative to the orientation of the longitudinal axis of rotation of the substantially cylindrical outer portion of the second roller may be obtained by rotating at least one bushing of the first roller within the substantially cylindrical outer portion of the first roller.

[0051] The second roller may comprise a substantially cylindrical outer portion having a first end and a second end, with a longitudinal axis of rotation extending between the first end and the second end, a first bushing mounted inside the first end of the roller and a second bushing mounted inside the second end of the roller, the first bushing and the second bushing each having a respective cylindrical bore having an axis parallel to the longitudinal axis of rotation, and at least one of the first bushing and the second bushing being adjustably mounted inside the respective end of the roller such that the axis of at least one of the first bushing and the second bushing is displaceable relative to the longitudinal axis of rotation.

[0052] Thus, both the first roller and the second roller may be adjustable without having to reposition or adjust the frame to which the first and second rollers are mounted by their shafts or the respective frames.

[0053] The substantially cylindrical outer surfaces of the first and second rollers may each be provided with a plurality of substantially parallel circumferential ridges. The circumferential ridges of the first roller may alternate with the circumferential ridges of the second roller in a tangential plane when the first and second rollers are correctly aligned. In this way, a crimping roller unit is obtained in which a sheet of material may pass between the rollers to be crimped. By allowing fine adjustment of the relative orientation of the rotation axes of the first and second rollers, it is possible to ensure that the sheet of material is crimped evenly across its width.

[0054] When the cylindrical outer surfaces of the first and second rollers approach each other along the tangent plane between the cylindrical outer surfaces, the circumferential ridges of the first roller interlock with the circumferential ridges of the second roller in the tangent plane between the first and second rollers, thereby defining the "crimp depth", which is a radial measure of the distance between the respective peaks of the circumferential ridges of the first and second rollers on either side of the tangent plane. Thus, fine tuning targets a uniform desired crimp depth across the width of the crimp rollers, where the radial distance between the axis of the first roller and the maximum value of the peak of the circumferential ridges of the first roller on one side of the tangent plane is greater than the radial distance between the axis of the first roller and the maximum value of the peak of the circumferential ridges of the second roller on the other side of the tangent plane. Advantageously, the circumferential ridges of the first roller are interleaved with the circumferential ridges of the second roller, the circumferential ridges of each roller being axially spaced such that the peaks of the circumferential ridges of the first roller are substantially aligned with corresponding troughs between the circumferential ridges of the second roller, and vice versa.

[0055] The crimp depth is preferably from 50 to 500 micrometers, and more preferably from 100 to 300 micrometers.

[0056] According to a third aspect of the present invention, there is provided a combination of an inner bushing and an outer flange portion configured to fit over an end of an adjustable roller for a crimper for sheet material, the outer flange portion having a first end and a second end, the longitudinal axis of rotation comprising a substantially cylindrical outer portion extending between the first end and the second end, the bushing having a cylindrical bore having an axis parallel to the longitudinal axis of rotation when the flange portion fits over the end of the adjustable roller, the bushing being adjustably mounted within the flange portion to allow an axis of the bushing to be displaced relative to the longitudinal axis of rotation.

[0057] The combination may be retrofitted to existing rollers to provide adjustability.

[0058] The bushing may be mounted inside the flange portion with a predetermined amount of play in a plane perpendicular to the longitudinal axis of rotation. The bushing may be adjustably securable relative to the flange portion by a number of adjustable fasteners.

[0059] The bushing may be rotatably adjustable relative to the flange portion to allow an axis of the bushing to move along an orbital path about the longitudinal axis during adjustment.

[0060] The offset or skew of the bushing axis from the longitudinal axis of rotation may be provided by eccentricity of the flange portion.The offset or skew of the bushing axis from the longitudinal axis of rotation may be provided by eccentricity of the bushing.

[0061] The bushings may be releasably secured to the respective flange portions by a plurality of bolts, and the bushings may be rotatably adjustable within the respective flange portions by loosening the plurality of bolts, rotating the bushings a predetermined amount, and then tightening the plurality of bolts.

[0062] The flange portion and the bushing may each be provided with indicia to indicate the amount of relative rotation between the flange portion and the bushing. The indicia may include a numerical scale.

[0063] The bushing may be provided with a number of recesses or protrusions configured to receive or be received by a tool for rotatably adjusting the bushing.

[0064] According to a fourth aspect of the present invention, there is provided a method of adjusting the orientation of a longitudinal axis of a roller for a crimper for a sheet material, the roller comprising:

[0065] a substantially cylindrical outer portion having a first end and a second end, with a longitudinal axis of rotation extending between the first end and the second end;

[0066] a first bushing mounted on the inside of a first end of the roller, and a second bushing mounted on the inside of a second end of the roller;

[0067] the first bushing and the second bushing each have a respective cylindrical bore having an axis parallel to the longitudinal axis of rotation;

[0068] at least one of the first bushing and the second bushing is adjustably mounted inside a respective end of the roller such that an axis of at least one of the first bushing and the second bushing is displaceable relative to the longitudinal axis of rotation;

[0069] The method includes adjusting a displacement of at least one of the first bushing and the second bushing relative to the cylindrical outer portion to displace an axis of at least one of the first bushing and the second bushing relative to the longitudinal axis.

[0070] The axis of at least one of the first bushing and the second bushing may be displaced from the longitudinal axis of rotation by up to 1 mm, optionally up to 0.5 mm, optionally up to 0.1 mm, optionally up to 0.05 mm.

[0071] At least one of the first bushing and the second bushing may be mounted inside the respective end of the roller with a predetermined amount of play in a plane perpendicular to the longitudinal axis. At least one of the first bushing and the second bushing may be adjustably securable relative to the respective end of the roller by a plurality of adjustable fasteners. At least one of the first bushing and the second bushing may be adjustably displaced relative to the cylindrical outer portion by adjusting the adjustable fasteners.

[0072] The plurality of adjustable fasteners may be circumferentially disposed about at least one of the first bushing and the second bushing. The plurality of adjustable fasteners may be evenly spaced circumferentially about at least one of the first bushing and the second bushing.

[0073] The multiple adjustable fasteners may include multiple set screws.

[0074] The substantially cylindrical outer portion may be provided with a plurality of radially oriented, circumferentially spaced threaded holes at the first end or the second end, or at both the first and second ends, and a plurality of set screws may be adjustably rotated within the threaded holes to securely hold the respective first bushing or second bushing in a fixed position relative to the respective first end or second end at different selectable displacements of the bushing axis relative to the longitudinal axis of rotation.

[0075] The plurality of adjustable fasteners may include at least three adjustable fasteners, or may include at least four adjustable fasteners.

[0076] An axis of at least one of the first bushing and the second bushing may be offset from or skewed relative to the longitudinal axis of rotation, or may be both offset from and skewed relative to the longitudinal axis of rotation. At least one of the first bushing and the second bushing may be rotatably adjusted relative to the cylindrical outer portion such that during adjustment, an axis of at least one of the first bushing and the second bushing moves along an orbital path about the longitudinal axis.

[0077] In some embodiments, only one of the first bushing and the second bushing is rotatably adjusted to a respective end of the roller with the axis of the bushing offset from or skewed relative to the longitudinal axis of rotation, or both offset from and skewed relative to the longitudinal axis of rotation.

[0078] In some embodiments, both the first bushing and the second bushing are rotatably adjusted relative to their respective ends of the roller with the axes of the bushings offset from or skewed relative to the longitudinal axis of rotation, or both offset from and skewed relative to the longitudinal axis of rotation.

[0079] The axes of the first bushing and the second bushing may be offset from the longitudinal axis of rotation by the same amount, or may be skewed relative to it, or may be both offset from and skewed relative to the longitudinal axis of rotation.

[0080] The axes of the first bushing and the second bushing may be offset from the longitudinal axis of rotation by different amounts, may be skewed relative to it, or may be both offset from and skewed relative to the longitudinal axis of rotation.

[0081] At least one end of the substantially cylindrical outer portion may be provided with a flange portion for receiving the respective first bushing or second bushing.

[0082] The bushings may be releasably secured to the respective flange portions by a plurality of bolts, and the bushings may be rotatably adjusted within the respective flange portions by loosening the plurality of bolts, rotating the bushings a predetermined amount, and then tightening the plurality of bolts.

[0083] The flange portion and the bushing may each be provided with indicia to indicate the amount of relative rotation between the flange portion and the bushing. The indicia may include a numerical scale.

[0084] At least one of the first bushing and the second bushing may be provided with a plurality of recesses or protrusions, and a tool may engage the plurality of recesses or protrusions for rotatably adjusting the bushing.

[0085] The axial offset or distortion, or both, of at least one of the first and second bushings from the longitudinal axis of rotation may be provided by eccentricity of the respective flange portions.

[0086] The axial offset or skew of at least one of the first and second bushings from the longitudinal axis of rotation, or both the offset and skew, may be provided by eccentricity of the bushings.

[0087] The axial offset of at least one of the first bushing and the second bushing from the longitudinal axis of rotation may be 1 mm or less, optionally 0.5 mm or less, optionally 0.1 mm or less, optionally 0.05 mm or less.

[0088] The substantially cylindrical outer portion may have a length along the longitudinal axis of from 200mm to 500mm, optionally a length along the longitudinal axis of from 300mm to 400mm.

[0089] The substantially cylindrical outer portion may have a diameter of from 100mm to 300mm, optionally from 150mm to 250mm.

[0090] The substantially cylindrical outer portion may be provided with a plurality of substantially parallel circumferential ridges.

[0091] The term "adjustable" as used herein describes an element that can be moved between at least two distinct positions, and the element will remain in place in the adjusted position unless intentionally adjusted to another position.

[0092] As used herein, the term "bushing" means a substantially cylindrical member having a longitudinal bore for receiving a shaft and configured to fit inside an outer substantially cylindrical tubular member.

[0093] As used herein, the term "corrugation" refers to a plurality of substantially parallel ridges formed from alternating peaks and troughs joined by flanks of the corrugation, including, but not limited to, corrugations having a square wave profile, a sinusoidal wave profile, a triangular wave profile, a sawtooth wave profile, or any combination thereof.

[0094] As used herein, the term "crimper" means a machine in which a sheet passes between at least a pair of corrugating rollers to impart a plurality of corrugations to the sheet.

[0095] The term "crimp depth" as used herein means a radial measure of the distance between the peaks of the circumferential ridges of the first and second rollers on either side of a tangent plane passing between the first and second rollers when the circumferential ridges of the first and second rollers are alternated in the tangent plane. The crimp depth is the maximum distance between the peaks of the circumferential ridges of the first and second rollers in the tangent plane when the circumferential ridges of each roller are alternated with each other.

[0096] The term "securable" as used herein describes an element that can be releasably secured in a fixed position relative to another element such that there is no relative movement between the elements.

[0097] As used herein, the term "flange portion" means an inner radial lip or rim of a substantially cylindrical outer portion that provides a mounting surface for a first bushing or a second bushing. The flange portion may be integrally formed with the cylindrical outer portion or may be a separate component attached to the cylindrical outer portion.

[0098] The term "alternating" as used herein refers to corrugations of the first and second rollers that are at least partially intermeshed. This includes symmetrical or asymmetrical arrangements of the corrugations of one or both of the rollers. The corrugations of the rollers may be substantially aligned or at least partially offset. A crest of one or more corrugations of the first or second roller may be interleaved with a trough of a single corrugation of the other of the first and second rollers. The corrugations of the first and second rollers may be interleaved such that, for at least a single or multiple sections along the circumference of the rollers, substantially all the corrugation troughs of one of the first and second rollers each receive a peak of a single corrugation of the other of the first and second rollers.

[0099] As used herein, the term "orbital path" means a substantially circular path about an axis of rotation. Movement along an orbital path includes movement along only a portion of the orbital path, for example, along an arc of the orbital path.

[0100] As used herein, the term "polymer sheet" means a sheet made of a polymer, for example polylactic acid.

[0101] As used herein, the term "setscrew" means a threaded element that can be moved in either direction along a threaded hole by rotating the set screw, with one end of the set screw protruding from the threaded hole to contact the element being adjusted to hold it in place. Set screws may have a head or may be headless, such as a grub screw.

[0102] As used herein, the term "sheet" means a laminar element having a width and length substantially greater than its thickness.

[0103] As used herein, the term "substantially cylindrical" refers to a cylindrical shape of substantially circular cross section having a substantially uniform diameter along the longitudinal length of the cylinder. The term "substantially cylindrical" encompasses generally cylindrical elements having surface features, such as corrugations, that have a depth or height that is at least an order of magnitude less than the diameter of the cylindrical element.

[0104] As used herein, the term "tobacco sheet" refers to a sheet made of homogenized tobacco material formed by agglomerating particulate tobacco with an optional binder. EXAMPLES

[0105] The present invention is defined in the claims. However, below is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of any other examples, embodiments, or aspects described herein.

[0106] Example 1: 1. An adjustable roller for a crimper for sheet material, comprising: a substantially cylindrical outer portion having a first end and a second end, with a longitudinal axis of rotation extending between the first end and the second end; a first bushing mounted on the inside of a first end of the roller, and a second bushing mounted on the inside of a second end of the roller; the first bushing and the second bushing each have a respective cylindrical bore having an axis parallel to the longitudinal axis of rotation; an adjustable roller, wherein at least one of the first bushing and the second bushing is adjustably mounted inside each end of the roller such that an axis of at least one of the first bushing and the second bushing is displaceable relative to the longitudinal axis of rotation; Example 2: An adjustable roller according to example 1, wherein the axis of at least one of the first bushing and the second bushing is displaceable from the longitudinal axis of rotation by up to 1 mm, optionally up to 0.5 mm, optionally up to 0.1 mm, optionally up to 0.05 mm. Example 3: An adjustable roller according to example 1 or 2, wherein at least one of the first bushing and the second bushing is mounted inside the respective end of the roller with a predetermined amount of play in a plane perpendicular to the longitudinal axis, and at least one of the first bushing and the second bushing is adjustably fixable to the respective end of the roller by a plurality of adjustable fasteners. Example 4: The adjustable roller according to example 3, wherein a plurality of adjustable fasteners are circumferentially disposed around at least one of the first bushing and the second bushing. Example 5: The adjustable roller according to example 4, wherein the plurality of adjustable fasteners are evenly spaced circumferentially around at least one of the first bushing and the second bushing. Example 6: The adjustable roller according to any one of claims 3-5, wherein the plurality of adjustable fasteners comprises a plurality of set screws. Example 7: An adjustable roller according to example 6, wherein the substantially cylindrical outer portion is provided with a plurality of radially oriented, circumferentially spaced threaded holes at the first end, or at the second end, or at both the first end and the second end, and a plurality of set screws are adjustably rotatable within the threaded holes to securely hold the respective first bushing or second bushing in a fixed position relative to the respective first end or second end at selectable different displacements of the axis of the bushing relative to the longitudinal axis of rotation. Example 8: The adjustable roller according to any one of embodiments 3-7, wherein the plurality of adjustable fixtures includes at least three adjustable fixtures, or the plurality of adjustable fixtures includes at least four adjustable fixtures. Example 9: an axis of at least one of the first bushing and the second bushing is offset from or skewed relative to the longitudinal axis of rotation, or both offset from and skewed relative to the longitudinal axis of rotation; The adjustable according to example 1, wherein at least one of the first bushing and the second bushing is rotatably adjustable relative to the cylindrical outer portion such that during adjustment, an axis of at least one of the first bushing and the second bushing can move along an orbital path about the longitudinal axis. Example 10: The adjustable roller according to any of the preceding embodiments, wherein only one of the first bushing and the second bushing is adjustably mounted inside each end of the roller. Example 11: The adjustable roller according to any one of embodiments 1-9, wherein both the first bushing and the second bushing are adjustably mounted inside each end of the roller. Example 12: An adjustable roller according to example 11, wherein the axes of the first bushing and the second bushing are offset from the longitudinal axis of rotation by the same amount, or skewed relative thereto, or both offset from the longitudinal axis of rotation and skewed relative thereto. Example 13: An adjustable roller according to example 11, wherein the axes of the first bushing and the second bushing are offset from the longitudinal axis of rotation by different amounts, or skewed relative thereto, or both offset from the longitudinal axis of rotation and skewed relative thereto. Example 14: An adjustable roller according to any of Examples 1 to 13, wherein at least one end of the substantially cylindrical outer portion is provided with a flange portion for receiving the respective first bushing or second bushing. Example 15: The adjustable roller according to example embodiment 14, wherein at least one of the first bushing and the second bushing is releasably secured to the respective flange portion by a plurality of bolts. Example 16: The adjustable roller according to example 15, wherein at least one of the first bushing and the second bushing is rotatably adjustable within the respective flange portion by loosening the plurality of bolts, rotating the bushing a predetermined amount, and then tightening the plurality of bolts. Example 17: The adjustable roller according to any one of Examples 14-16, wherein the flange portion and at least one of the first bushing and the second bushing are each provided with indicia to indicate an amount of relative rotation between the flange portion and the bushing. Example 18: The adjustable roller according to embodiment 17, wherein the indicia includes a numerical scale. Example 19: An adjustable roller according to any of Examples 1-18, wherein at least one of the first bushing and the second bushing is provided with a plurality of recesses or protrusions configured to receive or be received by a tool for rotatably adjusting the bushing. Example 20: The adjustable roller according to example 9 or any one of examples 10 to 19 dependent from example 9, wherein the axial offset or distortion, or the offset and distortion, of at least one of the first bushing and the second bushing from the longitudinal axis of rotation is provided by eccentricity of the respective flange portions. Example 21: The adjustable roller according to example 9 or any one of examples 10 to 19 dependent from example 9, wherein the axial offset or distortion, or the offset and distortion, of at least one of the first bushing and the second bushing from the longitudinal axis of rotation is provided by eccentricity of the bushings. Example 22: The adjustable roller according to Example 9, or any one of Examples 10-21 dependent from Example 9, wherein an axial offset of at least one of the first bushing and the second bushing from the longitudinal axis of rotation is 1 mm or less, optionally 0.5 mm or less, optionally 0.1 mm or less, optionally 0.05 mm or less. Example 23: An adjustable roller according to any of Examples 1-22, wherein the substantially cylindrical outer portion has a length along the longitudinal axis of 200mm to 500mm, optionally a length along the longitudinal axis of 300mm to 400mm. Example 24: An adjustable roller according to any of Examples 1-23, wherein the substantially cylindrical outer portion has a diameter of 100mm to 300mm, optionally 150mm to 250mm. Example 25: An adjustable roller according to any of Examples 1-24, wherein the substantially cylindrical outer portion is provided with a plurality of substantially parallel circumferential ridges. Example 26: 13. A roller unit for a crimper for sheet material, comprising a first adjustable roller according to any of the preceding claims in combination with a second roller, the second roller having a substantially cylindrical outer portion having a first end and a second end, a longitudinal axis of rotation extending between the first end and the second end, the longitudinal axis of the second roller being substantially parallel to the longitudinal axis of the first roller, the first and second rollers being movable relative to each other to bring their cylindrical outer surfaces into approximation along a tangent plane between the cylindrical outer surfaces. Example 27: A roller unit according to embodiment 26, wherein fine-tuning of the orientation of the longitudinal axis of rotation of the substantially cylindrical outer part of the first roller relative to the orientation of the longitudinal axis of rotation of the substantially cylindrical outer part of the second roller is obtained by displacing an axis of at least one of the first bushing and the second bushing relative to the longitudinal axis of rotation of the substantially cylindrical outer part of the first roller. Example 28: A roller unit according to embodiment 26, wherein fine adjustment of the longitudinal axis of rotation of the substantially cylindrical outer portion of the first roller relative to the orientation of the longitudinal axis of rotation of the substantially cylindrical outer portion of the second roller is obtained by rotating at least one bushing of the first roller within the substantially cylindrical outer portion of the first roller. Example 29: The second roller is a substantially cylindrical outer portion having a first end and a second end, with a longitudinal axis of rotation extending between the first end and the second end; a first bushing mounted on the inside of a first end of the roller, and a second bushing mounted on the inside of a second end of the roller; the first bushing and the second bushing each have a respective cylindrical bore having an axis parallel to the longitudinal axis of rotation; A roller unit according to any one of Examples 26 to 28, wherein at least one of the first bushing and the second bushing is adjustably mounted inside each end of the roller such that an axis of at least one of the first bushing and the second bushing is displaceable relative to the longitudinal axis of rotation. Example 30: A roller unit according to any one of Examples 26 to 29, wherein the substantially cylindrical outer surfaces of the first and second rollers are each provided with a plurality of substantially parallel circumferential ridges, the circumferential ridges of the first roller alternating with the circumferential ridges of the second roller in a tangential plane when the first and second rollers are precisely aligned.

[0107] Example 31: the outer flange portion having first and second ends, the longitudinal axis of rotation being configured to fit over an end of an adjustable roller for a crimper for sheet material, the crimper having a substantially cylindrical outer portion extending between the first and second ends; the bushing has a cylindrical bore with an axis parallel to the longitudinal axis of rotation when the flange portion fits over the end of the adjustable roller; An inner bushing and outer flange portion combination in which the bushing is adjustably mounted within the flange portion to permit the axis of the bushing to be displaced relative to the longitudinal axis of rotation. Example 32: The combination according to example 31, wherein the axis of the bushing is displaceable from the longitudinal axis of rotation by a maximum of 1 mm, optionally a maximum of 0.5 mm, optionally a maximum of 0.1 mm, optionally a maximum of 0.05 mm. Example 33: A combination according to example 31 or 32, wherein the bushing is mounted inside the flange portion with a predetermined amount of play in a plane perpendicular to the longitudinal axis of rotation, and the bushing is adjustably securable relative to the flange portion by a plurality of adjustable fasteners. Example 34: 34. The combination according to example embodiment 33, wherein the plurality of adjustable fasteners are circumferentially disposed around the bushing. Example 35: The combination according to example 34, wherein the plurality of adjustable fasteners are evenly spaced circumferentially around the bushing. Example 36: The combination according to any one of Examples 33-35, wherein the plurality of adjustable fasteners comprises a plurality of set screws. Example 37: A combination according to example 36, wherein the outer flange portion is provided with a plurality of radially oriented, circumferentially spaced threaded holes, and a plurality of set screws are adjustably rotatable within the threaded holes to securely hold the bushing in a fixed position relative to the outer flange portion at different selectable displacements of the axis of the bushing relative to the longitudinal axis of rotation. Example 38: The combination according to any one of Examples 33-37, wherein the plurality of adjustable fasteners includes at least three adjustable fasteners, or the plurality of adjustable fasteners includes at least four adjustable fasteners. Example 39: The combination according to example 31, wherein the bushing is rotatably adjustable relative to the flange portion to allow an axis of the bushing to move along an orbital path about the longitudinal axis during adjustment. Example 40: The combination according to embodiment 39, wherein the offset or distortion of the axis of the bushing from the longitudinal axis of rotation, or the offset and distortion, is provided by eccentricity of the flange portion. Example 41: The combination according to embodiment 39, wherein the offset or distortion of the axis of the bushing from the longitudinal axis of rotation, or the offset and distortion, is provided by eccentricity of the bushing. Example 42: The combination of any one of Examples 31-41, wherein the bushing is releasably secured to the outer flange portion by a plurality of bolts. Example 43: The combination according to example 42, wherein the bushings are rotatably adjustable within their respective flange portions by loosening the bolts, rotating the bushings a predetermined amount, and then tightening the bolts. Example 44: The combination according to example 43, wherein the outer flange portion and the bushing are each provided with indicia to indicate the amount of relative rotation between the outer flange portion and the bushing. Example 45: The combination according to example 44, wherein the indicia includes a numerical scale. Example 46: The combination according to any one of Examples 31-45, wherein the bushing is provided with a plurality of recesses or protrusions configured to receive or be received by a tool for rotatably adjusting the bushing. Example 47: 1. A method for adjusting the orientation of a longitudinal axis of a roller for a crimper for a sheet material, the method comprising: a substantially cylindrical outer portion having a first end and a second end, with a longitudinal axis of rotation extending between the first end and the second end; a first bushing mounted on the inside of a first end of the roller, and a second bushing mounted on the inside of a second end of the roller; the first bushing and the second bushing each have a respective cylindrical bore having an axis parallel to the longitudinal axis of rotation; at least one of the first bushing and the second bushing is adjustably mounted inside a respective end of the roller such that an axis of at least one of the first bushing and the second bushing is displaceable relative to the longitudinal axis of rotation; The method includes adjusting a displacement of at least one of the first bushing and the second bushing relative to the cylindrical outer portion such that an axis of at least one of the first bushing and the second bushing is displaced relative to the longitudinal axis. Example 48: The method according to example 47, wherein the axis of at least one of the first bushing and the second bushing is displaced from the longitudinal axis of rotation by up to 1 mm, optionally up to 0.5 mm, optionally up to 0.1 mm, optionally up to 0.05 mm. Example 49: A method according to embodiment 47 or 48, wherein at least one of the first bushing and the second bushing is mounted inside each end of the roller with a predetermined amount of play in a plane perpendicular to the longitudinal direction, at least one of the first bushing and the second bushing is adjustably fixable to each end of the roller by a plurality of adjustable fasteners, and at least one of the first bushing and the second bushing is adjustably displaced relative to the cylindrical outer portion by adjusting the adjustable fasteners. Example 50: The method according to example 49, wherein a plurality of adjustable fasteners are circumferentially disposed around at least one of the first bushing and the second bushing. Example 51: The method according to example embodiment 50, wherein the plurality of adjustable fasteners are evenly spaced circumferentially around at least one of the first bushing and the second bushing. Example 52: The method according to any one of embodiments 49-51, wherein the plurality of adjustable fasteners includes a plurality of set screws. Example 53: A method according to example 52, wherein the substantially cylindrical outer portion is provided with a plurality of radially oriented, circumferentially spaced threaded holes at the first end, or at the second end, or at both the first end and the second end, and a plurality of set screws are adjustably rotated within the threaded holes to securely hold the respective first bushing or second bushing in a fixed position relative to the respective first end or second end at selectable different displacements of the axis of the bushing relative to the longitudinal axis of rotation. Example 54: The method according to any one of Examples 49 to 53, wherein the plurality of adjustable fasteners includes at least three adjustable fasteners, or the plurality of adjustable fasteners includes at least four adjustable fasteners. Example 55: an axis of at least one of the first bushing and the second bushing is offset from or skewed relative to the longitudinal axis of rotation, or is both offset from and skewed relative to the longitudinal axis of rotation; A method according to example 47, wherein at least one of the first bushing and the second bushing is rotatably adjusted relative to the cylindrical outer portion such that during adjustment, an axis of at least one of the first bushing and the second bushing moves along an orbital path about the longitudinal axis. Example 56: The method according to example 55, wherein only one of the first and second bushings is rotatably adjusted relative to the respective end of the roller with the axis of the bushing offset from or skewed relative to the longitudinal axis of rotation, or offset from and skewed relative to the longitudinal axis of rotation. Example 57: The method according to example 55, wherein both the first and second bushings are rotatably adjusted relative to the respective ends of the roller, with the axes of the bushings offset from or skewed relative to the longitudinal axis of rotation, or offset from and skewed relative to the longitudinal axis of rotation. Example 58: The method according to example 57, wherein the axes of the first and second bushings are offset from or skewed relative to the longitudinal axis of rotation by the same amount, or are offset from and skewed relative to the longitudinal axis of rotation. Example 59: The method according to example 57, wherein the axes of the first and second bushings are offset from or skewed relative to the longitudinal axis of rotation by different amounts, or are offset from and skewed relative to the longitudinal axis of rotation. Example 60: The method according to any one of Examples 47-59, wherein at least one of the substantially cylindrical outer portions is provided with a flange portion for receiving a respective first or second bushing.

[0108] Example 61: The method according to example 60, wherein the bushing is releasably secured to each flange portion by a plurality of bolts. Example 62: The method according to example 61, wherein the bushings are rotatably adjusted within their respective flange portions by loosening the bolts, rotating the bushings a predetermined amount, and then tightening the bolts. Example 63: The method according to any one of examples 60-62, wherein the flange portion and the bushing are each provided with indicia to indicate the amount of relative rotation between the flange portion and the bushing. Example 64: The method according to example 63, wherein the indicia includes a numerical scale. Example 65: A method according to any one of Examples 47 to 64, wherein at least one of the first bushing and the second bushing is provided with a plurality of recesses or protrusions, and a tool engages with the plurality of recesses or protrusions to rotatably adjust the bushing. Example 66: The method according to example 55, or any one of examples 56 to 65 dependent from example 55, wherein the axial offset or distortion, or the offset and distortion, of at least one of the first bushing and the second bushing from the longitudinal axis of rotation is provided by eccentricity of the respective flange portions. Example 67: The method according to example 55, or any one of examples 56 to 65 dependent from example 55, wherein the axial offset or distortion, or the offset and distortion, of at least one of the first bushing and the second bushing from the longitudinal axis of rotation is provided by eccentricity of the bushing. Example 68: The method according to Example 55, or any one of Examples 56-67 dependent from Example 55, wherein an axial offset of at least one of the first bushing and the second bushing from the longitudinal axis of rotation is 1 mm or less, optionally 0.5 mm or less, optionally 0.1 mm or less, optionally 0.05 mm or less. Example 69: The method according to any one of Examples 47-68, wherein the substantially cylindrical outer portion has a length along the longitudinal axis of 200 mm to 500 mm, optionally a length along the longitudinal axis of 300 mm to 400 mm. Example 70: The method according to any one of embodiments 47-69, wherein the substantially cylindrical outer portion has a diameter of from 100 mm to 300 mm, optionally from 150 mm to 250 mm. Example 71: The method according to any one of Examples 47-70, wherein the substantially cylindrical outer portion is provided with a plurality of substantially parallel circumferential ridges. Example 72: The method according to any one of Examples 47-71, wherein prior to adjusting the displacement of at least one of the first bushing and the second bushing, the roller is adjustably mounted within a crimping machine frame substantially parallel to the second roller, and the roller is adjusted within the frame to a first predetermined tolerance such that a substantially cylindrical portion of the roller is aligned with a corresponding substantially cylindrical portion of the second roller along a tangential plane where the outer circumferential surfaces of the roller and the second roller are closest. Example 73: The method according to example 72, wherein the roller is adjusted by adjusting a displacement relative to a cylindrical outer portion of at least one of the first bushing and the second bushing to displace an axis of at least one of the first bushing and the second bushing relative to the longitudinal axis to a second predetermined tolerance that is finer than the first predetermined tolerance.

Claims

1. An adjustable roller for a crimping machine for sheet material, A substantially cylindrical outer portion having a first end and a second end, with a rotation axis in the longitudinal direction extending between the first end and the second end, The roller comprises a first bushing attached to the inside of the first end, and a second bushing attached to the inside of the second end, The first bushing and the second bushing each have cylindrical holes with axes parallel to the axis of rotation in the longitudinal direction, An adjustable roller, wherein at least one of the first bushing and the second bushing is adjustablely mounted inside the respective ends of the roller such that the shaft of at least one of the first bushing and the second bushing is displaceable with respect to the axis of rotation in the longitudinal direction.

2. The adjustable roller according to claim 1, wherein the shaft of at least one of the first bushing and the second bushing is displaceable from the axis of rotation in the longitudinal direction by a maximum of 1 mm, optionally up to 0.5 mm, optionally up to 0.1 mm, and optionally up to 0.05 mm.

3. The adjustable roller according to claim 1, wherein at least one of the first bushing and the second bushing is mounted inside the respective ends of the roller with a predetermined amount of play in a plane perpendicular to the longitudinal axis, and at least one of the first bushing and the second bushing is adjustablely fixed to the respective ends of the roller by a plurality of adjustable fasteners.

4. The adjustable roller according to claim 3, wherein the plurality of adjustable fasteners include a plurality of set screws, and the substantially cylindrical outer portion is provided with a plurality of radially oriented, circumferentially spaced threaded holes at the first end, or at the second end, or at both the first and second ends, and the plurality of set screws are adjustablely rotatable within the threaded holes to firmly hold the first bushing or the second bushing in place relative to the respective first or second end at different selectable displacements of the axis of the bushing relative to the axis of rotation in the longitudinal direction.

5. The shaft of at least one of the first and second bushings is offset from the axis of rotation in the longitudinal direction, or is distorted with respect to it, or is both offset from the axis of rotation in the longitudinal direction and distorted with respect to it. The adjustable according to claim 1, wherein at least one of the first bushing and the second bushing is rotatably adjustable with respect to the cylindrical outer portion such that the shaft of at least one of the first bushing and the second bushing can move along a trajectory path about the longitudinal axis during adjustment.

6. The adjustable roller according to claim 5, wherein the offset or distortion, or offset and distortion, of the axis of at least one of the first and second bushings from the axis of rotation in the longitudinal direction is provided by the eccentricity of the respective flange portions.

7. The adjustable roller according to claim 5, wherein the offset or distortion, or offset and distortion, of the axis of at least one of the first and second bushings from the axis of rotation in the longitudinal direction is provided by the eccentricity of the at least one bushing.

8. The adjustable roller according to claim 5, wherein the offset of the axis of at least one of the first and second bushings from the rotation axis in the longitudinal direction is 1 mm or less, optionally 0.5 mm or less, optionally 0.1 mm or less, optionally 0.05 mm or less.

9. A roller unit for a crimping machine for sheet material, comprising an adjustable first roller according to any one of claims 1 to 8 in combination with a second roller, wherein the second roller has a substantially cylindrical outer portion having a first end and a second end and a longitudinal axis of rotation extending between the first end and the second end, the longitudinal axis of the second roller being substantially parallel to the longitudinal axis of the first roller, and the first and second rollers being movable relative to each other such that their cylindrical outer surfaces are brought close together along a tangential plane between the cylindrical outer surfaces.

10. The roller unit according to claim 9, wherein fine adjustment of the orientation of the rotation axis in the longitudinal direction of the substantially cylindrical outer portion of the first roller with respect to the orientation of the rotation axis in the longitudinal direction of the substantially cylindrical outer portion of the second roller is achieved by displacing the axis of at least one of the bushings, the first bushing and the second bushing, with respect to the rotation axis in the longitudinal direction of the substantially cylindrical outer portion of the first roller.

11. A method for adjusting the orientation of the longitudinal axis of a roller for a crimping machine for sheet material, wherein the roller A substantially cylindrical outer portion having a first end and a second end, with a rotation axis in the longitudinal direction extending between the first end and the second end, The roller comprises a first bushing attached to the inside of the first end, and a second bushing attached to the inside of the second end, The first bushing and the second bushing each have cylindrical holes with axes parallel to the axis of rotation in the longitudinal direction, At least one of the first bushing and the second bushing is adjustablely mounted inside each of the ends of the roller such that the axis of at least one of the first bushing and the second bushing is displaceable with respect to the axis of rotation in the longitudinal direction. A method comprising adjusting the displacement of at least one of the first and second bushings relative to the cylindrical outer portion such that the axis of at least one of the first and second bushings is displaced with respect to the longitudinal axis.

12. The method according to claim 11, wherein the shaft of at least one of the first bushing and the second bushing is displaced from the axis of rotation in the longitudinal direction by a maximum of 1 mm, optionally up to 0.5 mm, optionally up to 0.1 mm, and optionally up to 0.05 mm.

13. The method according to claim 11, wherein at least one of the first bushing and the second bushing is mounted inside the respective ends of the roller with a predetermined amount of play in a plane perpendicular to the longitudinal axis, at least one of the first bushing and the second bushing is adjustablely fixed to the respective ends of the roller by a plurality of adjustable fasteners, and at least one of the first bushing and the second bushing is adjustablely displaced relative to the cylindrical outer portion by adjusting the adjustable fasteners.

14. The method according to claim 11, wherein, before adjusting the displacement of at least one of the first and second bushings, the roller is adjustablely mounted in a crimping machine frame substantially parallel to the second roller, and the roller is adjusted in the frame to a first predetermined tolerance such that the substantially cylindrical portion of the roller aligns with the corresponding substantially cylindrical portion of the second roller along the tangential surface where the outer surfaces of the roller and the second roller are closest.

15. The method according to claim 14, wherein the roller is adjusted by adjusting the displacement of the cylindrical outer portion of the first bushing and the at least one bushing among the first bushing and the second bushing so as to displace the axis of the at least one bushing among the first bushing and the second bushing with respect to the longitudinal axis, to a second predetermined tolerance which is finer than the first predetermined tolerance.

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