阅读说明：本技术 压痕机、用于压痕机的压痕滚筒和对片材进行压痕的方法 (Creasing machine, creasing roller for a creasing machine and method of creasing a sheet ) 是由 R·瓦尔特里奥 Y·鲁兰 于 2018-06-25 设计创作，主要内容包括：本发明涉及一种压痕机,具有压痕工具(14、20、21)、与压痕工具配合的反向元件(22、23)以及用于使片材(12)前进通过压痕工具(14、20、21)和反向元件(22、23)之间的压痕区域的输送系统(10),压痕工具具有设置有至少一个压痕突起(26)的压痕板(24),其特征在于,压痕板上的压痕突起(26)由多个小的塑性变形的区域构成,区域彼此融合以形成所述压痕突起(26)。本发明还涉及一种适用于根据前述权利要求中任一项所述的压痕机的压痕板(24),压痕板(24)由金属板材制成并且包括至少一个由多个小的塑性变形的区域形成的压痕突起(26),区域彼此融合以形成所述压痕突起。此外,本发明涉及一种对特别是由纸、纸板或箔片制成的片材(12)进行压痕的方法,包括以下步骤：提供关于要施加到片材(12)上的折叠压痕(30)的数据。控制器(60)确定是否库存中有合适的压痕板(24)或是否要制造新的压痕板(24)。基于控制器(60)的确定,从库存(62)中取出现有的压痕板(24),或者通过使用冲压模块(40)对压痕板柸(24’)施加多个小的变形来制造新的压痕板(24),变形构成至少一个压痕突起(26)。压痕板(24)安装在压痕工具(20、21)上,并且压痕工具(20、21)与反向元件(22、23)配合,以将折叠压痕(30)施加到前进通过压痕工具(20、21)和反向元件(22、23)之间的压痕区域的片材(12)。(The invention relates to an creasing machine having a creasing tool (14, 20, 21), a counter element (22, 23) cooperating with the creasing tool, and a conveying system (10) for advancing a sheet (12) through a creasing area between the creasing tool (14, 20, 21) and the counter element (22, 23), the creasing tool having a creasing plate (24) provided with at least one creasing protrusion (26), characterised in that the creasing protrusion (26) on the creasing plate is constituted by a plurality of small plastically deformed areas, which merge into each other to form said creasing protrusion (26). The invention also relates to a creasing plate (24) suitable for use in a creasing machine according to any of the preceding claims, the creasing plate (24) being made of sheet metal and comprising at least one creasing protrusion (26) formed by a plurality of small plastically deformed areas, the areas merging into each other to form said creasing protrusion. Furthermore, the invention relates to a method for creasing a sheet (12), in particular made of paper, paperboard or foil, comprising the steps of: data is provided regarding fold indentations (30) to be applied to the sheet (12). The controller (60) determines whether there are suitable creasing plates (24) in stock or whether a new creasing plate (24) is to be manufactured. Based on the determination by the controller (60), an existing creasing plate (24) is removed from the inventory (62), or a new creasing plate (24) is manufactured by applying a plurality of small deformations to the creasing plate (24') using the stamping module (40), the deformations constituting at least one creasing protrusion (26). The creasing plate (24) is mounted on a creasing tool (20, 21), and the creasing tool (20, 21) cooperates with a reversing element (22, 23) to apply a folding crease (30) to a sheet (12) advancing through a creasing area between the creasing tool (20, 21) and the reversing element (22, 23).)

1. Creasing machine having a creasing tool (14, 20, 21), a counter element (22, 23) cooperating with the creasing tool, and a conveying system (10) for advancing a sheet (12) through a creasing area between the creasing tool (14, 20, 21) and the counter element (22, 23), the creasing tool having a creasing plate (24) provided with at least one creasing protrusion (26), characterised in that the creasing protrusion (26) on the creasing plate is constituted by a plurality of small plastically deformed areas, which merge into each other to form the creasing protrusion (26).

2. The creasing machine according to claim 1, wherein a punching module (40) is provided.

3. The creasing machine of claim 2, wherein the punching module (40) is a turret punch or a plate punch.

4. The creasing machine according to claim 2 or 3, wherein the punching module (40) has a punch (42) and a die (46), the punch (42) having a rounded end.

5. The indenter of claim 4, wherein the rounded end has at least one of a large radius and a small radius.

6. The creasing machine of claim 4 or 5, wherein the radius at the rounded end of the die is 0.2-2 mm or 2-15 mm.

7. The creasing machine according to any of claims 4-6, wherein the punch (42) extends along a straight line and has a length, measured along the straight line, of 5-50 mm.

8. The creasing machine according to any one of claims 4 to 7, wherein the die (46) has a recess (50) for receiving material plastically deformed by the punch (42), the recess (50) having at least one lateral open end coinciding with one of the circular ends of the punch.

9. The creasing machine of claim 8, wherein the die (46) has an outer profile extending close to an open end of the recess (50) at an angle of less than 90 ° with respect to a longitudinal direction of the recess.

10. The creasing machine according to claim 9, wherein the outer contour extends at an angle of 45 ° with respect to a longitudinal direction of the recess (50).

11. The creasing machine according to any one of claims 4 to 10, wherein an elastic ejector (58) is associated with the mould (46).

12. The creasing machine of claim 11, wherein the elastic ejector (58) is a plate made of rubber or elastomer.

13. The creasing machine according to claim 11 or 12, wherein the ejector (58) surrounds the mould.

14. The creasing machine according to any of claims 2-13, wherein a handling system (64) is provided for transferring a manufactured creasing plate (24) from the stamping module (40) to the creasing tool (14).

15. The indenter of claim 14, wherein an inventory (62) is associated with the processing system.

16. The creasing machine according to any of the preceding claims, wherein the thickness of the creasing plate (24) is in the range of 0.2 to 0.6 mm.

17. The creasing machine according to any of the preceding claims, wherein the creasing plate (24) is made of carbon steel or stainless steel.

18. The creasing machine according to any of the preceding claims, wherein the height (h) of the creasing protrusions (26) is 0.6 to 1.6mm, in particular 1.2 mm.

19. The creasing machine according to any of the preceding claims, wherein the creasing protrusion has a radius at its apex of 0.2-0.8 mm, in particular 0.35-0.55 mm.

20. The creasing machine according to any of the preceding claims, wherein the cross-section of the creasing protrusion has a width at its bottom of 1-3 mm, preferably about 2 mm.

21. The creasing machine according to any of the preceding claims, wherein the creasing tool is a reciprocating plunger or piston (20) mounted with the creasing plate (24).

22. The creasing machine according to claim 21, wherein the counter element (22) is a support table.

23. The creasing machine according to claims 1-20, wherein the creasing tool is a creasing drum (21) on which the creasing plate (24) is mounted.

24. The creasing machine according to claim 23, wherein the creasing plate (24) is a curved plate clamped at the creasing drum (21).

25. The creasing machine according to claim 23, wherein the creasing plate (24) is a creasing sleeve clamped at the creasing drum (21).

26. The creasing machine according to any of claims 23-25, wherein the reversing element is a reversing drum (23).

27. Creasing machine according to claim 26, wherein the rollers (21, 23) are adjusted with respect to the plane in which the sheet (12) is conveyed.

28. The creasing machine according to claim 26 or 27, wherein a servo motor (62) is associated with each of the creasing roller (21) and counter roller (23).

29. The creasing machine according to claim 28, wherein a sensor is provided for detecting the position of the sheet (12).

30. The creasing machine according to any of claims 27 to 29, wherein the same clamping mechanism (60) is provided on both rollers (21, 23).

31. The creasing machine according to any of claims 23-30, wherein the clamping mechanism (60) comprises a clamping pin extending into an opening of the creasing plate (24).

32. The indenter of claim 31, wherein a cam mechanism is provided for moving the clamping pin between the clamping position and the release position.

33. The creasing machine according to any of the preceding claims, wherein the counter element is covered by an elastic layer (28).

34. The creasing machine according to claim 33, wherein the resilient layer (28) is made of rubber or elastomer.

35. The creasing machine according to any one of claims 1 to 32, wherein the reversing element is covered by a layer (29) of shape memory material.

36. The creasing machine according to any of claims 22-35, wherein a drive fillet (27) is provided on the creasing plate (24) extending along a majority of the circumference of the creasing drum (21).

37. The creasing machine according to claim 36, wherein the drive fillet (27) is added on the creasing plate (24) and is constituted, for example, by an epoxy material.

38. Creasing plate (24) suitable for use in an indenter according to any of the preceding claims, the creasing plate (24) being made of a sheet metal material and comprising at least one creasing protrusion (26) formed by a plurality of small plastically deformed areas, which areas are fused to each other to form the creasing protrusion.

39. Method for creasing a sheet (12), in particular made of paper, paperboard or foil, comprising the steps of:

-providing data on folding impressions (30) to be applied on the sheet (12),

-the controller (60) determines whether there are suitable creasing-plates (24) in stock or whether a new creasing-plate (24) is to be manufactured,

-based on the determination of the controller (60), taking an existing creasing-plate (24) from the inventory (62), or manufacturing a new creasing-plate (24) by applying a number of small deformations to a creasing-plate sheet (24') using the punching module (40), the small deformations constituting at least one creasing-protrusion (26),

-an indentation plate (24) is mounted on the indentation tool (20, 21),

-the creasing tool (20, 21) cooperates with the reversing element (22, 23) to apply a folding crease (30) to a sheet (12) advancing through a creasing area between the creasing tool (20, 21) and the reversing element (22, 23).

40. The method according to claim 39, wherein the creasing-plate blank (24') is pre-cut.

Technical Field

The present invention relates to an creasing machine having a creasing tool with a creasing plate provided with at least one creasing protrusion, a counter element cooperating with the creasing tool, and a conveying system for advancing a sheet material through a creasing area between the creasing tool and the counter element. The invention also relates to a creasing plate suitable for use in a creasing machine, and to a method of creasing a sheet, in particular made of carton, paperboard or foil.

Background

The creasing machine is used to create one or more creases in the sheet from which folded blanks are cut. Each indentation forms a type of "hinge" that allows the subsequently formed blank to be folded in a well-defined position.

The indenter may be formed as a device or system that may be a stand-alone unit or integrated into a larger machine or system (e.g., a printer or finisher).

The sheet may be made of cardboard, carton or foil and it may be provided to the creasing machine as part of a web, either individually or in a continuous manner.

The indentations are formed by locally applying pressure on the sheet. To this end, it is known that creasing blades press on the surface of the sheet to create a crease. It is also known to provide local protrusions on the indentation tool, for example by etching those parts of the indentation tool that should not protrude or by locally applying a plastic material in a liquid state and then curing it.

The creasing tool may be substantially flat and may move back and forth in a substantially perpendicular direction relative to the plane in which the sheet extends, or may be substantially cylindrical and may rotate so as to engage on the sheet as it is transferred through the creasing area.

A problem with all creasing machines is that it is difficult to quickly adapt to the specific creasing pattern to be applied to the sheet. This has been a problem since digital printing allows very rapid changes from one print job to another.

If the indentation tool is to be manufactured by an etching process, it may take several hours to use a new indentation tool. If the indentation protrusion is formed by applying a plastic material to the carrier, the manufacturing time may be shorter, depending on the time required for curing the plastic material. However, the lifetime of such indentation tools is significantly shorter than the lifetime of indentation tools comprising etched steel plates. In any case, the step of adapting the creasing machine to the new creasing job is the bottleneck when the creasing machine is used in conjunction with a digital printer.

Disclosure of Invention

It is an object of the present invention to provide a creasing tool and a creasing method that can be quickly changed from one creasing pattern to another.

In order to achieve this object, the invention provides a creasing machine as defined above, characterised in that the creasing protrusions on the creasing plate are constituted by a plurality of small plastically deformable areas, which areas merge into each other to form the creasing protrusions. Furthermore, the invention provides a creasing plate suitable for use in a creasing machine of this type, the creasing plate being formed from a sheet metal material and comprising at least one area consisting of a plurality of small plastic deformation areas, which areas merge into each other to form a creasing protrusion. Finally, the above object is solved by a method for creasing a sheet, in particular a sheet made of carton, paperboard or foil, wherein data on folding creases to be applied to the sheet is provided and a controller determines whether there are suitable creasing plates in stock or whether a new creasing plate is to be manufactured. Based on the determination of the controller, the existing creasing plate is taken from inventory, or a new creasing plate is manufactured by applying a number of small deformations to the creasing-plate sheet using a punching machine, the deformations constituting at least one creasing protrusion. Finally, the creasing plate is mounted on a creasing tool, and the creasing tool cooperates with a reversing element to apply a folding crease to a sheet advancing through a creasing area between the creasing tool and the reversing element.

The invention is based on the concept of using a metal creasing plate, wherein the creasing protrusions are formed by a large number of stamping strokes, each stamping stroke producing a creasing protrusion. This allows two advantages to be achieved. First, the service life of the creasing plate is long, because the wear of the creasing protrusions is small, simply because it is made of metal. The strain hardening that inevitably occurs during the stamping process contributes to the wear resistance of the indented panel. Secondly, a single creasing plate may be quickly manufactured with little effort by e.g. a turret punch or a plate punch.

According to a preferred embodiment, a stamping module is provided on the creasing machine. Therefore, it is not necessary to install a separate punch. Instead, a dedicated (smaller) stamping module may be integrated into the machine to form a self-contained indenter that does not require any external mechanical devices in the manufacture of the creasing plate.

The punching module is preferably a turret punch or a plate punch, since these types of machines allow to manufacture the creasing plates in a very flexible but fast manner.

Preferably, the punching module has a punch with a rounded end and a die. The rounded ends help to ensure a smooth transition between the various deformed regions, thereby forming a continuous indentation protrusion.

The rounded end has at least one of a large radius and a small radius depending on the geometry of the indentation protrusion. A large radius facilitates a smooth transition between the individual deformation zones forming the indentation protrusion. A small radius is advantageous for forming an indentation protrusion that is at a very small distance from, or even intersects, an adjacent indentation protrusion.

According to one embodiment, the punch extends along a straight line and has a length, measured along the straight line, of about 5 to 50 mm. The longer the punch, the fewer individual strokes are required to produce the indentation protrusion. However, shorter punches increase flexibility and reduce the force required to deform the creasing plate.

According to a preferred embodiment, the die has a recess for receiving the material plastically deformed by the punch, the recess having at least one lateral open end coinciding with one of the rounded ends of the punch. This geometry of the die helps to create creasing protrusions that are at a small distance from each other, or may even merge into each other, since the creasing protrusions that have been created may be located in close proximity to the open end of the die, so that the punch may very accurately deform the material of the creasing plate in a position very close to the existing creasing protrusions.

The mould preferably has an outer profile which extends adjacent the open end of the recess at an angle of less than 90 deg. relative to the longitudinal direction of the recess, more preferably at an angle of 45 deg. relative to the longitudinal direction of the recess. The advantage of this geometry is that it is possible to produce merged indentation protrusions that extend at an angle of 45 ° with respect to each other.

According to a preferred embodiment of the invention, the elastic ejector is associated with the mould. The ejector helps push the plastically deformed material out of the mold. Furthermore, it prevents the creasing plate from being scratched by contacting the mould.

The elastic ejector may have the form of a plate made of rubber or elastomer. Such a plate can be cut in a very precise manner by water-jet cutting.

Preferably, the ejector surrounds the mold. This allows the elastic ejector to be mounted to the mold by simply forming the elastic ejector with a suitable inner profile adapted to the outer profile of the mold.

According to a preferred embodiment, a processing system is provided for transferring a manufactured creasing plate from a stamping module to a creasing tool. An advantage of such a handling system is that it allows an automatic replacement of one creasing plate with a new creasing plate.

Preferably, the processing system has access to an inventory that stores "old" creasing plates. It is therefore not necessary to make a new creasing plate each time a different blank is to be created, in other words for each new job. Instead, it is likely that a suitable creasing plate is found in inventory.

The thickness of the indentation plate may be in the range of 0.2 to 0.6 mm. Sheet metal of this thickness on the one hand has sufficient strength to achieve a long service life and on the other hand does not require excessive punching forces.

Preferably, the creasing plate is made of carbon steel or stainless steel. This material is advantageous in terms of its mechanical strength and also does not suffer from corrosion problems.

The height of the indentation protrusion may be about 0.6 to 1.6 mm. Preferably, a value of about 1.2mm may be used, even if this depends on the material to be indented. A value of 1.2mm has proven to be a good result for cartons.

The radius of the indentation protrusion at the apex of the indentation protrusion may be about 0.2 to 0.8mm, more preferably about 0.35 to 0.55 mm. These values have proven to be a good compromise between sharp, well-defined indentations on the one hand and a small risk of breaking or damaging the material of the creasing plate during manufacture on the other hand.

Preferably, the cross-section of the indentation protrusion is about 1 to 3mm, preferably about 2mm, wide at its base. The width has an important effect on the impression, and for thinner material the width is preferably chosen smaller, whereas for thicker material (e.g. corrugated board) the larger width should be used.

According to one embodiment of the invention, the creasing tool is a reciprocating plunger mounted with a creasing plate. The counter element is then preferably a support plate. A reciprocating plunger or piston allows for the simultaneous creation of fold indentations in one sheet.

According to a different embodiment of the invention, the creasing tool is a creasing roller mounted with a creasing plate. The reversing element is then preferably a reversing drum. The creasing roller rotates at a peripheral speed corresponding to the speed at which the sheet advances through the creasing area. Thus, the creasing plate "rolls" over the surface of the sheet which may be continuously advanced.

According to a preferred embodiment of the invention, the cylinder can be adjusted with respect to the plane in which the web is conveyed. This allows the direction of creasing to be changed (from above the sheet to below the sheet and vice versa) so that the carton and corrugated board can be creased on the same machine. It is sufficient to replace the cylinders with creasing plates and the cylinders carrying the layers as counter-elements of the creasing plates and to vary the distance between the axes of rotation of the two cylinders and the plane of conveyance of the sheets through the creasing area between the cylinders.

Preferably, a servomotor is associated with each of the creasing roller and the counter roller. The use of separate drives makes it possible to easily adapt to different rotational speeds of the rollers, which is a necessary consequence of the functional interchangeability of the creasing roller and the counter roller.

In order to detect the position of the sheet advancing through the indentation area, a sensor is used. The sensor may detect the leading end of the arriving sheet, or may detect a mark on the sheet. When using a creasing roller as a creasing tool, the creasing plate may be a curved plate clamped on the creasing roller, or the creasing plate may be a creasing sleeve clamped on the creasing roller. Clamping the creasing plate on the creasing roller requires more effort than clamping the creasing sleeve on the creasing roller. However, the manufacture of the creasing plate may take less effort than the manufacture of the creasing sleeve.

Preferably, the same clamping mechanism is provided on both cylinders. This makes it very easy to change the drum from a creasing drum to a counter drum and vice versa.

In order to ensure that the creasing plate and the resilient layer are clamped evenly on the drum without the risk of trapping air pockets between the outer surface of the drum and the sleeve clamped on the drum, the clamping mechanism comprises clamping pins extending into the openings of the creasing plate. This allows the creasing plate to be clamped in a very uniform manner.

Preferably, a cam mechanism is provided for moving the clamp pin between the clamping position and the release position. The cam mechanism is technically very reliable and can be rotated manually using simple tools, thus avoiding complex mechanisms.

According to a preferred embodiment of the invention, the counter element is covered by an elastic layer. Thus, a "universal" counter element is formed, which does not have to be replaced or adapted when mounting different creasing plates to a creasing tool. Conversely, the resilient layer acts as a "mold" when the indentation protrusion deforms the carton, paperboard or foil.

The elastic layer can be made of rubber or elastomer, so that the elasticity and hardness of the elastic layer can be very easily adapted to the specific requirements.

In an alternative embodiment, the counter element is covered by a layer made of shape memory material. The shape memory material allows the use of a mold similar to one having depressions (depressions) that are counterparts to the indentations protrusions on the indentation plate. By rotating both cylinders in a state where the creasing plate is firmly pressed against the surface of the counter cylinder, the indentations can be very conveniently obtained, whereby the indentations are formed by the creasing protrusions. After the current indentation operation is completed, the depression can be "wiped" due to the shape memory effect of the material, so that a "new" counter cylinder with a smooth cylindrical surface can be used.

According to one embodiment of the invention, a drive fillet is provided on the creasing plate, which drive fillet extends along a substantial part of the circumference of the creasing drum. The drive fillet is chosen with regard to its height so that it exerts a constant driving force on the sheet advancing through the indentation area between the rollers, thereby ensuring that the sheet is driven correctly independently of the indentation on the creasing plate.

The drive fillet may be formed by a plastically deformed portion of the creasing plate in a similar manner to the creasing protrusions, or may be created by adding a strip of material, for example made of an epoxy material, to the creasing plate. This increases the flexibility as the height, width and location of the drive fillet can be set to be appropriate for each new creasing job and the creasing plate used therewith.

According to an embodiment of the invention, the creasing-plate blank is pre-cut. Since the creasing machine typically has a dedicated creasing tool, no flexibility in the size of the creasing plate is required. Instead, the manufacturing time of the creasing plate may be reduced by pre-cutting the creasing plate blank before it is sent to the punching module.

Drawings

The present invention will now be described with reference to the accompanying drawings. In the drawings:

figure 1 schematically shows a creasing machine,

figure 2 schematically shows an embodiment of a creasing tool used in the creasing machine of figure 1,

figure 3 schematically shows a second embodiment of a creasing tool for use in the creasing machine of figure 1,

figure 4 shows a cross-section of a creasing plate mounted on a creasing tool, the creasing plate creating a folding crease by pressing a sheet against a reversing element,

figure 5 schematically shows the process of forming creasing protrusions on a creasing plate,

figures 6a to 6c show three different embodiments of punches used in the creasing machine of figure 1,

figures 7a and 7b show a first embodiment of the die used in the creasing machine of figure 1,

figure 8 shows a second embodiment of the mould used in the creasing machine of figure 1,

figure 9 shows a mould according to the prior art,

figure 10 shows a cross section of the punch and the die when the creasing-plate blank is deformed,

FIGS. 11a and 11b schematically show the mold of FIGS. 7a and 7b when two fused creasing protrusions are produced, and the folding creases produced by these folding protrusions, and

figures 12a to 12e schematically show the die of figures 7a and 7b for making three fused folding protrusions, as well as the folding impressions produced by these creasing protrusions and the corresponding blanks cut out of the sheet and the boxes made from the blanks,

figures 13a and 13b show in more detail the creasing protrusions obtained by the punch of figures 6b and 6c,

figures 14a and 14b show a cross-section of a creasing protrusion for creasing a carton,

figures 15a and 15b show in cross-section the creasing protrusions and the creasing obtained thereby for creasing a corrugated carton,

figures 16a and 16b show the creasing tool of figure 3 in a first state and a second state,

figure 17 schematically shows in more detail a creasing tool incorporating a control of the rotational speed of the drum,

figure 18 shows a schematic cross-sectional view of the creasing tool illustrating the rotational speed of the drum,

figure 19 shows on a larger scale the contact areas between the two cylinders of the creasing tool and the sheet to be provided with the crease,

figures 20a to 20c show a top view of the creasing plate, a cross-section through a creasing tool provided with a drive fillet and a cross-section through a portion of the creasing plate provided with a drive fillet and a creasing protrusion,

figures 21a to 21c show perspective views of the cylinder for the creasing tool, enlarged views of the clamping mechanism for clamping the creasing plate and for clamping the resilient layer of the counter cylinder,

figures 22a to 22g show different steps of using counter-cylinders according to alternative embodiments,

figures 23a to 23d show in more detail the roller used in the creasing tool, an

Figures 24a and 24b show the counter cylinder in more detail.

Detailed Description

In fig. 1, the creasing machine is schematically shown. It comprises a conveyor system 10 for advancing a sheet 12 through a creasing area 14, in which creasing area 14 folding indentations may be applied to the sheet 12.

The additional processing stations 16, 18 may be provided as part of or associated with the creasing machine. The processing stations 16, 18 may be used to cut, fold, bond, or otherwise process the sheet 12 or articles produced therefrom.

The sheet 12 may be made from paperboard, carton or foil and may be subsequently processed to cut blanks from the sheet to form packages, boxes, bags, envelopes or similar products.

The sheet 12 may be supplied to the indented areas 14 individually as shown in the drawings or in the form of a continuous web directed through the indented areas 14.

It is also possible to integrate into the creasing area 14a cutting system that allows the separation of the individual blanks from the sheet.

In the creasing area 14, a creasing tool and a reversing element cooperate to apply at least one fold crease to the sheet 12. To this end, the creasing tool carries a creasing plate provided with creasing protrusions. The geometry and arrangement of the creasing protrusions on the creasing plate corresponds to the folding crease to be applied to the sheet.

Fig. 2 shows a first example of a creasing tool and a counter element for use in the creasing area 14.

The indentation tool is here in the form of a plunger 20, which plunger 20 can be advanced towards the counter element 22 and pressed against the counter element 22. On the plunger 20, a creasing plate 24 is mounted, which creasing plate 24 is provided with at least one creasing protrusion 26. For greater clarity, only one indentation protrusion 26 is shown here.

The counter element 22 is provided with an elastic layer 28, preferably formed of rubber or elastomer, on the side facing the plunger 20.

The sheet 12 provided with fold indentations is advanced in the transport system 10 so as to be located between the plunger 20 and the reversing element 22. The plunger 20 is then pressed against the resilient layer 28 so that the creasing protrusions 26 create folding creases 30 by locally deforming the sheet 12.

A second embodiment of the creasing tool and the reversing element is shown in fig. 3. Here, the creasing tool is provided in the form of a creasing roller 21 and the counter element is in the form of a counter roller 23. Thus, the creasing plate 24 is curved and the resilient layer 28 is cylindrical.

The fold impressions 30 are produced by passing the sheet 12 through the gap between the impression cylinder 21 and the counter cylinder 23.

The interaction between the creasing plate 24 and the sheet 12 is shown in more detail in FIG. 4.

The creasing protrusions 26 are formed on the creasing plate 24 by repeatedly and locally deforming the material of the creasing plate 24, thereby creating the creasing protrusions 26 in a desired pattern. To allow the desired plastic deformation, the creasing plate 24 is formed of steel, in particular of carbon steel or stainless steel. It preferably has a thickness of about 0.2 to 0.6 mm.

In order to produce the indentation projection 26, a punching module 40, in particular a turret punch or a plate punch, is provided. These types of punches are generally known. However, it is preferably somewhat suitable for use in conjunction with a creasing machine. In particular, the stamping module 40 may not be as versatile and powerful as a conventional stamping press, as it only requires a very limited number of different operations to be performed in a relatively thin material (i.e., to produce generally straight indentation protrusions).

In fig. 1a punching module 40 with a punch 42 for plastically deforming the creasing-plate blank 24' is schematically shown.

Furthermore, the punching module 40 comprises a turret 44, in which turret 44 a plurality of different punches 42 are stored.

Fig. 5 schematically shows how the stamping module 40 produces the creasing-protrusions 26 by repeatedly plastically deforming the creasing-plate blank 24'. The punch 42 is shown in solid lines and cooperates with a die 46 located on the opposite side of the creasing-plate blank 24'. The position of the punch 42 during the previous press stroke is shown with a dashed line, and the dashed line indicates the position of the punch 42 during the press stroke performed again.

Each stroke produces a small plastic deformation area on the creasing plate blank 24', the entire plastic deformation area forming the creasing protrusions 26.

Fig. 6a to 6c show different embodiments of the punch arranged on the carrier 43.

In fig. 6a, a punch 42 with a relatively short protruding part 45 is shown. The length of the protruding portion may be about one centimeter.

Relatively small radii are provided at the ends of the projecting portions 45 which are opposite to each other as viewed in the longitudinal direction thereof. The radius may be about 0.2 to 2 millimeters.

In fig. 6b, the punch 42 is shown with the protruding portion 45 being approximately three times the length of the protruding portion 45 of the punch 42 shown in fig. 6 a. It can be seen that the radius at the opposite end of the protruding portion is relatively large.

In fig. 6c, a punch 42 is shown having different radii at opposite ends of the protruding portion 45. Small radius R₁Only about 0.2 to 2mm, larger radius R₂About 2 to 15 mm.

The height H (see fig. 10) by which the protruding portion 45 protrudes on the front end surface of the punch 42 is about 1 to 2 mm.

Fig. 7a and 7b show an embodiment of a die 46 adapted to cooperate with the punch 42 and mounted on a carrier 47.

The die 46 has a support surface 48 against which the creasing plate blank 24' may rest during the stamping operation. A recess 50 is provided in the support surface 48. The recess 50 is sized to receive the plastically deformable material of the creasing plate blank 24' forming the creasing protrusion 26.

As can be seen in fig. 7a and 7b, the recess 50 is open at its opposite ends.

It can also be seen in fig. 7a that the outer contour of the mold 46 adjacent to one of the open ends of the recess 50 extends obliquely with respect to the longitudinal direction of the recess 50. In particular, the outer contour extension at each side of the recess 50 extends at an angle of 45 ° with respect to the longitudinal direction of the recess 50.

At the opposite end of the recess 50, the outer contour of the mold 46 extends perpendicularly with respect to the longitudinal direction of the recess 50.

An elastic ejector 58 is arranged at the mold 46. The ejector 58 is formed as a plate from rubber or elastomer and tightly surrounds the mould 46 so that it remains in the position shown in fig. 7b without any additional measures.

In fig. 8, a different embodiment of the mold 46 is shown. Here, the mold 46 has a slanted profile at both open ends of the recess 50 (see the portion pointed by the arrow P).

In fig. 9, a conventional mold 46 having a circular support surface 48 is shown.

In fig. 10, a schematic cross-sectional view through a punch 42 cooperating with a die 46 is shown.

During local deformation of the creasing plate blank 24 'to form the creasing protrusions 26, the creasing plate blank 24' is held between the die 46 and the carrier 43. The carrier 43 is thereby spring-loaded towards the mould 46, thus acting as a clamp.

This avoids tensions in the creasing-plate blank 24' that may cause undesired deformations.

In fig. 11a and 11b, it is schematically shown how adjacent indentation protrusions 26 are formed by a punch cooperating with a die 46. For a clearer illustration, the punch and the creasing plate are not shown in fig. 11 a. Instead, only the indentation protrusions 26 formed at the indentation plate 24 are shown.

The indentation projection 26 extending towards the left in fig. 11a is a previously formed projection. The indentation projection 26 extending through the recess in the die 46 is the indentation projection currently formed with the punch 42. It can be seen that the "new" creasing protrusion 26 may be formed as a point directly adjacent to the "old" creasing protrusion 26.

The result of directly adjacent creasing protrusions 26 is visible in fig. 11b, where folding creases 30 arranged at an angle of 90 ° with respect to each other and almost merging into each other are shown. Since very little non-creased material remains at the corners between the indentations 30, a very precise folding in this area can be achieved.

In fig. 12a to 12e, it is shown how three creasing protrusions 26 are formed on a creasing plate. Due to the specific contour at one of the open ends of the recess 50, the three indentation protrusions 26 may almost merge into each other at the intersection point. As can be seen in fig. 12d, such creasing protrusions 26 may be used to form folding creases 30 on sheet 12.

These indentation protrusions are intended to fold into a crash proof lock bottom box or a compound lid (compoteflap) for a four-cornered or hexagonal tray.

The stamping module 40 is capable of producing different creasing plates 24 by appropriately deforming the creasing plate blank 24' at the desired location. In particular for the schematically shown control device 60 of the creasing machine, in particular for the creasing machine, it may be determined, upon receiving data for a new creasing job, whether a new creasing plate 24 is to be manufactured or whether an "old" creasing plate used in a previous creasing job may be used. Depending on the determination, the controller 60 instructs the stamping module 40 to manufacture a new creasing plate 24, or to remove an "old" creasing plate 24 from an inventory 62 storing previously manufactured creasing plates 24.

The creasing plate 24 (either newly manufactured or removed from inventory 62) is taken over (take over) by the processing system 64 and then installed at the creasing tool.

If the creasing tool is a punch, the plate is mounted in a flat shape. If the creasing tool is a creasing roller, the creasing plate 24 may be bent and clamped to the creasing roller 23, or a circumferentially closed creasing sleeve may be formed and then mounted to the creasing roller 23.

As mentioned above, punches with larger radii on opposite sides (precisely: larger radii on opposite sides of their protruding portion 45) are used to obtain creasing protrusions 26, which creasing protrusions 26 have a smooth transition between the material being deformed with each stroke of the punch. Fig. 13a shows the indentation protrusions 26 at a larger distance from each other. The creasing protrusions 26 merge very smoothly into the creasing plate 24.

Fig. 13b shows two indentation protrusions 26, which are at a very small distance from each other and thus almost merge into each other. These creasing protrusions 26 are obtained by using a punch 42 having a small radius at least at its "front" end (referring to the direction in which the creasing plate blank 24' is displaced in successive strokes). The small radius allows the indentation projection 26 to rise relatively steeply from the indentation plate 24, so that the distance between adjacent ends of the indentation projection 26 can be made small.

It can be seen that the ends of the indentation projection at the opposite end terminate with a larger radius.

Fig. 14a and 14b show a cross-sectional view through a creasing protrusion 26, which creasing protrusion 26 has proven to be very effective for creasing cartons.

In fig. 14a, the thickness of the indentation plate is in the range of 0.4mm, while the height h of the indentation protrusion is in the range of 0.6 to 1.6 mm.

The radius R at the apex of the creasing protrusion 26 may be in the range of 0.25 to 0.7mm, depending on the particular carton to be creased. In other words, the apex matches an inscribed circle of diameter 2R.

Preferred values for the height h are in the range of 1.2mm, while preferred radii may be 0.35mm and 0.525 mm.

In fig. 15a, creasing protrusions 26 for creasing corrugated cardboard are shown, it can be seen that wider creasing protrusions are used compared to the profile shown in fig. 14a and 14b, in particular the angle α is larger than 90 deg. according to a preferred embodiment, this angle may be in the range of 110 to 120 deg., in particular 114 deg..

The wider conical shaped profile of the creasing protrusions 26 effectively compresses the carton on each side of the crease, creating the space required to fold the corrugated cardboard (due to its increased thickness), thereby reducing the tension created when the carton is folded.

Also, typical heights of the indentation protrusions 26 are in the range of 1.2 mm. A value of about 0.5 to 0.6mm, in particular 0.53mm, is suitable for the radius R at the apex of the contour.

A value of about 0.5mm for the radius R at the bottom of the indentation protrusion 26 has proven to be beneficial.

The inscribed circle here may be 1.05mm in diameter.

It is important to note that the creasing protrusions 26 on the same creasing plate 24 may have different heights, depending on the particular requirements.

Fig. 16a and 16b illustrate an advantageous aspect of the creasing tool.

When changing from a creasing paperboard to a creasing corrugated box, the direction of the creasing must be changed. This can be easily done by changing the function of the two rollers 21, 23.

In fig. 16a, the upper roller is used as counter roller 23 and the lower roller is creasing roller 21. Thus, the resilient layer 28 is mounted on the upper roller and the creasing plate 24 is mounted on the lower roller.

In the configuration shown in fig. 16b, the configuration is reversed. The resilient layer 28 is mounted on the lower roller and the creasing plate 24 is mounted on the upper roller. Thus, the upper roller serves as the impression roller 21, and the lower roller serves as the counter roller 23.

However, the same set of rollers is used. The function of the roller is determined only by the "tool" (creasing plate 24 or resilient layer 28) mounted thereon. Both rollers are therefore provided with the same gripping mechanism, here very schematically indicated with reference number 60, and have the same diameter.

The functional outer radius of the two rollers depends on the tool mounted thereon. In particular, the functional outer radius of the cylinder provided with the resilient layer 28 is larger than the functional radius of the cylinder provided with the creasing plate 24. Thus, the plane in which the sheet 12 advances through the impression area between the rollers must be adjusted according to a particular configuration. The respective Δ is indicated between fig. 16a and 16 b.

The plane in which the sheet 12 is arranged can be adjusted vertically by vertically adjusting the feeding device that advances the sheet or by vertically adjusting the two cylinders 21, 23 with respect to the feeding plane.

Another consequence of the difference in the functional radii of the two cylinders is that the rotational speeds of the cylinders are slightly different, since the tangential speeds at the joining point of the sheets 12 must be the same. Furthermore, it must be matched to the speed at which the sheet 12 is advanced through the creasing tool.

To allow individual control of the rotational speed, each drum is provided with a servo motor 62 controlled by a machine controller 64. The machine controller 64 also provides a signal relating to the position of the gripping device 60 as it creates a blind spot where indentation cannot be made.

In addition, the machine controller 64 also provides signals related to the position at which the sheet 12 is advanced through the creasing tool. This signal may be obtained by a sensor 66, which sensor 66 for example detects the leading edge of the sheet 12 upstream of the creasing tool.

Based on the effective radius R_EThe speed V of the advance of the sheet 12 through the creasing tool and the signal from the sensor 66, the machine controller 64 suitably controls the servo motor 62 to obtain the appropriate rotational speed U for each cylinder and the correct position of the blind spot relative to the individual sheet.

In order to manufacture the creasing plate 24, it has to be kept in mind that the creasing plate blank 24' will deform when in a flat shape, whereas the creasing plate is mounted in a curved shape when mounted on the creasing roller 21. This results in that the distance of the creasing protrusions 26 from each other when the creasing plate is mounted onto the creasing drum 21 is larger than in a flat configuration of the creasing plate.

As shown in fig. 18 and 19, the creasing protrusion 26 is pressed into the carton to be creased a certain distance (e.g. 1mm), however this distance is less than the total height of the creasing protrusion. Preferably, however, the outer surface of the creasing plate 24 does not contact the upper surface of the sheet 12. Thus, there is a gap between the outer surface of the creasing plate 24 and the upper surface of the sheet 12.

Fig. 18 shows in an example the actual length L of a straight line between two indentations 30 measured parallel to the feeding direction of sheet 12. Can be at a functional effective radius R_EThe same actual length L of the bend is measured between the apexes of the corresponding indentation protrusions 26. It can be seen that in the flat state of the creasing-plate 24, due to the unfolding radius R_DAnd a functional effective radius R_EDifference therebetween, deployment length L_DLess than the actual length L. Therefore, two creasing protrusions 26 have to be formed on the creasing plate 24 parallel to the feeding direction at a distance which is smaller than the actual distance the respective crease should have on the sheet 12.

In fig. 20a and 20b, another aspect of the creasing tool is shown.

Typically, the sheet 12 is driven between the creasing roller 21 and the counter roller 23 by contact of the creasing protrusions 26 with the sheet and due to contact of the sheet with the counter roller. However, there is an indentation configuration where the indentation protrusion 26 does not engage the sheet 12 at a certain point in time. Due to the gap G explained with reference to fig. 18 and 19, no appropriate driving force is applied to the sheet 12 at these points in time.

In order to ensure that the sheet 12 is always positively driven, irrespective of the specific location of the creasing protrusions 26, a drive fillet 27 is provided which extends in a circular direction along the entire creasing plate 24. The drive fillet 27 may be a plastically deformed portion of the creasing plate 24 in the same manner as the creasing protrusions 26.

However, the drive fillet 27 may also be manufactured in a different manner. For example, epoxy fillets may be added to the creasing plate in a separate manufacturing operation. Such a drive fillet can be seen in fig. 20 c.

The drive fillet 27 does not have to protrude on the surface of the creasing plate 24 in such a way as to create a distinct crease in the sheet 12. The height may be selected primarily based on the expected driving force to be generated.

Figures 21a to 21c show the clamping mechanism 60 in more detail.

The clamping mechanism 60 effectively anchors both ends of the creasing plate 24 or resilient layer 28, and brings both ends equally towards each other. This ensures that the respective sleeve is correctly positioned around the drum. Furthermore, this avoids the problem of air bubbles being trapped under the sleeve. Such air bubbles may cause damage to the creasing plate 24 or resilient layer 28 when the respective sleeve is under pressure during operation.

Fig. 22a to 22g show another aspect of the indenter.

In this embodiment, a sleeve of shape memory material 29 is used on the counter roll 23 instead of the resilient layer 28. The shape memory material layer 29 is plastically deformed by the creasing plate 24.

In fig. 22a, the creasing plate 24 has been mounted on the creasing roller 21, while the layer 29, which in the initial state has a flat surface, is mounted on the counter roller 23.

To shape the layer 29, the two rollers 21, 23 are advanced relative to each other so that the creasing protrusions 26 on the creasing plate 24 penetrate into the layer 29 (see fig. 22 b).

After increasing the distance between the rollers 21, 23 (and if necessary after curing), the layer 29 has the shape of a counter mould with respect to the creasing plate 24 (see fig. 22 c).

Subsequently, the creasing roller 21 with creasing plate 24 and the counter roller 23 with layer 29 may be used to crease the sheet 12 (see fig. 22 d).

After completion of a certain indentation work, the layer 29 returns to its original state. To this end, layer 29 (schematically indicated by reference H in fig. 22e and 22 f) may be heated to "erase" the depression in layer 29.

When the layer 29 returns to its original flat shape (see fig. 22g), the indenter is ready for the next indentation work, which is first to create a new counter mould by deforming the layer 29 using a new indentation plate 24.

Fig. 23a shows the creasing roller 21 in more detail.

The clamping mechanism 60 has a clamping pin 62 that is movable between a clamping position (as shown in fig. 23 c) and a release position (as shown in fig. 23 d).

In the release position, the clamp pins 62 are spread apart compared to the clamping position. Referring to fig. 23c and 23d, the distance between the clamp pins 62 in the clamped position is less than the distance in the released position. In other words, when the gripping pins are in their gripping position, the creasing plate 24, having a hole into which the gripping pin 62 engages, is pulled to the outer circumference of the creasing roller.

The gripping pin 62 is mounted to a sliding element 64, the sliding element 64 being arranged in a groove 66 formed in the creasing roller 21. The sliding elements 64 are biased towards the centre of the groove 66, towards each other (and into the clamped position), by means of a schematically shown spring 68.

A release mechanism is provided for moving the clamp pin 62 from the clamping position to the release position. The release mechanism is here formed as a cam mechanism.

The cam mechanism has a plurality of cams 70 non-rotatably mounted on a shaft 72. The shaft is rotatably mounted in the recess 66. The cam 70 is symmetrical about the center of the shaft 72. Thus, the two vertices are 180 ° apart.

The shaft 72 is provided with a hole for receiving an actuating tool 74, which actuating tool 74 may be a simple rod. The actuating means 74 allows the shaft to rotate and thus the cam 70 to rotate from the rest position shown in figure 23c to the deployed position shown in figure 23 d.

In the rest position, the cams 70 do not exert a significant force on the slide members 64 such that they are urged towards each other by the springs 68 towards the clamping position.

In the deployed position, the cams urge the slide members 64 apart into the release position against the force of the spring 68.

The amount of rotation of the shaft 72 for transitioning the cam 70 from the rest position to the deployed position is approximately 90. It can be seen that in the deployed position the cam 70 is moved "above" the blind spot position, where the two apexes are arranged horizontally as viewed in figure 23d, thereby ensuring that the release mechanism is reliably retained in the deployed position with the clamp pin 70 in the release position.

To install the creasing-plate, the clamping pin 62 is placed in its release position. The creasing plate is then mounted on the creasing drum 21 such that the gripping pins engage in holes provided near the edges of the creasing plate arranged opposite each other. The release mechanism then returns to the rest position so that the gripping pin 62 pulls the creasing plate 24 against the outer circumference of the creasing roller under the influence of the spring 68.

The holding pin 62 is hook-shaped and therefore has a slight undercut into which the creasing plate engages. This ensures that the creasing plate remains mechanically "under" the clamping pin 62 and does not disengage axially outwards when clamped to the creasing roller.

Fig. 24a and 24b show the same clamping mechanism 60, which is known from creasing rollers.

The resilient layer 28 has a reinforcing plate 80 provided with a hole 82, into which hole 82 the clamping pin 62 engages.