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(11) | EP 4 545 284 A1 |
| (12) | EUROPEAN PATENT APPLICATION |
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| (54) | DIE CUTTING APPARATUS AND METHOD FOR PERFORMING CREASING AND CUTTING OPERATIONS ON SHEET PRINTED WITH STAGGERED LAYOUT |
| (57) The present disclosure relates to a die cutting apparatus, comprising a longitudinal
creasing device, at least one longitudinal cutting device, an alignment device, a
transverse creasing device and a transverse cutting device. The longitudinal creasing
device forms at least two sets of longitudinal creases on a sheet conveyed in a longitudinal
direction to the longitudinal creasing device, the at least one longitudinal cutting
device longitudinally cuts the sheet on which the longitudinal creases are formed,
to form separate single sub-sheets, each single sub-sheet having a set of longitudinal
creases, the alignment device aligns patterns on the at least two single sub-sheets
with each other in the transverse direction, the transverse creasing device forms
transverse creases on the aligned at least two single sub-sheets, and the transverse
cutting device transversely cuts the at least two single sub-sheets on which the transverse
creases are formed, to form a plurality of separate products having transverse and
longitudinal creases. The die cutting apparatus of the present disclosure can produce
products of different specifications by means of one set of tooling, improving the
efficiency of the production process.
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TECHNICAL FIELD
[0001] The present disclosure relates to a die cutting apparatus and a method for performing creasing and cutting operations on a sheet printed with a staggered layout, and in particular to a die cutting apparatus enabling gradient (staggered layout) alignment and a method for performing creasing and cutting operations on a sheet printed with a staggered layout.
BACKGROUND
[0002] During flexographic printing, in order to improve printing efficiency, a plurality of repeating patterns of a product are generally printed at one time on the sheet, and protrusions of a printing roller corresponding to these repeating printed patterns are regularly distributed on a circumferential surface of the printing roller in a certain arrangement. In order to keep the printing roller always in full contact with the sheet, gradient layout or staggered layout is used in the prior art for relief printing. Printing with a gradient layout enables a plurality of protrusions, which are used to form a plurality of repeating printed patterns and located at different axial positions of the printing roller, on the printing roller to be uniformly arranged on an outer surface of the printing roller in a circumferential direction of the printing roller, ensuring that the printing roller always has raised portions in contact with the sheet during rotation of the printing roller, so as to avoid vibration and thus avoid overprinting. If the relief printing is not performed using a gradient layout, that is, if the protrusions of the printing roller for forming relief-printed patterns are arranged to be aligned with each other in axial direction on the surface of the printing roller, the printing roller will have problems with vibration and jump-out during printing, not facilitating printing operations.
[0003] A die cutting apparatus is used to process a printed sheet to form individual package products capable of containing a liquid to be packaged, such as milk and juice. Specifically, the die cutting apparatus can form creases on the printed sheet that are subsequently used to fold, and is used to cut the sheet into separate individual package products.
SUMMARY OF THE DISCLOSURE
[0004] According to a first aspect of the present disclosure, there is provided a die cutting apparatus for performing creasing and cutting operations on a sheet printed with a staggered layout, comprising a longitudinal creasing device, at least one longitudinal cutting device, an alignment device, a transverse creasing device and a transverse cutting device, wherein the longitudinal creasing device is configured to form at least two sets of longitudinal creases on the sheet conveyed in a longitudinal direction to the longitudinal creasing device, wherein the at least two sets of longitudinal creases are repeated in a transverse direction; the at least one longitudinal cutting device is configured to longitudinally cut the sheet on which the longitudinal creases are formed, to form at least two separate single sub-sheets, wherein each single sub-sheet has one set of longitudinal creases among the at least two sets of longitudinal creases; the alignment device is configured to align patterns on the at least two single sub-sheets with each other in the transverse direction; the transverse creasing device is configured to form transverse creases on the aligned at least two single sub-sheets; and the transverse cutting device is configured to transversely cut the at least two single sub-sheets on which the transverse creases are formed, to form a plurality of separate products having transverse and longitudinal creases.
[0005] According to the first aspect of the present disclosure, the alignment device comprises at least two offset rollers, the at least two offset rollers being configured to be staggered in the longitudinal direction, and to define different travel paths from the at least one longitudinal cutting device to the transverse creasing device for the at least two single sub-sheets respectively, the different travel paths having different travel distances.
[0006] According to the first aspect of the present disclosure, the longitudinal creasing device is a roller pressing device comprising a plurality of upper longitudinal creasing rollers and a plurality of lower longitudinal creasing rollers, wherein the plurality of upper longitudinal creasing rollers and the plurality of lower longitudinal creasing rollers are configured to be movably and parallel arranged to each other in the transverse direction such that an axial spacing between the longitudinal creasing device is adjustable.
[0007] According to the first aspect of the present disclosure, the at least one longitudinal cutting device comprises a plurality of longitudinal cutting devices movably and parallel arranged to each other in the transverse direction such that a spacing between the plurality of longitudinal cutting devices is adjustable.
[0008] According to the first aspect of the present disclosure, each of the longitudinal creasing device, the at least one longitudinal cutting device, the transverse creasing device and the transverse cutting device has a pair of upper and lower rollers, wherein a spacing between the pair of upper and lower rollers of each of the longitudinal creasing device and the transverse creasing device is adjustable, for adjusting the depths of the creases.
[0009] According to the first aspect of the present disclosure, the die cutting apparatus further comprises nip rollers configured such that the at least two single sub-sheets output from the alignment device are held in tension, and enter the transverse creasing device in the same orientation.
[0010] According to the first aspect of the present disclosure, the transverse cutting device has at least one pair of transverse cutting tools which are capable of covering the at least two single sub-sheets in the transverse direction such that the at least two single sub-sheets can be cut transversely at the same time.
[0011] According to the first aspect of the present disclosure, the die cutting apparatus further comprises a control device configured to adjust the spacing between the longitudinal creasing device, the spacing between the plurality of longitudinal cutting devices, a distance of movement of the at least two offset rollers, and the spacing between the pair of upper and lower rollers of each of the longitudinal creasing device and the transverse creasing device.
[0012] According to the first aspect of the present disclosure, the die cutting apparatus further comprises a frame, wherein the longitudinal creasing device, the at least one longitudinal cutting device, the nip roller, the transverse creasing device and the transverse cutting device are rotatably arranged on the frame, and the alignment device is arranged on the frame.
[0013] According to the first aspect of the present disclosure, rotating shafts of the longitudinal creasing device, the transverse creasing device, the transverse cutting device and the nip roller are arranged parallel to the transverse direction.
[0014] According to the first aspect of the present disclosure, each longitudinal creasing device of the longitudinal creasing devices is rotatably adjustable about a rotating shaft of the longitudinal creasing devices with respect to the other longitudinal creasing devices of the longitudinal creasing devices, to accommodate the sheet printed with a different staggered layout.
[0015] According to the first aspect of the present disclosure, the die cutting apparatus further comprises an alternate longitudinal creasing device, the alternate longitudinal creasing device being configured to form longitudinal creases on the sheet conveyed in the longitudinal direction to the alternate longitudinal creasing device, wherein the alternate longitudinal creasing device is configured to be used alternately with the longitudinal creasing device during forming of the longitudinal creases on the sheet when the specification of the sheet changes.
[0016] According to the first aspect of the present disclosure, the die cutting apparatus further comprises at least one alternate longitudinal cutting device, the at least one alternate longitudinal cutting device being configured to longitudinally cut the sheet on which the longitudinal creases are formed, to form at least two separate single sub-sheets, wherein the at least one alternate longitudinal cutting device is configured to be used alternately with the at least one longitudinal cutting device during longitudinal cutting of the sheet when the specification of the sheet changes.
[0017] According to a second aspect of the present disclosure, there is provided a method for performing creasing and cutting operations on a sheet printed with a staggered layout, comprising: a step S01 of forming longitudinal creases on the sheet conveyed in a longitudinal direction; a step S02 of longitudinally cutting the sheet on which the longitudinal creases are formed, to form at least two separate single sub-sheets; a step S03 of aligning patterns on the at least two single sub-sheets with each other in a transverse direction; a step S04 of forming transverse creases on the aligned at least two single sub-sheets; and a step S05 of transversely cutting the at least two single sub-sheets on which the transverse creases are formed, to obtain a plurality of products having transverse and longitudinal creases from the at least two single sub-sheets.
[0018] According to the second aspect of the present disclosure, the method further comprises, when it is necessary to produce a product of a different specification, setting an alternate longitudinal creasing device and an alternate longitudinal cutting device before the end of production of a product of a previous specification, switching a longitudinal creasing device and a longitudinal cutting device respectively into the alternate longitudinal creasing device and the alternate longitudinal cutting device after the end of production of the product of the previous specification, and repeating the above steps S01-S05 to produce the product of the different specification.
[0019] Some of the additional aspects and advantages of the present disclosure will be set forth in the following description, and some will become apparent from the following description, or be learned by practice of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020]
FIG. 1A is a schematic view of a sheet after being printed with a staggered layout.
FIG. 1B is a partial enlarged view particular A of the sheet in FIG. 1A.
FIG. 2A is a simplified schematic perspective view of a die cutting apparatus according to an embodiment of the present disclosure.
FIG. 2B is a side view of the die cutting apparatus shown in FIG. 2A.
FIG. 3A is a schematic transverse view of a longitudinal creasing device for performing a longitudinal crease operation on a product of a first specification according to an embodiment of the present disclosure.
FIG. 3B is a schematic transverse view of a longitudinal creasing device for performing a longitudinal crease operation on a product of a second specification according to an embodiment of the present disclosure.
FIG. 4A is a schematic overall view of an alignment device 212.
FIG. 4B is a perspective view of one of adjustment devices 234 of the alignment device 212 shown in FIG. 4A.
FIG. 4C is a schematic view of a simplified structure of another embodiment of the alignment device 212 shown in FIG. 4A.
FIG. 5 is a schematic view of a simplified structure of an embodiment of a transverse creasing device.
FIG. 6 is a schematic view of a simplified structure of an embodiment of a transverse cutting device.
FIG. 7 is a flow chart for performing creasing and cutting operations on a sheet printed with a staggered layout according to the present disclosure.
FIG. 8 is a schematic view of sheet patterns formed after step 704 in FIG. 7.
FIG. 9 is a schematic view of sheet patterns formed after step 710 in FIG. 7.
DETAILED DESCRIPTION OF EMBODIMENTS
[0021] Various specific implementations of the present disclosure will be described below with reference to the accompanying drawings which constitute part of the present disclosure, but does not limit the present disclosure. It should be understood that although the terms indicating directions, such as "upper", "lower", "left", "right", "front" and "rear" are used in the present disclosure to describe orientations of structural parts and elements in various examples of the present disclosure, these terms are used herein only for ease of illustration and are determined on the basis of the exemplary orientations shown in the accompanying drawings. Since the embodiments of the present disclosure can be arranged in different directions, these terms indicating directions are merely illustrative and should not be considered as limitations.
[0022] In order to facilitate the understanding of the viewing angle for the views, three-dimensional coordinate axes are introduced in FIGS. 1A-6 of the present disclosure to represent directions, where same arrows pointing in the same direction indicate the same direction. The X axis represents a direction (transverse direction) perpendicular to a printing feed direction, the Y axis represents the feed direction (longitudinal direction), and the Z axis represents a height direction of the die cutting apparatus. Since the embodiments of the present disclosure can be arranged in different directions, the X axis, the Y axis and the Z axis indicating the directions are merely illustrative and should not be considered as limitations.
[0023] The term "comprise/include" and derivatives thereof mean inclusion without limitation. Unless otherwise specified and limited, the terms "mounting", "connecting" and "connection" should be interpret broadly. For example, they may be mechanical, electrical or communication connection, internal communication between two elements, or direct connection or indirect connection via an intermediate medium. For those of ordinary skills in the art, the specific meanings of the above terms can be understood according to specific context. If possible, the same or similar reference numerals used in the present disclosure refer to the same components throughout the specification.
[0024] FIG. 1A is a schematic view of a sheet 100 after being printed with a gradient layout (staggered layout), in which, in order to show the creases more clearly, repeating product patterns (e.g., patterns shown by circles 180) printed on the sheet 100 are shown as circles in FIG. 1A. In addition, the dotted lines in FIG. 1A indicate transverse and longitudinal creases to be formed, and the solid lines indicate die cutting lines.
[0025] The sheet 100 printed with a staggered layout has a plurality of repeating product patterns in both the transverse direction and the longitudinal direction. The repeating product patterns in the transverse direction (the direction perpendicular to the printing feed direction) are offset from each other in the longitudinal direction by a distance D of, for example, 24 mm. If the number of sub-sheets included in the sheet 100 is defined by the number of the printed product patterns in the transverse direction of the printed sheet, the number of sub-sheets is the largest integer rounded down from the result of dividing a transverse dimension W of the printed sheet by a transverse length L of the single sub-sheet. For products of different specifications, the heights of the products, i.e. the transverse lengths L of the single sub-sheets, are also different. For example, when the transverse dimension W of the printed sheet is 600 mm and the transverse length L of the single sheet is 187 mm, the number of sub-sheets of the printed sheet is 3. As shown in FIG. 1A, the sheet 100 has three sub-sheets, namely, a first sub-sheet 101, a second sub-sheet 102, and a third sub-sheet 103. The three sub-sheets are connected together side-by-side in the transverse direction (i.e., the X direction in the figure) of the sheet, and each have a number of repeating patterns in the longitudinal direction, but only one repeating pattern in the transverse direction.
[0026] FIG. 1B is a partial enlarged view A of the sheet 100 in FIG. 1A. As shown in FIG. 1B, the dashed lines extending in the X direction represent transverse crease lines, such as transverse crease lines 110, and the remaining dashed lines (dashed lines extending in the Y direction, and obliquely extending dashed lines) represent longitudinal crease lines to be generated (hereinafter referred to as "longitudinal crease lines"), such as longitudinal crease lines 142, and the solid lines represent die cutting lines, such as die cutting lines 122, 124, 132, 134. A part of the sheet surrounded by two adjacent longitudinal die cutting lines 122,124 and two adjacent transverse die cutting lines 132,134 is a single product to be produced (hereinafter referred to as "single product"). As can be seen in FIG. 1B, the length P of the single product in the feed direction is the circumference of the single product (after being folded along the longitudinal creases), and the length of the single product in the transverse direction is the height H of the single product, i.e., the transverse length L of the single sub-sheet in FIG. 1A.
[0027] In general, in order to obtain a single package product from the sheet 100 after being printed with a gradient layout (staggered layout), a die cutting apparatus of the prior art performs the following operations on the sheet 100: performing a longitudinal creasing operation and a transverse creasing operation on the sheet 100, and then performing a cutting operation. In order to accommodate the distribution of the patterns printed with a staggered layout on the printed sheet, for products of different specifications, in existing die cutting apparatus, a set of separate creasing and die cutting rollers are generally required to produce products of each of these specifications, each set of creasing and die cutting rollers comprising a longitudinal creasing device, a transverse creasing device and a die cutting roll, where the longitudinal creasing device and the transverse creasing device are used to form creases usable for folding the product along longitudinal and transverse creases on the sheet, the die cutting rollers are used to cut the sheet into individual products along the die cutting lines on the sheet, and each individual product can be folded from a flat sheet into a three-dimensional package box.
[0028] Therefore, when using the die cutting apparatus of the prior art, a corresponding number of sets of creasing and die cutting rollers are required for products of different specifications. For example, for products of different specifications with a transverse length L of 200 mm or 250 mm, two sets of creasing and die cutting rollers are required, namely, two longitudinal creasing devices, two transverse creasing devices and two die cutting rollers. When changing the production specifications of the products, the corresponding tooling and die cutting tools need to be replaced, however, the replacement of the tooling or cutting tools will take up time in the production process. If the product has many specifications, multiple sets of creasing and die cutting rollers are required, which undoubtedly increases the cost of production. At the same time, more creasing and die cutting rollers need to be maintained, and more space is required to store the multiple sets of creasing and die cutting rollers.
[0029] Furthermore, when an creasing operation is performed with the die cutting apparatus of the prior art, the plurality of sub-sheets have not been cut apart from each other due to the gradient layout of the printed patterns on the sheet. It is therefore difficult to form complete transverse creases on the current sub-sheet without compromising the adjacent sub-sheet.
[0030] Specifically, as shown in FIG. 1B, taking a transverse crease line 110 on the third sub-sheet 103 as an example, if the transverse crease line 110 on the third sub-sheet 103 extends too long to the left, it may interfere with the adjacent second sub-sheet 102, that is, a left end 112 of the transverse crease line 110 inevitably extends beyond a longitudinal boundary line (i.e., a longitudinal die cutting line 122) between the adjacent third sub-sheet 103 and second sub-sheet 102, to form the transverse creases on the second sub-sheet 102. However, if it is to be avoided that undesired transverse creases are generated on the second sub-sheet 102, the transverse crease line 110 cannot be extended to the position of the longitudinal boundary line (i.e., the longitudinal die cutting line 122), that is, the left end 112 of the transverse crease line 110 cannot reach the longitudinal boundary line (i.e., the longitudinal die cutting line 122), thereby causing the problem of insufficient transverse crease.
[0031] FIGS. 2A-2B show simplified schematic perspective and side views, respectively, of a die cutting apparatus 200 according to an embodiment of the present disclosure, illustrating the positional relationship of the components of the die cutting apparatus 200 and the mating relationship between the components and the sub-sheets. It should be noted that individual components in the die cutting apparatus 200 are shown in a simplified manner only, and the specific structure of the individual components is not shown.
[0032] As shown in FIGS. 2A-2B, the die cutting apparatus 200 has a frame (not shown), on which a first set of tension roller devices 201, 202, an alternate longitudinal creasing device 203, 204, a longitudinal creasing device 205, 206, an alternate longitudinal cutting device 207, 208, a longitudinal cutting device 209, 210, an alignment device 212, a nip roller 221, 222, a transverse creasing device 223, 224, a second set of tension rollers 225, 226 and a transverse cutting device 227, 228 are arranged in sequence along the feed direction. The first set of tension rollers 201, 202, the alternate longitudinal creasing device 203, 204, the longitudinal creasing device 205, 206, the alternate longitudinal cutting device 207, 208, the longitudinal cutting device 209, 210, the nip roller 221, 222, the transverse creasing device 223, 224, the second set of tension rollers 225, 226 and the transverse cutting device 227, 228 are all roller pressing devices, each having a pair of upper and lower rollers positioned above and below the sheet 100. The sheet 100 can travel in the feed direction under the friction of the pair of upper and lower rollers of each of the first set of tension rollers 201, 202 and the second set of tension rollers 225, 226. The pairs of upper and lower rollers described above are arranged on the frame by means of their respective rotating shafts perpendicular to the feed direction, so that they can rotate relative to the frame. The die cutting apparatus 200 may perform creasing and cutting operations on the sheet 100 shown in FIG. 1A, which is printed with a gradient layout.
[0033] As shown in FIG. 2B, in an embodiment of the present disclosure, the feed direction is generally horizontal to the left in the Y direction, so that the upper roller of each of the first set of tension rollers 201, 202, the alternate longitudinal creasing device 203, 204, the longitudinal creasing device 205, 206, the alternate longitudinal cutting device 207, 208, the longitudinal cutting device 209, 210, the nip roller 221, 222, the transverse creasing device 223, 224, the second set of tension rollers 225, 226, and the transverse cutting device 227, 228 rotates in a counterclockwise direction, and the lower roller thereof rotates in a clockwise direction, thereby causing the sheet 100 to be indented and cut approximately in a horizontal direction to the left. It will be appreciated by those of ordinary skill in the art that in some other embodiments, depending on the feed direction, the directions of rotation of the upper and lower rollers may be set accordingly. For example, when the feed direction is to the right, it is also possible that the upper rollers rotate in the clockwise direction, and that the lower rollers rotate in the counterclockwise direction.
[0034] With continued reference to FIGS. 2A-2B, the pair of upper and lower rollers of each of the longitudinal creasing device 205, 206 and the alternate longitudinal creasing device 203, 204 mate with each other in a male-female manner. That is, if an creasing surface of the upper roller has a raised crease pattern, an creasing surface of the corresponding lower roller has a recessed crease pattern. Alternatively, if the creasing surface of the upper roller has a recessed crease pattern, the creasing surface of the corresponding lower roller has a raised crease pattern. The longitudinal creasing device 205, 206 and the alternate longitudinal creasing device 203, 204 may form longitudinal creases on the sheet 100 in the feed direction. The upper and lower rollers of each of the longitudinal creasing device 205, 206 and the alternate longitudinal creasing device 203, 204 are provided with a plurality of creasing rollers (see FIGS. 3A-3B for details) in an axial direction of the rotating shaft, and a distance in the axial direction between the plurality of creasing rollers can be adjusted, to adapt to the need for creasing operations on products of different specifications. When an creasing operation is performed, only one of the longitudinal creasing device 205, 206 and the alternate longitudinal creasing device 203, 204 performs the longitudinal creasing operation on the sheet 100 and the other is in an alternate state or in a state to be adjusted. The detailed structures of the longitudinal creasing device 205, 206 and the alternate longitudinal creasing device 203, 204 will be described below in conjunction with the description of FIGS. 3A-3B.
[0035] With continued reference to FIGS. 2A-2B, the longitudinal cutting device 209, 210 or the alternate longitudinal cutting device 207, 208 is positioned downstream of the longitudinal creasing device 205, 206 and the alternate longitudinal creasing device 203, 204 in the feed direction, and the respective pair of upper and lower rollers of the longitudinal cutting device or the alternate longitudinal cutting device are each provided with a plurality of cutting tools in the axial direction (transverse direction) of the rotating shaft. An axial distance of the plurality of cutting tools is adjustable, to adapt to the needs for longitudinal cutting operations on products of different specifications. The upper roller of the longitudinal cutting device 209, 210 or the alternate longitudinal cutting device 207, 208 is an upper circular knife, and a roller surface of the lower roller thereof is provided with a groove in a position corresponding to an edge of the upper circular knife, so as to cooperate with the upper circular knife to cut the sheet 100. Specifically, depending on the number of the sub-sheets of the sheet 100, the plurality of cutting tools may be transversely adjusted to align with the longitudinal die cutting lines (e.g., the longitudinal die cutting lines 122, 124 shown in FIG. 1B) of the product, so as to perform a longitudinal cutting operation on the sheet 100 along the longitudinal die cutting lines, such that the sheet 100 is cut longitudinally to form a plurality of separate single sub-sheets (e.g., five separate single sub-sheets 261, 262, 263, 264, 265 shown in FIG. 2A). During the longitudinal cutting operation, only one of the longitudinal cutting device 209, 210 and the alternate longitudinal cutting device 207, 208 performs the longitudinal cutting operation on the sheet 100 and the other is in an alternate state or in a state to be adjusted.
[0036] It will be appreciated by those of ordinary skill in the art that in some other embodiments, if the number of sub-sheets of the sheet 100 is two, only one cutting tool may be provided on the respective pair of upper and lower rollers of the longitudinal cutting device 209, 210 or the alternate longitudinal cutting device 207, 208.
[0037] In an embodiment of the present disclosure, only one of the longitudinal creasing device 205, 206 and the alternate longitudinal creasing device 203, 204 is in an operating state during the longitudinal creasing and cutting operations performed on the sheet 100. Accordingly, only one of the longitudinal cutting device 209, 210 and the alternate longitudinal cutting device 207, 208 is in an operating state. For example, when performing the creasing and cutting operation on a sheet having three sub-sheets, the longitudinal creasing device 205, 206 and the longitudinal cutting device 209, 210 that are adjusted to correspond to the three sub-sheets are used. If the specification of the sheet 100 that needs to be indented and cut subsequently is changed from three sub-sheets to five sub-sheets, the alternate longitudinal creasing device 203, 204 and the alternate longitudinal cutting device 207, 208 are adjusted during the current die cutting operation on the sheet having three sub-sheets, such that the corresponding creasing rollers and blades are set to correspond to the sheet having five sub-sheets. After the current die cutting operation of the sheet having three sub-sheets is completed, the longitudinal creasing device 205, 206 and the longitudinal cutting device 209, 210 are switched to the alternate longitudinal creasing device 203, 204 and the alternate longitudinal cutting device 207, 208 by means of a switching device (not shown), a die cutting operation can be performed on a sheet having five sub-sheets with only small adjustments, thus saving time in configuring the longitudinal creasing device and the longitudinal cutting device when changing sheets having different numbers of sub-sheets, so that the die cutting operation is more efficient and convenient. In an embodiment of the present disclosure, the switching device may remove the current tooling and install a tooling to be replaced.
[0038] With continued reference to FIGS. 2A-2B, the alignment device 212 is positioned downstream of the longitudinal cutting device 209, 210 and the alternate longitudinal cutting device 207, 208 in the feed direction, and is used to align the patterns, the transverse crease lines and the transverse die cutting lines on the plurality of sub-sheets, which are separated from each other through longitudinal cutting operation, with each other in the transverse direction.
[0039] In the embodiment shown in FIGS. 2A-2B, the alignment device 212 is provided with five adjustment devices 231, 232, 233, 234, 235. Adjacent two adjustment devices are staggered in the feed direction of the sheet 100 to define different travel paths from the longitudinal cutting device 209, 210 or the alternate longitudinal cutting device 207, 208 to the transverse creasing device 223, 224, respectively, such that two adjacent single sub-sheets of five separate single sub-sheets 261, 262, 263, 264, 265 have different travel distances in the feed direction, thereby creating a travel displacement difference. In FIG. 2B, the adjustment device 231 is concealed by the adjustment device 234 and the adjustment device 232 is concealed by the adjustment device 235.
[0040] The distances by which the five adjustment devices 231, 232, 233, 234, 235 are staggered in the feed direction are respectively set according to the distances by which the patterns on the sheet 100 printed with a staggered layout are staggered in the transverse direction, such that the patterns printed in a staggered layout on adjacent two single sub-sheets of the five separate single sub-sheets 261, 262, 263, 264, 265 can be aligned with each other after subjected to displacement adjustment by the adjustment devices 231, 232, 233, 234, 235, that is, the patterns, the transverse crease lines and the transverse die cutting lines on adjacent two single sub-sheets are aligned with each other in the transverse direction, to facilitate subsequent transverse creasing and transverse cutting operations. The detailed structure of the alignment device 212 will be described below in conjunction with the description of FIGS. 4A-4B.
[0041] With continued reference to FIGS. 2A-2B, the transverse creasing device 223, 224 is positioned downstream of the alignment device 212 in the feed direction. Similar to the longitudinal creasing device, the pair of upper and lower rollers of the transverse creasing device 223, 224 also mate with each other in a male-female manner. That is, if an creasing surface of the upper roller has a raised crease pattern, an creasing surface of the corresponding lower roller has a recessed crease pattern. Alternatively, if the creasing surface of the upper roller has a recessed crease pattern, the creasing surface of the corresponding lower roller has a raised crease pattern. The transverse creasing device 223, 224 may be used to form transverse creases on the separate single sub-sheets 261, 262, 263, 264, 265 aligned by the five adjustment devices 231, 232, 233, 234, 235 of the alignment device 212. The detailed structure of the transverse creasing device 223, 224 will be described below in conjunction with the description of FIG. 5.
[0042] In order to adjust the depths of the longitudinal creases and the transverse creases formed on the sheet 100, the spacing between the pair of upper and lower rollers of each of the longitudinal creasing device 205, 206, the alternate longitudinal creasing device 203, 204 and the transverse creasing device 223, 224 can be adjusted. Since the longitudinal creases (e.g., triangular folds near the longitudinal crease lines 142, 143 in FIG. 1B) are positioned at the top (e.g., on the left side of the third sub-sheet 103 shown in FIG. 1B) or at the bottom (e.g., on the right side of the third sub-sheet 103 shown in FIG. 1B) of the package, and need to be intended deeper than the transverse creases (e.g., the transverse crease lines 110 in FIG. 1B), the spacing between the upper and lower rollers of the longitudinal creasing device 205, 206 or the alternate longitudinal creasing device 203, 204 needs to be adjusted to be smaller than the spacing between the upper and lower rollers of the transverse creasing device 223, 224.
[0043] With continued reference to FIGS. 2A-2B, the transverse cutting device 227, 228 is positioned downstream of the transverse creasing device 223, 224 in the feed direction for transversely cutting the single sub-sheets 261, 262, 263, 264, 265, on which the transverse creases are formed, which are separate from each other, and which are aligned with each other in the transverse direction, to form a plurality of separate products 282 having transverse and longitudinal creases. The detailed structure of the transverse cutting device 227, 228 will be described below in conjunction with the description of FIG. 6.
[0044] With continued reference to FIGS. 2A-2B, the first set of tension rollers 201, 202 are positioned upstream of the longitudinal creasing device 205, 206 and the alternate longitudinal creasing device 203, 204 in the feed direction, and the second set of tension rollers 225, 226 are positioned between the transverse creasing device 223, 224 and the transverse cutting device 227, 228 in the feed direction, or may be positioned downstream of the transverse cutting device 227, 228 in the feed direction, to provide tension for the sheet 100 or the separate single sub-sheets 261, 262, 263, 264, 265 to travel in the feed direction. Specifically, the upper and lower rollers of each of the first set of tension rollers 201, 202 and the second set of tension rollers 225, 226 together apply a certain pressure to the sheet 100 or the separate single sub-sheet 261, 262, 263, 264, 265, and the rotation speed of the second set of tension rollers 225, 226 is slightly greater than that of the first set of tension rollers 201, 202. Since the second set of tension rollers 225, 226 is positioned downstream of the first set of tension rollers 201, 202 in the feed direction, the second set of tension rollers 225, 226 thus pulls the sheet 100 or the separate single sub-sheet 261, 262, 263, 264, 265 in the feed direction relative to the first set of tension rollers 201, 202, to ensure that sheet 100 or the separate single sub-sheets 261, 262, 263, 264, 265 are always held in tension and thus tightened during travel, no wrinkling will be occurred.
[0045] With continued reference to FIGS. 2A-2B, the nip roller 221, 222 is positioned between the alignment device 212 and the transverse creasing device 223, 224 in the feed direction for maintaining a stable tension in the separate single sub-sheets 261, 262, 263, 264, 265 output from the alignment device 212, such that the single sub-sheets 261, 262, 263, 264, 265 separated by the adjustment devices 231, 232, 233, 234, 235 of the alignment device 212 are returned back to the same travel plane, and enter the transverse creasing device 223, 224 in the same orientation (in a direction to the left), thereby facilitating a subsequent transverse creasing operation.
[0046] FIGS. 3A and 3B show simplified schematic views of the upper roller of the longitudinal creasing device of FIG. 2A for two different specifications of products, respectively. It should be noted that FIGS. 3A and 3B only show the upper roller of an exemplary longitudinal creasing device, and only show a simplified structure of the upper roller of the creasing device.
[0047] The alternate longitudinal creasing device 203, 204 is substantially identical in structure to the longitudinal creasing device 205, 206, and the distribution positions of the crease patterns on the creasing surfaces of the upper and lower rollers of the alternate longitudinal creasing device roller 203, 204 and the longitudinal creasing device 205, 206 are the same, and the difference is only whether the crease patterns are raised or recessed. Therefore, in FIGS. 3A and 3B, the upper roller 205 of the longitudinal creasing device is used as a representative to describe the structures and adjustment means of the alternate longitudinal creasing device 203, 204 and the longitudinal creasing device 205, 206.
[0048] As shown in FIGS. 3A-3B, the upper roller 205 of the longitudinal creasing device has a rotating shaft 301 perpendicular to the feed direction, and the upper roller 205 of the longitudinal creasing device has a plurality of creasing rollers, namely a first creasing roller 302, a second creasing roller 304, a third creasing roller 306, a fourth creasing roller 308, a fifth creasing roller 310 and a sixth creasing roller 312, in an axial direction of the rotating shaft 301. The first creasing roller 302, the second creasing roller 304, the third creasing roller 306, the fourth creasing roller 308, the fifth creasing roller 310 and the sixth creasing roller 312 can simultaneously rotate about the rotating shaft 301, and an axial spacing between every two of the first creasing roller 302, the second creasing roller 304, the third creasing roller 306, the fourth creasing roller 308, the fifth creasing roller 310 and the sixth creasing roller 312 can be adjusted.
[0049] With continued reference to FIGS. 3A-3B, crease patterns 322 for forming longitudinal creases on the left side of the first sub-sheet are provided uniformly and circumferentially on a side of the first creasing roller 302 close to the second creasing roller 304, crease patterns 324 for forming longitudinal creases on the right side of the first sub-sheet are provided uniformly and circumferentially on a side of the second creasing roller 304 close to the first creasing roller 302, crease patterns 326 for the left side of the second sub-sheet are provided uniformly and circumferentially on a side of the second creasing roller 304 close to the third creasing roller 306, crease patterns 328 for forming longitudinal creases on the right side of the second sub-sheet are provided uniformly and circumferentially on a side of the third creasing roller 306 close to the second creasing roller 304, crease patterns 332 for forming longitudinal creases on the left side of the third sub-sheet are provided uniformly and circumferentially on a side of the third creasing roller 306 close to the fourth creasing roller 308, crease patterns 334 for forming longitudinal creases on the right side of the third sub-sheet are provided uniformly and circumferentially on a side of the fourth creasing roller 308 close to the third creasing roller 306, crease patterns 336 for forming longitudinal creases on the left side of the fourth sub-sheet are provided uniformly and circumferentially on a side of the fourth creasing roller 308 close to the fifth creasing roller 310, crease patterns 338 for forming longitudinal creases on the right side of the fourth sub-sheet are provided uniformly and circumferentially on a side of the fifth creasing roller 310 close to the fourth creasing roller 308, crease patterns 342 for forming longitudinal creases on the left side of the fifth sub-sheet are provided uniformly and circumferentially on a side of the fifth creasing roller 310 close to the sixth creasing roller 312, and crease patterns 344 for forming longitudinal creases on the right side of the fifth sub-sheet are provided uniformly and circumferentially on a side of the sixth creasing roller 312 close to the fifth creasing roller 310. The crease patterns for adjacent two sub-sheets (e.g., the crease patterns 324 for the right side of the first sub-sheet and the crease patterns 326 for the left side of the second sub-sheet) are staggered by a distance D in the circumferential direction. The staggered distance D corresponds to the distance D by which the repeating patterns on the sheet 100 printed with a staggered layout are staggered in the transverse direction, so that longitudinal creases corresponding to each sub-sheet can be formed on the sheet 100 printed with a staggered layout. In addition, the crease patterns described above are formed by protrusions or recesses on the rollers.
[0050] It will be appreciated by those of ordinary skill in the art that in some other embodiments, the crease patterns for adjacent two sub-sheets (e.g., the crease patterns 324 corresponding to the right side of the first sub-sheet and the crease patterns 326 corresponding to the left side of the second sub-sheet) may not be provided on the same creasing roller (e.g., the second creasing roller 304). Alternatively, the crease patterns for adjacent two sub-sheets may be provided on two adjacent creasing rollers, respectively. Therefore, the distance D by which the crease patterns for adjacent two sub-sheets are staggered in the circumferential direction may also be adjusted by rotating two adjacent creasing rollers and thus changing an angle by which the two adjacent creasing rollers are staggered in the circumferential direction.
[0051] It will be appreciated by those of ordinary skill in the art that in some other embodiments, the number of creasing rollers is not limited to 6, but may be adaptively designed and adjusted depending on the height H (i.e., the transverse length L of the single sheet) of the products of different specifications.
[0052] As shown in FIG. 3A, when performing a longitudinal crease operation on a product having a height H1, for example, when the transverse dimension of the sheet is 600 mm and the height H1 of a single product (i.e., the transverse length L of the single sheet) is 120 mm, the number of sub-sheets that can be provided on the sheet is 5. The axial distance between two adjacent creasing rollers is adjusted accordingly such that a transverse distance covered by the crease patterns on the left and the crease patterns on the right of the same sub-sheet corresponds to the height H1 of the product. For example, the distance between the second creasing roller 304 and the first creasing roller 302 is adjusted with the first creasing roller 302 as a reference, until the distance between the left end of the crease patterns 322 of the first creasing roller 302 for the left side of the first sub-sheet and the right end of the crease patterns 324 of the second creasing roller 304 for the right side of the first sub-sheet is equal to the height H1 of the product.
[0053] As shown in FIG. 3B, when performing a longitudinal crease operation on a product having a height H2, for example, when the transverse dimension of the sheet is 600 mm and the height H2 of a single product (i.e., the transverse length L of the single sheet) is 187 mm, the number of sub-sheets that can be provided on the sheet is 3. The axial distance between two adjacent creasing rollers is adjusted accordingly such that a transverse distance covered by the crease patterns on the left and the crease patterns on the right of the same sub-sheet corresponds to the height H2 of the product. For example, the distance between the second creasing roller 304 and the first creasing roller 302 is adjusted with the first creasing roller 302 as a reference, until the distance between the left end of the crease patterns 322 of the first creasing roller 302 for the left side of the first sub-sheet and the right end of the crease patterns 324 of the second creasing roller 304 for the right side of the first sub-sheet is equal to the height H2 of the product. Since there are only 3 single sheets on the sheet, the fifth creasing roller 310 and the sixth creasing roller 312 are in a non-operating state, and it is only necessary to adjust the axial spacing between every two of the first creasing roller 302, the second creasing roller 304, the third creasing roller 306 and the fourth creasing roller 308.
[0054] FIGS. 4A-4C show perspective views of a simplified structure of an embodiment of the alignment device 212 of FIGS. 2A-2B, where FIG. 4A is a schematic overall view of the alignment device 212, FIG. 4B is a perspective view of one of the adjustment devices 234 of the alignment device 212 shown in FIG. 4A, and FIG. 4C is a schematic view of an alternative to the alignment device 212 shown in FIG. 4A.
[0055] As shown in FIGS. 4A-4B, the alignment device 212 is provided with five adjustment devices 231, 232, 233, 234, 235. Each of the five adjustment devices 231, 232, 233, 234, 235 is provided with an offset roller 411, 412, 413, 414, 415. Since the five adjustment devices 231, 232, 233, 234, 235 are of the same structure and principle of operation, the structure and principle of operation of these adjustment devices are described in FIG. 4B with the adjustment device 234 as a representative.
[0056] As shown in FIG. 4B, the adjustment device 234 is provided with a screw driving mechanism, comprising a nut 402 and a thread screw 404. The thread screw 404 is connected to the nut 402 by a thread, and the nut 402 is fixedly mounted on the frame, so that a rotational movement of the thread screw 404 in the nut 402 can be converted into a linear movement of the thread screw 404 in the height direction relative to the frame. That is, every revolution of the thread screw 404 in the nut 402 will cause the thread screw to move upwardly or downwardly by a fixed distance. The adjustment device 234 is further provided with an offset roller 414 and an offset roller support 406. The offset roller 414 is rotatably fixed to the offset roller support 406 via a rotating shaft 408. The direction of the rotating shaft 408 of the offset roller is perpendicular to the feed direction and parallel to the direction of the rotating shaft of the longitudinal cutting device 209, 210 upstream thereof and the direction of the rotating shaft of the nip roller 221, 222 downstream thereof, and the direction of the rotating shaft 408 of the offset roller is perpendicular to an extension direction of the thread screw 404. An upper end of the thread screw 404 is perpendicularly connected to the bottom of the offset roller support 406 and is rotatable, so that the linear movement of the thread screw 404 in the height direction can drive both the offset roller support 406 and the offset roller 414 to move upwardly or downwardly. In some other embodiments, according to the same principle of operation of the screw driving mechanism, the height of the offset roller 414 can be adjusted by rotating the nut 402 with respect to the thread screw 404, which will not be described here.
[0057] As shown in FIG. 4B, the single sub-sheet 264 formed by cutting the sheet 100 with the longitudinal cutting device 209, 210 passes under the offset roller 414 of the adjustment device 234 and enters the nip roller 221, 222 after being diverted by the offset roller 414. Since the single sub-sheet 264 is always held in tension under the pulling of the first set of tension rollers 201, 202, a certain pressure is always maintained between the single sub-sheet and the offset roller 414. The linear movement of the offset roller 414 in the height direction may cause the single sub-sheet 264 to be correspondingly offset under pressure, such that the path of movement of the single sub-sheet 264 between the longitudinal cutting device 209, 210 and the nip roller 221, 222 changes. In an embodiment of the present disclosure, the greater the distance by which the offset roller 414 moves downwardly, the longer the path of movement of the single sub-sheet 264 between the longitudinal cutting device 209, 210 and the nip roller 221, 222. On the contrary, the smaller the distance by which the offset roller 414 moves downwardly, the shorter the path of movement of the single sub-sheet 264 between the longitudinal cutting device 209, 210 and the nip roller 221, 222. The downward movement distance of the offset roller 414 is correspondingly controlled and adjusted based on a distance by which the printed patterns on the single sub-sheet 264 are staggered from the printed patterns on a transversely adjacent single sub-sheet, such that the increased movement distance of the single sub-sheet 264 between the longitudinal cutting device 209, 210 and the nip roller 221, 222 can compensate for the distance by which the printed patterns on the single sub-sheet are staggered from the printed patterns on the adjacent single sub-sheet, the printed product patterns on the five separate single sub-sheets 261, 262, 263, 264, 265 that are originally staggered from one another are adjusted by the adjustment devices 231, 232, 233, 234, 235, and finally the five separate single sub-sheets enter the nip roller 221, 222 with the patterns thereon aligned with each other.
[0058] Other implementations of the adjustment device may be possible, based on the same principle as the adjustment device 234 in FIG. 4B adjusting the displacement of the single sub-sheet 264.
[0059] FIG. 4C is a schematic view of a simplified structure of another embodiment of the alignment device 212 shown in FIG. 4A, and also uses a separate adjustment device 434 as a representative example for illustration.
[0060] As shown in FIG. 4C, the adjustment device 434 comprises a fixed roller 422 and an adjustment roller 424. The adjustment roller 424 is positioned downstream of the fixed roller 422 in the feed direction and located above the fixed roller 422. Rotating shafts of the fixed roller 422 and the adjustment roller 424 are both perpendicular to the feed direction, the fixed roller 422 is rotatably fixed to the frame via its rotating shaft, and the adjustment roller 424 is rotatably and movably connected to the frame via its rotating shaft. The rotating shaft of the adjustment roller 424 may be movably connected with the frame using connection means (e.g., a ball screw, or a hydraulic, pneumatic or linear motor) commonly used in the mechanical field. The single sub-sheet 264 formed by cutting the sheet 100 with the longitudinal cutting device 209, 210 passes under the fixed roller 422 of the adjustment device 434, is diverted by the fixed roller 422 and then passes around the top of the adjustment roller 424, is diverted again by the adjustment roller 424, and then enters the nip roller 221, 222.
[0061] Since the single sub-sheet 264 is always held in tension under the pulling of the first set of tension rollers 201, 202, pressure is always maintained between the single sub-sheet and the adjustment roller 424. Movement of the adjustment roller 424 in a direction indicated by an arrow in the figure may cause the single sub-sheet 264 to be offset in the corresponding direction, such that the path of movement of the single sub-sheet 264 between the longitudinal cutting device 209, 210 and the nip roller 221, 222 changes.
[0062] It will be appreciated by those of ordinary skill in the art that ways of changing the path of movement of the single sub-sheet between the longitudinal cutting device 209, 210 and the nip roller 221, 222 include, but are not limited to, the embodiments shown in FIGS. 4A-4C, and any technical solution that enables the cut single sub-sheet to have an adjustable path of movement (displacement) in the feed direction is equivalent to the embodiments shown in FIGS. 4A-4C, and shall be included in the scope of protection of the present disclosure.
[0063] FIG. 5 is a schematic view of a simplified structure of an embodiment of a transverse creasing device. The distribution positions of the crease patterns on the creasing surfaces of the upper and lower rollers of the transverse creasing device 223, 224 are the same, and the difference is only whether the crease patterns are raised or recessed. Therefore, in FIG. 5, the upper roller 223 of the transverse creasing device is used as a representative to describe the structure of the transverse creasing device 223, 224.
[0064] As illustrated in FIG. 5, the upper roller 223 of the transverse creasing device can rotate about a rotating shaft 502 perpendicular to the feed direction. The upper roller 223 of the transverse creasing device is provided on its circumferential surface with a number of transverse crease patterns 511-518 corresponding to transverse crease lines (e.g., the transverse crease lines 110 shown in FIG. 1B) on the sheet 100. The number of transverse crease patterns 511-518 extend in the transverse direction, and may cover all the single sub-sheets in the transverse direction, so that transverse creases can be formed simultaneously along the transverse crease lines on the five separate single sub-sheets 261, 262, 263, 264, 265 that have been aligned from the staggered layout. In an embodiment of the present disclosure, three sets of transverse crease patterns are uniformly arranged continuously along one revolution of the upper roller 223 of the transverse creasing device, each set of transverse crease patterns being arranged on the circumferential surface of the upper roller 223 of the transverse creasing device at a position corresponding to transverse crease lines on a product. For example, the transverse crease lines 513-516 over the distance P in FIG. 5 (with reference to FIG. 1B described above, where the distance P represents the perimeter of a single product) correspond to the transverse crease lines of a product on a single sub-sheet. With this arrangement, after every revolution of the upper roller 223 of the transverse creasing device, transverse crease lines of three products can be formed on a single sub-sheet.
[0065] It will be appreciated by those of ordinary skill in the art that according to the requirements of actual production, it is also possible to provide a different number of sets of transverse crease patterns continuously along one revolution of the transverse creasing device, or to provide only one set of transverse crease patterns along one revolution of the transverse creasing device.
[0066] FIG. 6 is a schematic view of a simplified structure of an embodiment of a transverse cutting device. Since the transverse cutting tools on the upper and lower rollers of the transverse cutting device 227, 228 are mounted in the same positions, the upper and lower cutting tools are aligned with each other like scissors for cutting the sub-sheets transversely. Therefore, in FIG. 6, the upper roller 227 of the transverse cutting device is used as a representative to describe the structure of the transverse cutting device 227, 228.
[0067] As illustrated in FIG. 6, the upper roller 227 of the transverse cutting device can rotate about a rotating shaft 602 perpendicular to the feed direction. The upper roller 227 of the transverse cutting device is mounted, on its circumferential surface, with a number of transverse cutting tools 611, 612 aligned with transverse die cutting lines(e.g., the transverse die cutting lines 132, 134 shown in FIG. 1B) on the sheet 100. The number of transverse cutting tools 611, 612 have a cutting direction perpendicular to the feed direction and can cover all the single sub-sheets in the transverse direction, so that the five separate single sub-sheets 261, 262, 263, 264, 265 can be simultaneously cut transversely along the transverse die cutting lines, so as to form a plurality of products having transverse and longitudinal creases (e.g., a plurality of products 282 in FIG. 2A). For example, the transverse cutting tools 611, 612 separated by the distance P in FIG. 6 (with reference to FIG. 1B described above, where the distance P represents the perimeter of a single product) correspond to the transverse die cutting lines at two side boundaries of a product on a single sub-sheet. In an embodiment of the present disclosure, three transverse cutting tools are continuously and uniformly mounted along one revolution of the upper roller 227 of the transverse cutting device, so that with every revolution of the upper roller 227 of the transverse cutting device, three products can be cut from each single sub-sheet 261, 262, 263, 264, 265.
[0068] It will be appreciated by those of ordinary skill in the art that according to the requirements of actual production, it is also possible to provide a different number of transverse cutting tools continuously along one revolution of the transverse cutting device, or to provide only one transverse cutting tool along one revolution of the transverse cutting device.
[0069] It will be appreciated by those of ordinary skill in the art that the die cutting apparatus 200 of the present disclosure may further comprise a control device (not shown), which is communicatively connected to the first set of tension rollers 201, 202, the alternate longitudinal creasing device 203, 204, the longitudinal creasing device 205, 206, the alternate longitudinal cutting device 207, 208, the longitudinal cutting device 209, 210, the alignment device 212, the nip roller 221, 222, the transverse creasing device 223, 224, the second set of tension rollers 225, 226 and the transverse cutting device 227, 228. It is possible to input corresponding commands on a control panel of the control device, so as to separately control the rotation speed of the pair of upper and lower rollers of each of the first set of tension rollers 201, 202, the alternate longitudinal creasing device 203, 204, the longitudinal creasing device 205, 206, the alternate longitudinal cutting device 207, 208, the longitudinal cutting device 209, 210, the nip roller 221, 222, the transverse creasing device 223, 224, the second set of tension rollers 225, 226, and the transverse cutting device 227, 228; or to control the spacing between the pair of upper and lower rollers of each of the longitudinal creasing device 205, 206, the alternate longitudinal creasing device 203, 204 and the transverse creasing device 223, 224; or to control the axial spacing between the plurality of creasing rollers of the longitudinal creasing device 205, 206 or the alternate longitudinal creasing device 203, 204, and the axial spacing between the plurality of cutting tools of the longitudinal cutting device 209, 210 or the alternate longitudinal cutting device 207, 208; or to control the rotation of the thread screw 404 or the nut 402 of the alignment device 212, and the movement of the adjustment roller 424; or to control the replacement use between the longitudinal creasing device 205, 206 and the alternate longitudinal creasing device 203, 204 and the switching use between the longitudinal cutting device 209, 210 and the alternate longitudinal cutting device 207, 208, thereby enabling automatic control of the die cutting apparatus.
[0070] FIG. 7 is a flow chart for performing creasing and cutting operations on a sheet printed with a staggered layout according to the present disclosure. FIG. 8 is a schematic view of sheet patterns formed after step 704 in FIG. 7, and FIG. 9 is a schematic view of sheet patterns formed after step 710 in FIG. 7.
[0071] As shown in FIG. 7, in step 702, for a product of a particular specification, the rotation speed of the pair of upper and lower rollers of each of the first set of tension rollers 201, 202, the longitudinal creasing device 205, 206, the longitudinal cutting device 209, 210, the nip roller 221, 222, the transverse creasing device 223, 224, the second set of tension rollers 225, 226 and the transverse cutting device 227, 228, the spacing between the pair of upper and lower rollers of each of the longitudinal creasing device 205, 206 and the transverse creasing device 223, 224, the axial spacing between the plurality of creasing rollers of the longitudinal creasing device 205, 206, the axial spacing between the plurality of cutting tools of the longitudinal cutting device 209, 210, and an offset distance of each of the five offset rollers 411, 412, 413, 414, 415 of the alignment device 212 are preset, and for the production of a product of the next specification, the axial spacing between the plurality of creasing rollers of the alternate longitudinal creasing device 203, 204 and the axial spacing between the plurality of cutting tools of the alternate longitudinal cutting device 207, 208 tare set in advance. After the operation of step 702 is completed, the flow proceeds to step 704.
[0072] In step 704, the sheet 100 printed with a staggered layout travels to the longitudinal creasing device 205, 206, and longitudinal creases (e.g., longitudinal crease lines 810) are formed on the sheet 100 by the longitudinal creasing device 205, 206. The sheet patterns formed in step 704 are shown in FIG. 8, and it can be seen that the crease patterns (e.g., patterns 801, 802, 803) on adjacent sub-sheets are staggered in the transverse direction. After the operation of step 704 is completed, the flow proceeds to step 706.
[0073] In step 706, the sheet 100 on which the longitudinal creases are formed travels to the longitudinal cutting device 209, 210, and the sheet 100 is separated into five separate single sub-sheets 261, 262, 263, 264, 265 by longitudinal cutting operation of the longitudinal cutting device 209, 210. After the operation of step 706 is completed, the flow proceeds to step 708.
[0074] In step 708, the five separate single sub-sheets 261, 262, 263, 264, 265 formed by the cutting operation travel to the alignment device 212, and the offset distance of each of the five offset rollers 411, 412, 413, 414, 415 of the alignment device 212 is set to cause the five separate single sub-sheets 261, 262, 263, 264, 265 to create travel displacement differences in the feed direction, such that the patterns of the products on the five separate single sub-sheets 261, 262, 263, 264, 265 that are printed with a staggered layout are aligned with each other in the transverse direction. After the operation of step 708 is completed, the flow proceeds to step 710.
[0075] In step 710, the aligned five separate single sub-sheets 261, 262, 263, 264, 265 are adjusted by the nip roller 221, 222 and then enter the transverse creasing device 223, 224 in the same orientation, and at least one set of transverse creases (e.g. transverse crease lines 902) are simultaneously formed on the five separate single sub-sheets 261, 262, 263, 264, 265 by the transverse creasing device 223, 224. The sheet patterns formed in step 710 are shown in FIG. 9, and it can be seen that the crease patterns (e.g., patterns 801, 802, 803) on adjacent sub-sheets are aligned in the transverse direction. After the operation of step 710 is completed, the flow proceeds to step 712.
[0076] In step 712, the five separate single sub-sheets 261, 262, 263, 264, 265 on which the transverse creases are formed travel to the transverse cutting device 227, 228, and a plurality of products 282 having transverse and longitudinal creases are cut from the five separate single sub-sheets 261, 262, 263, 264, 265 by transverse cutting operation of the transverse cutting device 227, 228. After the operation of step 712 is completed, the flow proceeds to step 714 where the creasing and cutting operations of the sheet 100 are completed.
[0077] It will be appreciated by those of ordinary skill in the art that, for the production of a product of the next specification, the axial spacing between the plurality of creasing rollers of the alternate longitudinal creasing device 203, 204 and the axial spacing between the plurality of cutting tools of the alternate longitudinal cutting device 207, 208 may be set in an operation prior to step 714 as long as the settings of the alternate longitudinal creasing device 203, 204 and the alternate longitudinal cutting device 207, 208 are completed before the end of production of the product of the previous specification. After the production of the product of the previous specification is completed, the longitudinal creasing device 205, 206 and the longitudinal cutting device 209, 210 are switched to the alternate longitudinal creasing device 203, 204 and the alternate longitudinal cutting device 207, 208, respectively, by means of the switching device, and steps 704 to 712 above are repeated to continue to produce the product of the next specification.
[0078] An objective of the present disclosure is to at least partially solve the foregoing technical problem.
[0079] Compared with the prior art, the die cutting apparatus of the present disclosure has the following beneficial technical effects.
[0080] First, the die cutting apparatus of the present disclosure is provided with a longitudinal cutting device and an alignment device such that the transversely staggered patterns on the sheet printed with a staggered layout are longitudinally separated from each other by the longitudinal cutting device and then transversely aligned by the alignment device, thereby facilitating the subsequent transverse creasing operation and transverse cutting operation, not only avoiding the replacement of the transverse creasing device and the transverse cutting device, but also avoiding that the transverse crease lines on the sheet cannot be pressed to the longitudinal boundary lines of the patterns (insufficient transverse creases), or avoiding that unwanted transverse creases are formed on adjacent sub-sheets.
[0081] Second, on the basis of the first point, the die cutting apparatus of the present disclosure is provided with a longitudinal creasing device having an adjustable axial spacing and at least one longitudinal cutting device having an adjustable axial spacing, so that the production of products of different specifications can be achieved by means of one set of tooling, avoiding the use of multiple sets of tooling or cutting tools for the production of products of different specifications, thus saving the production and maintenance costs of the tooling and cutting tools, and saving the storage space for multiple sets of creasing and die cutting rollers.
[0082] Third, the present disclosure adapts to the production of products of different specifications by adjusting the axial spacing of the longitudinal creasing device or the longitudinal cutting device, not only making the operations easy, but also saving time for replacing the tooling and die cutting tools, and improving the efficiency of the production process. The scrap rate of the product is also reduced because fewer components need to be adjusted than the existing technology in which the complete set of tooling or cutting tools are replaced.
[0083] Fourth, on the basis of the above three points, the die cutting apparatus of the present disclosure is further provided with an alternate longitudinal creasing device and an alternate longitudinal cutting device. If the specification of the product is to be changed, the axial spacings of the alternate longitudinal creasing device and the alternate longitudinal cutting device are adjusted in advance. After the production of the product of the previous specification, the longitudinal creasing device and the longitudinal cutting device are switched to the alternate longitudinal creasing device and the alternate longitudinal cutting device, respectively, by means of the switching device, so that the die cutting operation can be performed without interruption on sheets having different numbers of sub-sheets, thereby saving time for adjusting the longitudinal creasing device and the longitudinal cutting device during the change of the product with different specification, making the die cutting operation more efficient and convenient, further improving the efficiency of the production process, and resulting in a reduction in the time required for the process by about 30%.
[0084] Although the present disclosure is described in conjunction with the examples of embodiments outlined above, various modifications may be obvious to those skilled in the art. In addition, the technical effects and/or technical problems described in the present disclosure are illustrative rather than restrictive. Accordingly, the examples of the embodiments of the present disclosure as set forth above are intended to be illustrative rather than limiting. The present disclosure is intended to include all alternatives which are technical equivalents to the claimed ones.
1. A die cutting apparatus (200) for performing creasing and cutting operations on a
sheet (100) printed with a staggered layout, comprising:
a longitudinal creasing device (205, 206) configured to form at least two sets of longitudinal creases on the sheet (100) conveyed in a longitudinal direction to the longitudinal creasing device (205, 206), the at least two sets of longitudinal creases being repeated in a transverse direction;
at least one longitudinal cutting device (209, 210) configured to longitudinally cut the sheet (100) on which the longitudinal creases are formed, to form at least two separate single sub-sheets (261, 262, 263, 264, 265), each single sub-sheet has one set of longitudinal creases among the at least two sets of longitudinal creases;
an alignment device (212) configured to align patterns on the at least two single sub-sheets (261, 262, 263, 264, 265) with each other in the transverse direction;
a transverse creasing device (223, 224) configured to form transverse creases on the aligned at least two single sub-sheets (261, 262, 263, 264, 265); and
a transverse cutting device (227, 228) configured to transversely cut the at least two single sub-sheets (261, 262, 263, 264, 265) on which the transverse creases are formed, to form a plurality of separate products (282) having transverse and longitudinal creases.
2. The die cutting apparatus according to claim 1, wherein
the alignment device (212) comprises at least two offset rollers (411, 412, 413, 414, 415), the at least two offset rollers (411, 412, 413, 414, 415) being configured to be staggered in the longitudinal direction, and to define different travel paths from the at least one longitudinal cutting device (209, 210) to the transverse creasing device (223, 224) for the at least two single sub-sheets (261, 262, 263, 264, 265) respectively, the different travel paths having different travel distances.
the alignment device (212) comprises at least two offset rollers (411, 412, 413, 414, 415), the at least two offset rollers (411, 412, 413, 414, 415) being configured to be staggered in the longitudinal direction, and to define different travel paths from the at least one longitudinal cutting device (209, 210) to the transverse creasing device (223, 224) for the at least two single sub-sheets (261, 262, 263, 264, 265) respectively, the different travel paths having different travel distances.
3. The die cutting apparatus according to claim 2, wherein
the longitudinal creasing device (205, 206) is a roller pressing device comprising a plurality of upper longitudinal creasing rollers and a plurality of lower longitudinal creasing rollers, wherein the plurality of upper longitudinal creasing rollers and the plurality of lower longitudinal creasing rollers are configured to be movably and parallel arranged to each other in the transverse direction such that an axial spacing between the longitudinal creasing device (205, 206) is adjustable.
the longitudinal creasing device (205, 206) is a roller pressing device comprising a plurality of upper longitudinal creasing rollers and a plurality of lower longitudinal creasing rollers, wherein the plurality of upper longitudinal creasing rollers and the plurality of lower longitudinal creasing rollers are configured to be movably and parallel arranged to each other in the transverse direction such that an axial spacing between the longitudinal creasing device (205, 206) is adjustable.
4. The die cutting apparatus according to claim 3, wherein
the at least one longitudinal cutting device (209, 210) comprises a plurality of longitudinal cutting devices movably and parallel arranged to each other in the transverse direction such that a spacing between the plurality of longitudinal cutting devices is adjustable.
the at least one longitudinal cutting device (209, 210) comprises a plurality of longitudinal cutting devices movably and parallel arranged to each other in the transverse direction such that a spacing between the plurality of longitudinal cutting devices is adjustable.
5. The die cutting apparatus according to claim 4, wherein
each of the longitudinal creasing device (205, 206), the at least one longitudinal cutting device (209, 210), the transverse creasing device (223, 224) and the transverse cutting device (227, 228) has a pair of upper and lower rollers,
wherein a spacing between the pair of upper and lower rollers of each of the longitudinal creasing device (205, 206) and the transverse creasing device (223, 224) is adjustable for adjusting depths of the creases.
6. The die cutting apparatus according to claim 1, further comprising:
nip rollers (221, 222) configured such that the at least two single sub-sheets (261, 262, 263, 264, 265) output from the alignment device (212) are held in tension, and enter the transverse creasing device (223, 224) in the same orientation.
nip rollers (221, 222) configured such that the at least two single sub-sheets (261, 262, 263, 264, 265) output from the alignment device (212) are held in tension, and enter the transverse creasing device (223, 224) in the same orientation.
7. The die cutting apparatus according to claim 1, wherein
the transverse cutting device (227, 228) has at least one pair of transverse cutting tools which are capable of covering the at least two single sub-sheets (261, 262, 263, 264, 265) in the transverse direction such that the at least two single sub-sheets (261, 262, 263, 264, 265) can be cut transversely at the same time.
the transverse cutting device (227, 228) has at least one pair of transverse cutting tools which are capable of covering the at least two single sub-sheets (261, 262, 263, 264, 265) in the transverse direction such that the at least two single sub-sheets (261, 262, 263, 264, 265) can be cut transversely at the same time.
8. The die cutting apparatus according to claim 5, further comprising:
a control device configured to adjust the spacing between the longitudinal creasing device (205, 206), the spacing between the plurality of longitudinal cutting devices, a distance of movement of the at least two offset rollers (411, 412, 413, 414, 415), and the spacing between the pair of upper and lower rollers of each of the longitudinal creasing device (205, 206) and the transverse creasing device (223, 224).
a control device configured to adjust the spacing between the longitudinal creasing device (205, 206), the spacing between the plurality of longitudinal cutting devices, a distance of movement of the at least two offset rollers (411, 412, 413, 414, 415), and the spacing between the pair of upper and lower rollers of each of the longitudinal creasing device (205, 206) and the transverse creasing device (223, 224).
9. The die cutting apparatus according to claim 6, further comprising:
a frame, wherein the longitudinal creasing device (205, 206), the at least one longitudinal cutting device (209, 210), the nip roller (221, 222), the transverse creasing device (223, 224) and the transverse cutting device (227, 228) are rotatably arranged on the frame, and the alignment device (212) is arranged on the frame.
a frame, wherein the longitudinal creasing device (205, 206), the at least one longitudinal cutting device (209, 210), the nip roller (221, 222), the transverse creasing device (223, 224) and the transverse cutting device (227, 228) are rotatably arranged on the frame, and the alignment device (212) is arranged on the frame.
10. The die cutting apparatus according to claim 9, wherein
rotating shafts of the longitudinal creasing device (205, 206), the transverse creasing device (223, 224), the transverse cutting device (227, 228) and the nip roller (221, 222) are arranged parallel to the transverse direction.
rotating shafts of the longitudinal creasing device (205, 206), the transverse creasing device (223, 224), the transverse cutting device (227, 228) and the nip roller (221, 222) are arranged parallel to the transverse direction.
11. The die cutting apparatus according to claim 1, wherein
each longitudinal creasing device of the longitudinal creasing devices (205, 206) is rotatably adjustable about a rotating shaft of the longitudinal creasing devices (205, 206) with respect to the other longitudinal creasing devices of the longitudinal creasing devices (205, 206), to accommodate the sheet (100) printed with a different staggered layout.
each longitudinal creasing device of the longitudinal creasing devices (205, 206) is rotatably adjustable about a rotating shaft of the longitudinal creasing devices (205, 206) with respect to the other longitudinal creasing devices of the longitudinal creasing devices (205, 206), to accommodate the sheet (100) printed with a different staggered layout.
12. The die cutting apparatus according to claim 1, further comprising:
an alternate longitudinal creasing device (203, 204) configured to form longitudinal creases on the sheet conveyed in the longitudinal direction to the alternate longitudinal creasing device,
wherein the alternate longitudinal creasing device (203, 204) is configured to be used alternately with the longitudinal creasing device (205, 206) during forming of the longitudinal creases on the sheet (100) when the specification of the sheet changes.
13. The die cutting apparatus according to claim 1, further comprising:
at least one alternate longitudinal cutting device (207, 208) configured to longitudinally cut the sheet on which the longitudinal creases are formed, to form at least two separate single sub-sheets,
wherein the at least one alternate longitudinal cutting device (207, 208) is configured to be usable alternately with the at least one longitudinal cutting device (209, 210) during longitudinal cutting of the sheet (100) when the specification of the sheet changes.
14. A method for performing creasing and cutting operations on a sheet (100) printed with
a staggered layout, comprising:
a step S01 of forming longitudinal creases on the sheet (100) conveyed in a longitudinal direction;
a step S02 of longitudinally cutting the sheet (100) on which the longitudinal creases are formed, to form at least two separate single sub-sheets (261, 262, 263, 264, 265);
a step S03 of aligning patterns on the at least two single sub-sheets (261, 262, 263, 264, 265) with each other in a transverse direction;
a step S04 of forming transverse creases on the aligned at least two single sub-sheets (261, 262, 263, 264, 265); and
a step S05 of transversely cutting the at least two single sub-sheets (261, 262, 263, 264, 265) on which the transverse creases are formed, to obtain a plurality of products (282) having transverse and longitudinal creases from the at least two single sub-sheets (261, 262, 263, 264, 265).
15. The method according to claim 14, further comprising:
when it is necessary to produce a product of a different specification, setting an alternate longitudinal creasing device and an alternate longitudinal cutting device before the end of production of a product of a previous specification, switching a longitudinal creasing device and a longitudinal cutting device respectively into the alternate longitudinal creasing device and the alternate longitudinal cutting device after the end of production of the product of the previous specification, and repeating the above steps S01-S05 to produce the product of the different specification.
when it is necessary to produce a product of a different specification, setting an alternate longitudinal creasing device and an alternate longitudinal cutting device before the end of production of a product of a previous specification, switching a longitudinal creasing device and a longitudinal cutting device respectively into the alternate longitudinal creasing device and the alternate longitudinal cutting device after the end of production of the product of the previous specification, and repeating the above steps S01-S05 to produce the product of the different specification.