Abstract:
A method and work material for making embossed blanks for sample packages and other free-standing three dimensional display items from a sheet-type work material includes a printer for printing a graphic image on the work material, and a processing mechanism for performing work operations on the work material. The sheet-type work material has a top layer of sheet material, an intermediate layer of sheet material, and a carrier layer of sheet material, with a first layer of adhesive material bonding the top and intermediate layers of sheet material together, and a second layer of adhesive material bonding the intermediate and carrier layers of sheet material together. Any, all, or a combination of the top, intermediate, or carrier layers of sheet material may have shape retaining deformability characteristics to aid in holding an embossed design in the work material. In operation, the printer prints an image onto the work material, which is then advanced to the processing mechanism where a creaser places indented fold lines into the work material, a knife cuts the blank from the work material, and an embosser, moving in either a rasterwise or vectorial motion, embosses a design into the work material. The blank can then be removed from the work material and erected into a package or other free-standing three dimensional display item.
Abstract:
An embossing system for embossing and perforating at least a portion of a web is provided comprising a first embossing roll having embossing elements and at least a second embossing roll having embossing elements, wherein the elements of the first and second embossing rolls define perforate nips for embossing and perforating the web and wherein at least a predominate number of the perforate nips are substantially oriented in the cross-machine direction. Moreover, substantially all of the nips defined by the embossing elements of the first and second embossing rolls can be substantially oriented in the cross-machine direction. Further, the cross-machine embossing elements are at an angle of about 85null to 95null from the machine direction.
Abstract:
A method for making embossed blanks for sample packages and other free-standing three dimensional display items from a sheet-type work material. The sheet-type work material has a top layer of sheet material, an intermediate layer of sheet material, and a carrier layer of sheet material. In operation, a printer prints an image onto the work material, which is then advanced to a processing mechanism where a creaser places indented fold lines into the work material, a knife cuts a blank from the work material, and an embosser embosses a design into the work material.
Abstract:
A method of copying a three-dimensional surface having X, Y, and Z dimensions forms a translucent impression of the surface to be copied and then captures a two-dimensional image of the translucent impression. The captured image has X and Y dimensions and a grayscale value for each X, Y coordinate of the image. Then, the method converts each grayscale value of the image to a Z height value, thereby generating a digital file of X, Y, and Z values. The digital file may then be provided as an input to a numerically controlled machine, which can be operated to reproduce the surface to be copied. The method of the present invention finds particular application in digitizing handcrafted emboss dies and the like.
Abstract:
A rotary embossing machine includes an embossing mechanism in which an embossing gap is formed between an embossing cylinder and a counter pressure cylinder. For conveying an embossing film web through the embossing gap, the rotary embossing machine includes a conveying mechanism for producing a movement of the web at the same speed as a material layer to be embossed, during an embossing interval. The film conveying mechanism includes a pulling device downstream of the embossing gap which is provided with a slip drive for the embossing film web and a controllable film supply device upstream of the embossing gap which cooperates with the pulling device. This arrangement avoids the risk of the embossing films or foils tearing and improves the embossing quality.
Abstract:
Tissue sheets, such as are useful for facial or bath tissue, can be embossed with a fine scale embossing pattern to increase bulk with a minimal loss in strength. The fine scale embossing pattern contains at least about 15 discrete intermeshing embossing elements per square centimeter (100 per square inch) and can enable the tissue manufacturer to produce premium quality tissues having adequate softness, bulk and strength from conventional tissue basesheets without layering or throughdrying equipment. Depending on the starting basesheet material, tissues having a unique balance of properties can be produced, especially for conventional wet-pressed basesheets.
Abstract:
A system is disclosed for securing registration of a patterned embossing roll with a similarly patterned printed moving web. The purpose of the embossing roll is to indent the surface of the printed web in register with the printing in certain designated areas. In one embodiment, a series of randomly spaced register marks on the printed web selvage edge and identically spaced register marks on the embossing roll are viewed by appropriate scanners. Electrical signatures representing the two sets of register marks are generated by the sensors and fed to a signal correlator for comparison. The correlator determines the degree of statistical error between the two signatures and displays this error in the form of a time delay on a CRT (Cathode Ray Tube). If manual registration control is desired, an operator can manually adjust the speed or phase of the embossing roll by observing the peaked wave display on the CRT to bring the roll into a statistical best fit of the embossing pattern with the printed pattern. Automatic control of embossing roll speed and orientation to achieve registration is also possible if the correlator is interfaced with a digital computer and servo correction motors on the embosser drive system. The disclosed system is an improvement over conventional benchmark oriented registration sensing and control systems in that it is capable of continuous error determinations and asynchronous error corrections on demand rather than periodically at the end of pattern length intervals.
Abstract:
Embossing method, and material made by the method, including at least a pair of embossing rolls having unmatched embossing patterns engraved independently from each other, and having enlarged sidewall clearances between adjacent, inter-engaged protrusions and recessions of the embossing patterns. The sidewall clearances can range from about 0.050mm to about 1.27 mm. The width of the protrusions can be greater than about 0.050mm. The peripheral surface of at least one of the embossing rolls can comprise a metal, a plastic, a ceramic, or a rubber. Also disclosed is an embossed web material capable of being used as a wrap material for food products, made by the above process.