Apparatus and method for producing single face corrugated web

Abstract: An apparatus for producing a single face corrugated web is disclosed. The apparatus includes a first corrugating roll (14), a second corrugating roll (16), a first smoothing roll (34) provided in a feeding path of a liner web (34), a second smoothing roll (48) provided in a feeding path of the single face corrugated web, and a mechanism for generating a tension on the liner web (32) between the first and second smoothing rollers (34,48). The apparatus further includes a third smoothing roll (46) provided in the feeding path of the liner web (32) between the first smoothing roll (34) and the second smoothing roll (48) so that the tension generated on the liner web (32) between the first and second smoothing rollers (34,48) is exerted on an outer circumferential surface of the second corrugating roll (16).

Description: BACKGROUND OF THE INVENTION Field of the Invention The present invention relates to an apparatus and a method for for producing single face corrugated web, and in particular to an apparatus and a method for producing single face corrugated web by adhering a liner web to a medium web corrugated by a first corrugating roll and a second corrugating roll. Description of the Related Art There is known an apparatus (so-called single facer) for producing a single face corrugated web having a liner web adhered to corrugation crests of a medium web formed to be corrugated. In the single facer, a first corrugating roll and a second corrugating roll, the outer circumferences of which are have corrugated flutes, are disposed in an up and down relationship so as to be rotatable while they are being engaged at the flutes, and a pressure roll is pressure-contacted to the second corrugating roll via the medium web and liner web. That is, the medium web is supplied between the first corrugating roll and the second corrugating roll and is provided with predetermined corrugated flutes while passing between both rolls. Starch-based glue is coated onto the corrugation crests, by a gluing roller secured to a gluing mechanism. Furthermore, a liner web is supplied from the opposite side of the medium web via the pressure roll, wherein the liner web is pressure-contacted to the crests of the medium web and adhered to the medium web between the pressure roll and the second corrugating roll, thereby producing a single face corrugated web. A pressure roll used for a single face corrugated web producing apparatus is provided with a metal roll of a large diameter, and the roll is opposite to the second corrugating roll with a clearance retained therebetween. And by giving a predetermined nipping pressure to a medium web and liner web passing between the second corrugating roll and the pressure roll, both of them are adhered to each other at the corrugation crests of the medium web, to which glue is coated. In this case, since flutes consisting of a crest and a trough in continuation are formed at a predetermined pitch on the outer circumference of the second corrugating roll, the center of rotation of both rolls slightly changes when the roll pressure-contacting position is made transient from a crest to a trough or from a trough to a crest. As a result of cyclic proximity and separation of the center of rotation of both rolls along with the rotation of both rolls, great vibrations and high noise are generated when producing single face corrugated web, whereby the factory environment is excessively worsened. Furthermore, the crests of the second corrugating roll are cyclically brought into contact with the surface of a pressure roll, resulting from cyclic proximity and separation of the rotation center of both rolls with impacting generated (so-called hammering phenomena occur). Therefore, such a problem arises, by which' press lines (so-called press marks) are given to the liner web of single face corrugated web produced, in the lateral direction at a pitch of the crests of the second corrugating roll, resulting in a lowering of the commodity value. Each of the various problems results due to the nipping pressure being necessarily set to a greater level since, in a conventional apparatus for producing single face corrugated web, the medium web and liner web are nipped at only one point where the second corrugating roll and pressure roll are opposed to each other. Therefore, as a means to cope with this, such a proposal was made, in which a plurality of pressure rolls are disposed with a spacing therebetween in the circumferential direction of the second corrugating roll, the nipping pressure is set to a smaller value at each of the pressure rolls so that a greater nipping pressure is not given to the medium web and liner web, thereby press marks attached to single face corrugated web are suppressed. Furthermore, such a proposal was made, in which an endless belt is disposed so as to freely travel along the outer circumference of the second corrugating roll, whereby the medium web and liner web are caused to be brought into facial contact with the second corrugating roll in order to suppress generation of vibration, noise or press marks. However, in any one of the countermeasures, since the medium web and liner web are pressure-contacted to the second corrugating roll by a mechanical pressing means, it is impossible to completely eliminate press marks. Furthermore, since the respective pressure rolls are pressed with predetermined nipping pressure in a case where a plurality of pressure rolls are used, it is unavoidable for the hammering phenomena to be generated in each pressure roll, and a small vibration and noise are generated at each of the pressure rolls, wherein they are multiplied and cause a new problem from which great vibrations and high level noise result. Furthermore, in a case where an endless belt is used, the belt is worn out in time, and it is necessary to replace it periodically. It is pointed out that such a fault arises, by which the running cost is increased. And there is a shortcoming where a "shining" is produced at the liner web since the endless belt is brought into contact with the liner web. In the industry of producing corrugated board, it was a common sense in prior arts that preparation of a certain mechanical pressing means was required, as described above, in order to adhere the medium web and liner web together. Therefore, the inventor of the present invention actively studied and developed a novel apparatus and a novel method for producing a single face corrugated web, freeing from common sense in the art of this field. As a result, the inventor confirmed that the present apparatus and method for producing single face corrugated web has the ability to adhere the medium web and liner web together without the use of any mechanical pressing means. Document JP-A-9076379, on which the preamble of claim 1 is based, discloses an apparatus having a first smoothing roll for the liner and a second smoothing roll for the corrugated web. SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide an apparatus and a method for producing a single face corrugated web which can generate no press mark on a liner web and decrease vibration and noise when producing a single face corrugated web. The above object is achieved according to the present invention to provide an apparatus for producing a single face corrugated web comprising a first corrugating roll having corrugation flutes formed on an outer circumferential surface thereof, a second corrugating roll having corrugation flutes engaged with the corrugation flutes of the first corrugating roll, the second corrugating roll forming predetermined corrugation flutes on a medium web passing between the first and second corrugating rolls, and gluing means for carrying out gluing at corrugation crests of the corrugation flutes of the medium web, and producing the single face corrugated web by adhering a liner web to the glued corrugation crests of the medium web, whereby the apparatus comprises a first smoothing roll provided in a feeding path of the liner web so as to have a rotation speed which is equal to or less than a feeding speed of the liner web, a second smoothing roll provided in a feeding path of the single face corrugated web so as to have a rotation speed which is equal to or greater than a feeding speed of the liner web, means for generating a tension on the liner web between the first and second smoothing rollers, and a third smoothing roll provided in the feeding path of the liner web between the first smoothing roll and the second smoothing roll so that the tension generated on the liner web between the first and second smoothing rollers is exerted on an outer circumferential surface of the second corrugating roll. In a preferred embodiment of the present invention, the tension generating means generates the tension by making a difference in a rotation speed between the first and second smoothing rolls. In another embodiment of the present invention, the tension generating means generates the tension by providing a feeding speed of the single face corrugated web which is greater than that of the liner web while the rotation speed of the first smoothing roll is substantially equal to that of the second smoothing roll. In another embodiment of the present invention, the apparatus further includes means for moving the third smoothing roll near to or away from the third smoothing roll based on at least one of a paper quality, a paper width and a production speed of the medium web or the liner web. The above object is also achieved according to the present invention to provide a method for producing a single face corrugated web using an apparatus comprising a first corrugating roll having corrugation flutes formed on an outer circumferential surface thereof, a second corrugating roll having corrugation flutes engaged with the corrugation flutes of the first corrugating roll, the second corrugating roll forming predetermined corrugation flutes on a medium web passing between the first and second corrugating rolls, gluing means for carrying out gluing at corrugation crests of the corrugation flutes of the medium web, a first smoothing roll provided in a feeding path of a liner web, a second smoothing roll provided in a feeding path of the single face corrugated web, and a third smoothing roll provided in the feeding path of the liner web between the first smoothing roll (34) and the second smoothing roll, the method comprising the steps of generating a tension on the liner web between the first smoothing roll and the second smoothing roll, and exerting the tension generated on the liner web on an outer circumferential surface of the second corrugating roll while the third smoothing roll feeds the liner web between the first smoothing roll and the second smoothing roll so as to travel along the outer circumferential surface of the second corrugating roll so that the liner web is adhered to the glued corrugation crests of the medium web. The above and other objects and features of the present invention will be apparent from the following description by taking reference with accompanying drawings employed for preferred embodiments of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS In the accompanying drawings: Figure 1 is a schematic side view showing an apparatus for producing single face corrugated web according to a preferred embodiment of the present invention; Figure 2 is a schematic sectional side view the apparatus according to the preferred embodiment of the present invention; Figure 3 is a front view showing a drive system of a second corrugating roll, and second and third smoothing rolls according to the preferred embodiment of the present invention; Figure 4 is a front view showing a relationship between the first corrugating roll and the second corrugating roll according to the preferred embodiment of the present invention; Figure 5 is a sectional front view of the second corrugating roll according to the preferred embodiment of the present invention; Figure 6 is an enlarged front partial sectional view showing major parts of the second corrugating roll according to the preferred embodiment of the present invention; Figure 7 is a front view showing a drive system of the first smoothing roll and a pre-heater for a medium web according to the preferred embodiment of the present invention; Figure 8 is a control block diagram of the apparatus according to the preferred embodiment of the present invention; Figure 9 is a schematic side view of the producing apparatus, in which the third smoothing roll is positioned at a non-pressure-contacted position, according to the preferred embodiment of the present invention; Figure 10 is a schematic side view of the apparatus, in which the third smoothing roll is positioned at a pressure-contacted position, according to the preferred embodiment of the present invention; and Figure 11 is a schematic side view showing an apparatus for producing single face corrugated web according to another preferred embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the preferred embodiments of the present invention will be explained with reference to the drawings. Figure 1 is a schematic side view showing an apparatus for producing single face corrugated web according to a preferred embodiment of the present invention. Referring to Figure 1, in an apparatus for producing single face corrugated web or a single facer according to a preferred embodiment, an opening 10a is respectively formed at a pair of main frames 10 and 10 (only one is shown in Figure 1) which is spaced at a predetermined distance in the width direction crossing a sheet feeding direction, and a carrier 12 is movably disposed in a width direction at a portion where the openings 10a and 10a are arranged. The carrier 12 is provided with a pair of sub frames 13 and 13 which are spaced at a predetermined distance in the width direction. A first corrugating roll 14 having a corrugated fluted portion formed on its outer circumferential surface and a second roll 16 having a corrugated fluted portion formed on its outer circumferential surface, as well, are rotatably supported between both sub frames 13 and 13 and extend in the width direction. Subsequently, it is constructed that, by causing the carrier 12 to move from its operation position inside the main frames 10 and 10 to its maintenance or replacement position outside them, maintenance of both rolls 14,16 can be easily performed outside the frames. The center of rotation of the first corrugating roll 14 is positioned right below the center of rotation of the second corrugating roll 16, and the respective corrugated fluted portions are made engageable with each other via a medium web 18 described later (see Figure 2). Furthermore, a positioning mechanism 22 which is activated by a cylinder 20 is disposed at each of both sides, between which the opening 10a is placed, outside each of the main frames 10, whereby it is constructed that the carrier 12 can be positioned and fixed at its operation position by the positioning mechanisms 22 and 22. A gluing mechanism 28 composed of a gluing roll 24, a doctor roll 26, etc. is disposed at the side of the first corrugating roll 14 at the operation position and diagonally downward of the second corrugating roll 16 between the main frames 10 and10. A medium web 18 is supplied from a material paper supplying source (not shown) at the right side in Figure 2 to the. area of engagement between the first corrugating roll 14 and second corrugating roll 16 via a roll-like medium web pre-heater 30 heated with steam, wherein the medium web 18 is corrugated to a predetermined shape by passing through the engagement area. The corrugated medium web 18 goes along the outer circumferential surface of the second corrugating roll 16 after their crests are glued by the gluing mechanism 28. Furthermore, a liner web 32 is supplied from the material paper supplying source (not shown) at the left side in Figure 2 to the second corrugating roll 16 via a roll-like first smoothing roll 34, described later, heated with steam, and is fed in such a state that it is adhered to the glued crests of the medium web 18. The second corrugating roll 16 is supported so that its rotation shaft 16a is rotatable with respect to the sub frames 13 and13 of the carrier 12, and as shown in Figure 3, the end portion of the rotation shaft 16a outwardly extending from the sub frame 13 at the drive side (the right side in the drawing) is connected to the main drive motor 38 via a speed reducer 36, and is constructed so that the second corrugating roll 16 is driven and rotated at a rotation speed (peripheral speed) which is coincident with the feed-rate (production speed) of the medium web 18 and liner web 32. Furthermore, it is constructed so that the first corrugating roll 14, which is rotatably supported via a rotation shaft 14a with respect to the sub frames 13 and 13 of the carrier 12, is driven and rotated in accordance with the second corrugating roll 16 under an engagement of the corrugated fluted portion formed at the roll 14 with the corrugated fluted portion formed at the second corrugating roll 16. The diameter L 2 of the second corrugating roll 16 is set to 150% or more (see Figure 9) of the diameter L 1 of the first corrugating roll 14, and it is constructed so that a greater pressure-contact area of the medium web 18 and the liner web 32 pressure-contacted to the outer circumferential surface of the second corrugating roll 16 can be obtained between the second smoothing roll 48 and the third smoothing roll 46, both of which are described later. It is preferable that the range of the diameter L 2 of the second corrugating roll 16 is from 150% to 200% of the diameter L 1 of the first corrugating roll 14. The second corrugating roll 16 is a hollow cylindrical body as shown in Figures 5 and 6, wherein a plurality of circumferential grooves 82 are formed at a predetermined interval in the axial direction on the outer shell portion 80 thereof, and a plurality of negative pressure paths 84 extending in the axial direction are formed at a predetermined interval in the circumferential direction, and a plurality of ventilation portions 86 communicating with the negative pressure paths 84 are drilled at a predetermined interval in the circumferential direction at the bottom of the respective circumferential grooves 82. All the negative pressure paths 84 are connected to a suction source 89 via a suction path 88 formed in a one side shaft of the second corrugating roll 16. That is, by making all the negative pressure paths 84 enter a negative state by activating the suction source 89, the pressure of the circumferential grooves 82 is made negative via the respective ventilation ports 86, wherein it is constructed so that medium web 18 wound on the second corrugating roll 16 is fed in a stable state while being adsorbed and retained on the outer circumferential surface of the roll 16. Furthermore, since the medium web 18 is adsorbed onto the outer circumferential surface of the second corrugating roll 16 under negative pressure, such an effect is obtained, by which the water content of the glue liquid at the adhered portion of the medium web 18 and liner web 32 is sucked in, and drying of the glue liquid is accelerated. A steam chamber 90 is internally sectioned in the second corrugating roll 16, and heated steam is supplied from a steam supply source (not shown), which is connected to the steam chamber 90 via a steam supplying path 94 formed in the another side shaft of the second corrugating roll 16, into the steam chamber 90. That is, heated steam is supplied into the steam chamber 90 of the second corrugating roll 16 to heat the roll surface to a predetermined temperature, whereby the medium web 18 in contact with the roll 16 is heated, giving heat to the gluing portion between the medium web 18 and the liner web 32 in order to accelerate gelling of a starch-based glue, and the medium web 18 is surely adhered to a liner web 32. Furthermore, a steam return path (not shown) is formed in one or the other shaft of the second corrugating roll 16, and the heated steam is circulated in the steam chamber 90. Still furthermore, heated steam is also supplied and circulated similarly in the first corrugating roll 14, where heat is given to the gluing portion between the medium web 18 and the liner web 32. The medium web pre-heater 30 is such that its rotation shaft 30a is rotatably supported with the main frames 10 and10, a drive motor 54 is connected to the end portion of the rotation shaft 30a extending from the main frame 10 at the operation side (left side in FIG.7), and the medium web pre-heater 30 is driven at a predetermined rotation speed (peripheral speed). Three smoothing rolls 34,46 and48 which adhere the medium web 18 and the liner web 32 together in cooperation with the second corrugating roll 16 at the operation position are disposed in a predetermined relationship between the main frames 10 and 10. That is, the first smoothing roll 34 is rotatably disposed in the feeding path of the liner web 32, and the liner web 32 wound on the first smoothing roll 34 is fed toward the second corrugating roll 16. The first smoothing roll 34 is such that its rotation shaft 34a is rotatably supported with respect to the main frames 10 and 10, and as shown in Figure 7, and a motor 52 with a brake which functions as an adjusting means is connected, via a speed reducer 50, to the end portion of the rotation shaft 34a extending from the main frame 10 at the drive side. Accordingly, the motor 52 with a brake is actuated and controlled by a production control apparatus 100 which acts as a controlling means shown in Figure 8, where the rotation speed (peripheral speed) V 1 of the first smoothing roll 34 is controlled so as to be equal to or less than the rotation speed (peripheral speed) V 0 of the second corrugating roll 16 (V 1 ≦V 0 ). Furthermore, since the rotation speed of the second corrugating roll 16 is set to be equal to the feeding speed of the liner web 32, the rotation speed of the first smoothing roll 34 becomes equal to or less than the feeding speed of the liner web 32. The second smoothing roll 48 is rotatably disposed at the downstream side of the first smoothing roll 34 opposite to the second corrugating roll 16 in a feeding path of a single face corrugated web for which the medium web 18 and the liner web 32 are adhered to each other. Furthermore, the second smoothing roll 48 is, as shown in Figure 2, positioned in such relationship that the medium web 18 and the liner web 32 are not pressure-contacted to the second corrugating roll 16. As shown in Figure 3, a belt pulley 66 is disposed at the rotating shaft 48a of the second smoothing roll 48 extending from the main frame 10 at the drive side, and a belt 68 is applied between the corresponding belt pulley 66 and a belt pulley 62 disposed at the speed reducer 36 of the second corrugating roll 16, whereby the corresponding second smoothing roll 48 is constructed so as to be driven and rotated by the main drive motor 38. Furthermore, the belt pulley 66 of the second smoothing roll 48 is set to such a dimension where the rotation speed (peripheral speed) V 2 of the second smoothing roll 48 becomes greater than the rotation speed (peripheral speed) V 0 of the second corrugating roll 16 (that is, V 0 <V 2 ). That is, the relationship between the rotation speed V 1 of the first smoothing roll 34 and the rotation speed V 2 of the second smoothing roll 48 is V 1 <V 2 , wherein the liner web 32 fed between the rolls 34 and 48 is given a predetermined tension. The third smoothing roll 46 on and by which the liner web 32 passing through the first smoothing liner web 34 is wound and guided is rotatably disposed between the main frames 10 and 10 in the feeding path of the liner web 32 between the first smoothing roll 34 and the second smoothing roll 48. And the third smoothing roll 46 is positioned so that the liner web 32 between the roll 46 and the second smoothing roll 48 is caused to travel on one-fourth or more of the peripheral length of the second corrugating roll 16 along the outer circumferential surface of the second corrugating roll 16. Thereby, the tension given to the liner web 32 by the difference in the rotation speed between the first smoothing roll 34 and the second smoothing roll 48 acts, as shown in Figure 9, as a pressing force with which the liner web 32 presses the medium web 18, which is fed along the outer circumferential surface of the second corrugating roll 16, toward the second corrugating roll 16. Thereby, it is constructed so that the medium web 18 is adhered to the liner web 32. Furthermore, it is preferable that the pressure-contacting distance where the liner web 32 travels along the outer circumferential surface of the second corrugating roll 16 is equal to or greater than 300mm. In order to keep this distance and to achieve a satisfactory heat efficiency, it is highly preferable that a second corrugating roll 16 having a diameter of 400mm or more is used. Referring to Figure 3, a belt 68 wound on the belt pulley 66 of the second smoothing roll 48 is commonly wound on the belt pulley 64 disposed at the rotation shaft 46a of the third smoothing roll 46 and the corresponding third smoothing roll 46 is driven and rotated by the main drive motor 38. Furthermore, the belt 64 of the third smoothing roll 46 is set to such a dimension where the relationship between the rotation speed (peripheral speed) V 3 of the third smoothing roll 46 and the rotation speed (peripheral speed) V 0 of the second corrugating roll 16 becomes V 3 ≦V 0 . Furthermore, it is preferable that the outer circumferential surface of the first smoothing roll 34 and the third smoothing roll 46 is satin-finished or is wrapped with urethane in order to increase a contacting resistance so that adequate tension is surely given to the liner web 32. Referring back to Figure 1, the third smoothing roll 46 is rotatably supported at supporting plates 56 and 56 (only one is shown) swingably disposed at the main frames 10 and 10, and it is constructed so that by normally or reversely pressing the respective supporting plates 56 by a fluid pressure cylinder 58 as a corresponding movement means, the rotation center of the corresponding roll 46 is moved near to or moved away from the second corrugating roll 16. The fluid pressure cylinder 58 is actuated and controlled by the production control apparatus 100, wherein in compliance with a change in any one of the conditions such as paper quality, paper width, production speed, etc., of the medium web 18 and the liner web 32, or a change in combinations of these factors, the third smoothing roll 46 is set so as to selectively move between a non-contacted position (Figure 9) where the medium web 18 and the liner web 32 are not pressure-contacted with respect to the second corrugating roll 16, and a contacted position (Figure 10) where they are pressure-contacted. Furthermore, the third smoothing roll 46, according to the preferred embodiment, is constructed so as to be movable to a flute roll replacement position, which is greatly spaced from the second corrugating roll 16, separately from the non-contacted position and contacted position. When moving the carrier 12 to its maintenance or replacement position from the main frames 10 and 10 in replacing both corrugating rolls 14 and 16, the corresponding third corrugating roll 46 is caused to move to the flute roll replacement position by the fluid pressure cylinder 58. Furthermore, an adjustment device 60, in which an eccentric mechanism is adopted, is incorporated in the pivotal portion of the supporting plates 56 and 56, wherein when the third smoothing roll 46 is positioned at the contacted position, the nipping pressure adjustment at the third smoothing roll 46 is able to be carried out by the corresponding adjustment device 60. The adjustment device 60 is actuated and controlled by the production control apparatus 100 in compliance with a change in any one of paper quality, paper width, production speed, etc., of the medium web 18 or the liner web 32, or a change in combinations in any of these factors. The third smoothing roll 46 and the second smoothing roll 48 are connected to a supply source of heated steam (not shown), in order to circulate high temperature steam into the corresponding rolls, whereby the temperature of the roll surfaces is increased to a predetermined temperature level. Accordingly, the liner web 32 in contact with both smoothing rolls 46 and 48 is heated, wherein heat is given to the gluing portion of the medium web 18 and the liner web 32 in order to accelerate gelling of starch-based glue, thereby causing the adhering of the medium web 18 and the liner web 32 to be surely carried out. Referring to Figure 8, a paper quality sensor MS 1 , a paper width sensor MS 2 , and a production speed sensor MS 3 are disposed in the feeding path of the medium web 18 as detecting means to correspondingly detect the paper quality, paper width and production speed of the corresponding medium web 18, and it is constructed so that detection signals of the respective sensors MS 1 , MS 2 and MS 3 are inputted into the production control apparatus 100. Furthermore, a plaper quality sensor LS 1 , a paper width sensor LS 2 and a production speed sensor LS 3 which correspondingly detect the paper quality, paper width and production speed of the corresponding liner web 32 are similarly provided in the feeding path channel of the liner web 32, wherein detection signals of the respective sensors LS 1 , LS 2 and LS 3 are inputted into the production control apparatus 100. And the production control apparatus 100 actuates and controls the motor 52 with a brake upon receiving input signals from the respective sensors, varies the difference in the rotation speed between the first smoothing roll 34 and the second smoothing roll 48, and controls to displace the rotation center of the third smoothing roll 46 by actuating and controlling the fluid pressure cylinder 58. Furthermore; the production control apparatus 100 is provided with reference values used in selecting any one of the contacted positions or non-contacted positions of the third smoothing roll 46, wherein the detection value by each sensor is less than the reference value, the third smoothing roll 46 is caused to move to the non-contacted position, and if being greater than the reference value, the third smoothing roll 46 is caused to move to the contacted position. Furthermore, "paper quality" in the embodiment is defined as that it includes thickness, weight, etc. Next, there will be explained about the operations of the apparatus for producing single face corrugated web according to the above-mentioned preferred embodiment. By driving and rotating the second corrugating roll 16 by the main drive motor 38, the first corrugating roll 14 is driven and rotated in accordance with the engagement of the corrugation fluted portion. Detection signals coming from each of the paper quality sensors MS 1 and LS 1 , the paper width sensors MS 2 and LS 2 and the production speed sensors MS 3 and LS 3 , all of which are disposed in the feeding path of the medium web 18 and the liner web 32, are inputted into the production control apparatus 100, wherein the rotation speed of the first smoothing roll 34 is established on the basis of the detection value, and the position of the third smoothing roll 46 is determined. That is, if the detection value of each of the sensors is less than the predetermined reference value and the production control apparatus 100 judges that no pressure contact is required at the third smoothing roll 46, the fluid pressure cylinder 58 is actuated and controlled, and the third smoothing roll 46 is caused to move to the non-contacted position shown in Figure 9 and is positioned there. In this state, the medium web 18 supplied from the material paper source into the area of engagement of the first corrugating roll 14 with the second corrugating roll 16 via the medium web pre-heater 30 is formed to a predetermined flute shape by passing through the engagement area: The medium web 18 thus fluted is stably fed toward the gluing mechanism 28 in such a state where it is adsorbed and retained at the outer circumferential surface of the roll 16 by the negative pressure created in the respective peripheral grooves 82 of the second corrugating roll 16. Accordingly, after the corrugation crests of the medium web 18 are glued by the gluing mechanism 28, the medium web 18 is caused to go along the outer circumferential surface of the second corrugating roll 16 (see Figure 9). Furthermore, since in the embodiment the second corrugating roll 16 of the large diameter is positioned right above the first corrugating roll 14, an efficient nipping pressure is given to the medium web 18 at the area of engagement, and a secure flute formation can be carried out. Furthermore, since both corrugating rolls 14 and 16 are disposed at the sub frames 13 and 13 of the carrier 12 structurally separated from the main frames 10 and 10, vibration generated between both corrugating rolls 14 and 16 are not transmitted to the main frames 10 and 10, wherein there is an effect by which vibration and noise incidental therewith can be suppressed. Furthermore, the liner web 32 supplied from the material paper supply source to the third smoothing roll 46 via the first smoothing roll 34 is supplied to the second smoothing roll 48 along the outer circumferential surface of the second corrugating roll 16. In this case, the predetermined tension is given to the liner web 32 between both rolls 34 and 48 by the difference in the rotation speed between the first smoothing roll 34 and the second smoothing roll 48. Since the liner web 32 is caused to travel the predetermined distance along the outer circumferential surface of the second corrugating roll 16 by the third smoothing roll 46, the medium web 18 and the liner web 32 supplied along the outer circumferential surface of the second corrugating roll 16 are pressure-contacted to the outer circumferential surface of the second corrugating roll 16 over the predetermined distance by the tension given to the liner web 32 as shown in Figure 9, and. the medium web 18 and the liner web 32 are adhered to each other, thereby producing a single face corrugated web. The negative pressure is created over the entire circumference of the respective peripheral grooves 82 of the second corrugating roll 16, and the medium web 18 is adsorbed to and retained on the outer circumferential surface of the second corrugating roll 16 by negative pressure at the entire area where the medium web 18 and liner web 32 are pressure-contacted to the second corrugating roll 16. Accordingly, with the adsorption power resulting from the negative pressure, the water content of the glue liquid at the position, at which the medium web 18 and liner web 32 are adhered to each other, is absorbed to cause the drying thereof to be accelerated, wherein it is possible to securely achieve a gluing and adhering of both 18 and 32 at a high speed operation. Thus, in the case where the third smoothing roll 46 is caused to be positioned to be in the non-contacted position, the medium web 18 and the liner web 32 between the third smoothing roll 46 and the second smoothing roll 48 are pressure-contacted and adhered to each other only by the tension. Therefore, no hammering phenomena described above is permitted to occur, there is no fear that any press mark is given to the liner web of a single face corrugated web, and further, vibrations and/or noise which may be generated in producing a single face corrugated web are able to be suppressed. Furthermore, by setting the diameter of the second corrugating roll to 150% or more of the diameter of the first corrugating roll 14, a greater pressure-contacted area of the medium web 18 and liner web 32 between the third smoothing roll 46 and the second smoothing roll 48 with respect to the second corrugating roll 16 can be obtained. That is, the time during which the medium web 18 and the liner web 32 are in contact with the second corrugating roll 16 can be sufficiently lengthened even if the production speed is increased, wherein sufficient heat is given from the second corrugating roll 16 to the medium web 18 and the liner web 32 in order to achieve a secure adhering of both. Therefore, capacity can be increased by high speed production. Next, if the values detected by the paper quality sensors MS 1 and LS 1 , the paper width sensors MS 2 and LS 2 and the production speed sensors MS 3 and LS 3 are greater than the predetermined reference values and the production control apparatus 100 judges that it is necessary to provide pressure contacting by the third smoothing roll 46, the fluid pressure cylinder 58 is actuated and controlled to move and position the third smoothing roll 46 to the pressure-contacting position shown in Figure 10. Furthermore, since the adjustment device 60 is also actuated and controlled by the production control apparatus 100, the nipping pressure is adjusted by the third smoothing roll 46. That is, in the case where the third smoothing roll 46 is positioned at the pressure contacting position, the liner web 32 supplied from the first smoothing roll 34 to the third smoothing roll 46 is preliminarily adhered to the medium web 18 supplied along the outer circumferential surface of the second corrugating roll 16 by the predetermined nipping pressure. Thereafter, the medium web 18 and the liner web 32 are completely adhered to each other by the tension produced by the difference in the rotation speed between the first smoothing roll 34 and the second smoothing roll 48. Furthermore, in this case, the nipping pressure produced by the third smoothing roll 46 and the tension are concurrently utilized, the nipping pressure of the third smoothing roll 46 can be set to such a small value by which no press mark is substantially given to the liner web, whereby it is possible to prevent any press marks from being generated. That is, a small value by which no press mark is substantially given to the liner web is about one-third to one-fifth of the nipping pressure in the conventional single face corrugated web production apparatus, and this is a slight value in comparison with the conventional value. The present invention is not limited to the above-mentioned preferred embodiment. It is easily understood that various modifications and variations are included in the present invention. As shown in Figure 11, such a construction may be employed, where a compression case 101 which covers the area where the liner web 32 travels along the outer circumferential surface of the second corrugating roll is provided between the third smoothing roll 46 and the second smoothing roll 48, compressed air is supplied from a supply source into the compression case 101 to produce the compressed state in the case 101, and the liner web 32 and medium web 18 are pressed to the outer circumferential face of the second corrugating roll 16. Although this embodiment employs the construction where the medium web is retained on the entire circumferential surface by making the negative pressure path internally formed in the second corrugating roll negative, such a construction may be employed, in which negative pressure is created in the peripheral grooves of the second corrugating roll by an external suction source, and the medium web is retained only from the engagement position with the first corrugating roll with respect to the second corrugating roll to the pressure contact commencing end position with a liner web furthermore, such a construction may be employed, where a compression chamber which covers an area from the above-mentioned engagement area to the pressure contact commencing end position is provided and the pressure inside the compression chamber is made higher than the atmospheric pressure, whereby the medium web is pressed to the outer circumferential face of the second corrugating roll. Furthermore, such a construction may also be employed, in which dry air is supplied into the trough portions on the outer circumferential face of the second corrugating roll from the axial direction in order to accelerate drying the water content of glue liquid. As a means for varying the rotation speed of the above-mentioned first smoothing roll, a powder brake or a mechanical braking means disposed separately from the motor may be employed. Furthermore, a means for. moving the rotation center of the above-mentioned third smoothing roll is not limited to a fluid pressure cylinder (hydraulic or pneumatic) of the above-mentioned embodiment, and such an eccentric mechanism in which a motor is used may be employed. Furthermore, the nipping pressure adjustment of the third smoothing roll is not separately carried out by an adjustment device, and the adjustment may be performed by controlling the supply quantity (or supply pressure) of fluid (hydraulic or pneumatic) into the fluid pressure cylinder with the adjusting device omitted. In this case, the adjustment work may be remarkably simplified. As regards adjustment of the difference in the rotation speed between the above-mentioned first smoothing roll and the second smoothing roll and movement displacement of the rotation center of the third smoothing roll, such a construction may be employed, where various kinds of conditions such as paper quality, paper width, production speed, etc. of medium web and liner web are predetermined in the above-mentioned production control apparatus (see Figure 8), the input data is selected in changing orders, and the difference in the rotation speed between the first smoothing roll and the second smoothing roll and the position of the rotation center of the third smoothing roll are automatically adjusted. Furthermore, such a construction may be employed, where an operator manually adjusts the adjusting means (motor with brake) and moving means (fluid pressure cylinder), whereby it is possible that the operator is able to adjust the difference in the rotation speed and the displacing position by operating the corresponding means as necessary. Still furthermore, the first smoothing roll does not always necessarily rotate, wherein tension is given to the liner web by braking the liner web supplied on the roll with the adjusting means retained at the stop state, or the first smoothing roll may be constructed of a fixed drum which is made unrotatable. Still furthermore, although in this embodiment the difference in the rotation speed between the first smoothing roll and the second smoothing roll is adjusted by varying the rotation speed of the first smoothing roll, this can be solved by varying the rotation speed by a construction and control which are similar to the above. And the third smoothing roll may be of such a construction where it is not driven by the main drive motor as in the embodiment, but it may be separated from the drive source and may rotate, following the travelling of the liner web. Furthermore, a single face corrugated web produced by the single face corrugated web production apparatus is continuously supplied to a subsequent process via the above-mentioned second smoothing roll and a sandwich conveyor, etc. However, the supplying speed of a single face corrugated web is set to a faster speed than the feeding speed of a liner web. Therefore, since the predetermined tension is given to the liner web between the first smoothing roll and the second smoothing roll even though the difference in the rotation speed between the first smoothing roll and the second smoothing roll is zero (V 1 =V 2 ), the adhering of the liner web and medium web can be achieved. For example, in a case where a thin medium web and a liner web are adhered to each other, both can be securely adhered to each other even though the rotation speed of the first smoothing roll is set to the same as that of the second smoothing roll. As explained above, the second smoothing roll is disposed so that the medium web and liner web (single face corrugated web) are disposed at a position where they are not pressure-contacted to the second corrugating roll. However, the second smoothing roll may be constructed so that it moves near to or moves away from the second corrugating roll by a position adjusting apparatus of the eccentric mechanism, in which a fluid pressure cylinder and a motor are used, and the medium web and liner web are moved to positions where they are pressure-contacted or not pressure-contacted to the second corrugating roll, in compliance with a change in any one of paper quality, paper width of the medium web or liner web, and production speed, or a change in combinations of these factors. That is, any one of these combinations may be selected, in which both of the second smoothing roll and third smoothing roll are at the non-pressure-contacted position or pressure-contacted position, or in which the third smoothing roll is at the pressure-contacted position while the second smoothing roll is at the non-pressure-contacted position or in which third smoothing roll is at the non-pressure-contacted position while the second smoothing roll is at the pressure-contacted position. Furthermore, the second smoothing roll may be constructed so as to rotate by an independent motor, and the difference in the rotation speed between the first smoothing roll and the second smoothing roll may be changed by controlling the motor. An arrangement of the above-mentioned first corrugating roll and the second corrugating roll is not limited to the above-mentioned construction in which the second corrugating roll is disposed right above the first corrugating roll. The rotation center of the second corrugating roll may be disposed so as to be positioned diagonally upwards with respect to the rotation center of the first corrugating roll and the rotation center of the second corrugating roll may be disposed diagonally downward with respect to the rotation center of the first corrugating roll. As explained above, the diameter of the second corrugating roll may be made greater than that of the first roll. However, they may be made with the same diameter. Although the present invention has been explained with reference to specific, preferred embodiments, one of ordinary skill in the art will recognize that modifications and improvements can be made while remaining within the scope of the appended claims.

Claims: An apparatus for producing a single face corrugated web comprising a first corrugating roll (14) having corrugation flutes formed on an outer circumferential surface thereof, a second corrugating roll (16) having corrugation flutes engaged with the corrugation flutes of the first corrugating roll (16), the second corrugating roll (16) forming predetermined corrugation flutes on a medium web (18) passing between the first and second corrugating rolls (14,16), and gluing means (28) for carrying out gluing at corrugation crests of the corrugation flutes of the medium web (18), and producing the single face corrugated web (S) by adhering a liner web (32) to the glued corrugation crests of the medium web (18), a first smoothing roll (34) provided in a feeding path of the liner web (32) so as to have a rotation speed which is equal to or less than a feeding speed of the liner web (32); a second smoothing roll (48) provided in a feeding path of the single face corrugated web so as to have a rotation speed which is equal to or greater than:a:feeding speed of the liner web (32); means for generating a tension on the liner web (32) between the first and second smoothing rollers (34,48); characterized in that the apparatus further comprises: a third smoothing roll (46) provided in the feeding path of the liner web (32) between the first smoothing roll (34) and the second smoothing roll (48) so that the tension generated on the liner web (32) between the first and second smoothing rollers (34,48) is exerted on an outer circumferential surface of the second corrugating roll (16). An apparatus according to claim 1, wherein said tension generating means generates the tension by making a difference in a rotation speed between the first and second smoothing rolls (34,48) or wherein said tension generating means generates the tension by providing a feeding speed of the single face corrugated web which is greater than that of the liner web (32) while the rotation speed of the first smoothing roll (34) is substantially equal to that of the second smoothing roll (48). An apparatus according to claim 1 or 2, wherein the apparatus further includes means (58) for moving the third smoothing roll (46) near to or away from the third smoothing roll based on at least one of a paper quality, a paper width and a production speed of the medium web (18) or the liner web (32). An apparatus according to claim 3, wherein said moving means (58) moves the third smoothing roll (46) to a first position where the third smoothing roll (46) does not press the medium web (18) and the liner web (32) against the second corrugating roll (16) and a second position where the third smoothing roll (46) presses the medium web (18) and the liner web (32) against the second corrugating roll (16) by a nipping presser provided between the third smoothing roll (46) and the second corrugating roll (16). An apparatus according to claim 3 or 4, wherein said moving means (58) moves the third smoothing roll to a first position where the third smoothing roll does not press the medium web and the liner web against the second corrugating roll, a second position where the third smoothing roll presses the medium web and the liner web against the second corrugating roll by a nipping presser provided between the third smoothing roll and the second corrugating roll, and a third position where the second corrugating roll can be replaced. An apparatus according to one of the claims 3 to 5, wherein said movement means (58) includes a fluid pressure cylinder (58), and the nipping pressure is adjustable by controlling fluid pressure supplied to the cylinder (58). An apparatus according to anyone of the preceeding claims, wherein said third smoothing roll (46) has a rotation speed which is equal to or less than the feeding speed of the liner web (32). An apparatus according to anyone of the preceeding claims, wherein the third smoothing roll (46) is provided so that the liner web (32) fed between the first smoothing roll (34) and the second smoothing roll (48) travel along at least one-fourth distance of the outer circumferential surface of the second corrugating roll (16), or, wherein the third smoothing roll (46) is provided so that the liner web (32) fed between the first smoothing roll and the second smoothing roll travel along at least 300mm distance of the outer circumferential surface of the second corrugating roll (16). An apparatus according to anyone of the preceeding claims, wherein said second corrugating roll (16) has a diameter of at least 400mm. An apparatus according to anyone of the preceeding claims, wherein the apparatus further comprises means (52) for varying the rotation speed of at least either one of the first smoothing roll (34) and the second smoothing roll (48) based on at least a paper quality, a paper width and a production speed of the medium web or the liner web. An apparatus according to anyone of the preceeding claims, wherein the first smoothing roll (34) is maintained in a non-rotatable state. An apparatus according to anyone of the preceeding claims, wherein the apparatus further includes second means for moving the second smoothing roll (48) to a first position where the second smoothing roll (48) does not press the medium web (18) and the liner web (32) against the second corrugating roll (16) and a second position where the second smoothing roll (48) presses the medium web (18) and the liner web (32) against the second corrugating roll (16) by a nipping presser provided between the second smoothing roll (48) and the second corrugating roll (16). An apparatus according to anyone of the preccding claims, wherein the apparatus further comprises a pair of first frames (10,10) for supporting the first, second and third smoothing rolls (34,46,48) and a pair of second frames (13,13) provided separately from the first frames for supporting the first and second corrugating rolls (14,16). A method for producing a single face corrugated web using an apparatus comprising a first corrugating roll (14) having corrugation flutes formed on an outer circumferential surface thereof, a second corrugating roll (16) having corrugation flutes engaged with the corrugation flutes of the first corrugating roll (14), the second corrugating roll forming predetermined corrugation flutes on a medium web (18) passing between the first and second corrugating rolls (14,16), gluing means (28) for carrying out gluing at corrugation crests of the corrugation flutes of the medium web (18), a first smoothing roll (34) provided in a feeding path of a liner web (32), a second smoothing roll (48) provided in a feeding path of the single face corrugated web (S), and a third smoothing roll (46) provided in the feeding path of the liner web (32) between the first smoothing roll (34) and the second smoothing roll (48), the method comprising the steps of: generating a tension on the liner web (32) between the first smoothing roll (34) and the second smoothing roll (48); and exerting the tension generated on the liner web (32) on an outer circumferential surface of the second corrugating roll (16) while the third smoothing roll (46) feeds the liner web between the first smoothing roll (34) and the second smoothing roll (48) so as to travel along the outer circumferential surface of the second corrugating roll (16) so that the liner web (32) is adhered to the glued corrugation crests of the medium web (18). A method according to claim 14 wherein the tension generating step generates the tension by making a difference in a rotation speed between the first smoothing roll (34) and the second smoothing roll (48) while the first smoothing roll (34) has a rotation speed which is equal to or less than a feeding speed of the liner web (32) and the second smoothing roll (48) has a rotation speed which is equal to or greater than a feeding speed of the liner web (32) or wherein the tension generating step generates the tension by providing a feeding speed of the single face corrugated web which is greater than that of the liner web (32) while the rotation speed of the first smoothing roll (34) is substantially equal to that of the second smoothing roll (48). A method according to claim 14 or 15 wherein the method further comprises the step of moving the third smoothing roll (46) to a first position where the third smoothing roll does not press the medium web (18) and the liner web (32) against the second corrugating roll (16) and a second position where the third smoothing roll presses the medium web and the liner web against the second corrugating roll by a nipping presser provided between the third smoothing roll and the second corrugating roll. A method according to anyone of the claims 14 to 16, wherein the third smoothing roll moving step moves the third smoothing roll (46) to a first position where the third smoothing roll does not press the medium web (18) and the liner web (32) against the second corrugating roll (16) and a second position where the third smoothing roll presses the medium web and the liner web against the second corrugating roll by a nipping presser provided between the third smoothing roll and the second corrugating roll.

Inventors: ISOWA EIICHI, ISOWA, EIICHI
Applicants: ISOWA KK, KABUSHIKI KAISHA ISOWA
Application year: 1999
Main classification: B31F1
IPC codes: B31F1