Note: Descriptions are shown in the official language in which they were submitted.
liO~Q28
The present invention relates to the art of packaging
or protective wrapping large diameter reels of paper for trans-
port.
The finished product of the papermaking process is a
continously issued web approximately twenty feet (6 meters)
wide. For shipment to customers and converters, the web is
slit into a multiplicity of more manageable widths and wound
into cylindrical reels or rolls of normally three to six feet
in diameter. Shipment weights of such rolls may range from
1700 to 9200 pounds.
To protect such finished reels of paper from handling
and shipment damage, the usual industry practice is to wrap
the rolls with a heavy grade of paperboard of greater than 0.009
inch thickness caliper and normally 0.020 inch to 0.024 inch
caliper.
The presently prevailing technique for such roll
wrapping is to draw a strip of wrapping board from a supply
reel o greater axial length than the roll to be protected.
This web strip is wrapped tightly about the cylindrical surface
of the protected roll. The axially overhanging portion is
crimped radially inward toward the roll center and tightly
creased against circular roll end. To seal the roll ends and
hold the crimps down against the end faces, two circular header
disks of approximately the same diameter as the protected roll
are used at each roll end-face. One disk is inserted within
the surface wrap overhang flush against the roll end-face.
Adhesive is then applied to the outer face of this first or
inner disk. Next, the overhanging portion of the surface wrap
is crimped and pleated into the inner disk adhesive. There-
after, a second or outer disk having adhesive applied to theinner face thereof is pressed against the outer face of the
surface wrap pleats. ~
~lO~Q2B
U.S. Patent Numbers 3,924,375; 3,828,523; 3,633,335;
3,577,703; 2,893,191; and 2,644,282 disclose numerous methods
and apparatus to mechanize the aforedescribed wrapping
technique.
U.S. Patent 3,924,375 describes an apparatus for
incrementally pleating the overhanging portion of an over-
hanging, cylindrical surface wrapping sheet onto against the
roll end-face.
U.S. Patent 3,828,523 describes an apparatus for
holding an inner roll disk header in place while the over-
hanging portion of a surface wrapping sheet is incrementally
folded over the end corner and pleats formed against the roll
end-face.
V.S. Patent 3,633,335 describes a rotating star-wheel
apparatus for incrementally folding the overhang of a surface
wrapping sheet over a roll end corner into a follower roll to
be pleated and creased against the roll end-face.
U.S. Patent 3,577,703 describes a rotating cylinder
having a helical groove cut into the surface thereof for
incrementally folding the overhanging portion of a surface
wrapping sheet over the roll end-edge and creasing the result-
ing pleat against the roll end-face.
U.S. Patent 2,893,191 describes a rotating disk
apparatus for incrementally folding the overhanging portion
of a surface wrapping sheet over the roll end-edge and creasing
the resulting pleat against the roll end-face.
U.S. Patent 2,644,282 describes an apparatus for
incrementally folding the overhanging portion of surface
wrapping sheet over the roll end-edge and creasing the result-
ing pleat against the roll end-face by rolling the roll along
~lO~Q28
a floor line with a surface drive belt applied to the upper -~
tangent of the roll. The folding and pleating device is
secured to the floor along the roll line and the roll end-face
is pressed thereagainst.
Common to all such prior art apparatus and character-
istic of the wrapping method in general is the need for circular
usually die cut, header disks of substantially the same ~
diameter as the roll. If several different diameter sizes are `-
prepared for shipment by the producing mill, it is necessary
to make or purchase and store such respectively sized header
disks preparatory to use.
Moreover, the mere need of several sizes of header
disks creates a material handling obstacle at a roll wrapping
station where several different roll sizes are wrapped in mixed
succession. As the roll is circumferentially wrapped, the
operator must select the proper disk size and manually place
it against the roll end face within the overhanging flange of -~
wrapping material that is to serve as the crimped pleats.
Although these tasks are neither difficult nor
excessively time consuming under relaxed conditions, in many
cases the papermachine produces more rapidly than the product
can be wrapped, even with the aid of semiautomatic equipment
suGh as that disclosed above.
James Arnold Morgan has taught a method of first
applying a band of adhesive, either glue or double-faced tape,
around the roll circumference at both axial ends thereof. Next
a header disk having a diameter greater than the subject roll
is positioned against the respective roll end faces and crimped
into the adhesive band with the crimp pleats lying against and
around the circumferential surface of the roll. Finally, a
1100~28
circumferential wrap of approximately the same axial length as
the roll is adhesively applied over the header disk pleats and
the circumferential surface of the roll therebetween.
The aforesaid Morgan technique of roll wrapping permits
a single diameter, oversized header disk to be used for a wide
range of roll diameters and simultaneously avoids the necessity
of carefully inserting a closely sized, pliable disk within the
recess of a circumferential wrap overhang.
One object of the present invention is to improve the
Morgan technique by eliminating the need of a circular wrap
header piece whereby a square header piece such as is cut from a
continuous reel of header web stock may be utilized.
Another object of the present invention is to teach an
improved method and apparatus for applying oversized roll headers
pursuant to the Morgan wrapping technique whereby the header
piece is crimped around the entire roll circumference with a
single stroke of movement.
Another object of the present invention is to eliminate
the need for rotating a roll during the header piece application
step.
Another object of the present invention is to teach a
method and apparatusthat quickly applies a header piece with
such security that the header capped roll may be transferred to
another process station for circumferential wrapping thereby
substantially reducing the full cycle time at a single station in
a process line.
According to one aspect of the invention, a method of
protectively wrapping a cylindrical mill reel of paper comprises
the steps of;
applying a band of adhesive around the circumferential
~- 4 -
'iB
llOQQ28
surface of the reel near an axial end thereof,
positioning a sheet of head wrapping material adjacent
to and substantially parallel-planar with an end-face of the
reel, the sheet being of such size and area as to exceed the
diameter and area of the end-face;
folding the sheet over an outer edge corner of the
reel end-face simultaneously around the entire circumference
thereof; and
pleating all excess sheet material that is radially
beyond the edge corner onto the cylindrical surface and against
the adhesive ~and around the entire circumference thereof; said
pleating being carried out simultaneously with the folding step.
According to a further aspect of the invention, there
is provided a method of covering the circular plane end-face of
a substantially solid cylinder with a sheet of covering material
having a greater surface area than the end-face, the method
comprising the steps of:
A. providing structural plate means having cylindrical
ring means secured thereto one axial end of the ring means
projecting transversely from the plane of the plate means;
B. securing a sheet of elastomer material around the
periphery of the projecting axial end of the cylindrical ring
means, the elastomer sheet having at least an annular portion
extending radially within the circular section encompassed by
the cylindrical ring means;
C. aligning the ring means concentrically about an
end-face of a substantially solid cylinder of less outer diameter
than the inner diameter of the ring means, the projecting axial
end of the ring means being projected over the cylindrical sur-
~- 4a -
C
~10~1:P28
face side of the plane of the end-face and the plate means
positioned on the other side of the end-face plane;
D. positioning a sheet of the covering material
between the solid cylinder end-face and the radially extended
portion of the elastomer sheet;
E. pressing the covering sheet and the elastomer
sheet between the solid cylinder end-face and the plate means;
F. applying fluid pressure to the plate means side of
the elastomer sheet to expand a toroidal shape from the portion
of the elastomer sheet between the projecting end of the ring
means and a radially outer edge corner of the solid cylinder
end-face whereby the area of the covering sheet exceeding the
area of the solid cylinder end-face is creased over the edge
corner and simultaneously pleated against the cylindrical surface.
According to a still further aspect of the invention,
there is provided a method of protectively wrapping a cylindrical
mill reel of paper comprising a first station having nonrotation-
al reel lifting means and a second station having reel rotating
means, the method comprising the steps of:
Ar providing sheets of header wrapping material
having a greater area than a normal end-face of the reel;
B. at the first station, capping the end-faces of
the reel with respective sheets of the wrapping material by
simultaneously creasing and pleating all of that area portion of
the sheets radially beyond the cylindrical periphery of the
reel over the peripherial edges of the end-face and into
respective bands of adhesive circumscribing the cylindrical
surface of the reel;
C. moving the capped reel product of the first station
to the secGnd station; and
~ 4b -
110~28
D. at the second station, wrapping the cylindrical
surfaces of the capped reel with a sheet of protective wrap-
ping material that overlaps the pleated portions of the end
capping sheets.
According to another aspect of the invention, an
apparatus for protectively wrapping a cylindrical mill reel of
paper comprises:
substantially circular wall means secured to axial
displacement means for selective reciprocation along a line per-
pendicular to the circular wall;
cylindrical rim means coaxially surrounding a faceplane of the wall and projecting therefrom substantially parallel
with the line to an outer edge thereof;
elastomer membrane means secured around the rim means
at the outer edge to confine a fluid chamber defined by the wall
` means, the rim means and the membrane means; and
fluid conduit means to admit a pressurized fluid to
the interior volume of the chamber when the wall is positioned to
confine a central region of the membrane between the face plane
and an end face of paper reel whereby the membrane is expanded
into a toroidal configuration around the paper reel.
According to still another aspect of the invention,
an apparatus for protectively wrapping a cylindrical mill reel of
paper comprises header means disposed at each end of reel lift
means, the header means each comprising substantially circular,
coaxially aligned pan means, each said pan means having a
substantially circular elastomer membrane cover for fluid pressure
chamber means therewithin, at least one of t-he pan means being
axially extensible to clamp the end faces of a reel of paper
~- 4c -
l~a
~10~
between elastomer covers respective to the two pan means, and
conduit means for admitting pressurized fluid to the chamber
means, the circule of the membrane having a greater radius than
that of the reel of paper whereby the annular excess of the
membrane is expanded by the pressurized fluid into a toroidal
configuration around the respective ends of the reel.
In the disclosed preferred embodiment, there is
provided an oppositely facing pair of axially shiftable header
pans having a flexible, elastomer diaphragm spanning the
circular opening with the cylindrically projecting
- 4d -
pan rim. A roll, subject to be wrapped, is positioned over
notched elevator stanchions to be raised to an elevation
coaxial with the header pans. Either before or after arrival
at the header station, the subject roll is provided with a band
of adhesive around the roll circumference near both axial ends
thereof. Such adhesive may be either the flow-on (brush or
spray) type or double-faced tape. With the roll so positioned,
webs of header wrapping material drawn from respective supply
reels are draped between the opposite roll ends and adjacent
header pans. Small diameter center platens positioned coaxially
of the header pans are axially extended from both header pans
to press the header wrapping web against respective roll end-
faces. With the web secured in place, a square header sheet
is severed from the supply web continuum. Thereafter, linear
motors are actuated to axially extend the header pans into
compressive engagement with the roll end-faces, pressing the
header sheets therebetween. Pressurized fluid is then introduced
to a chamber volume between the header pan rigid structure
and the elastomeric diaphragm stretched thereover. Such
pressurized air expands the diaphragm in the annular region
radially beyond the roll diameter and within the header pan
rim onto a toroidal configuration thereby drawing, pressing and
creasing the header sheets smoothly over the circular roll
end edges and firmly into the bands of adhesive on the roll
circumference.
The sharp creases pressed into the header sheet by
the inflated diaphragm leaves the crimped portion of the header
sheet in contact with the circumferential surface of the roll
with relatively light restoration strength thereby permitting
the adhesive bands on the subject roll to hold tne header sheet
~10~
firmly in place so tnat the capped roll may be immediately
released by the diaphragms and header pans and transferred to
a rotational station without losing or loosening the freshly
applied header cap.
The entire header capping procedure described above
requires approximately forty-five seconds for completion.
Since the following circumferential wrapping procedure which
applies a protective web around the roll girth overlying the
crimped and pleated portion of the header also requires
approximately forty-five seconds for completion, the capacity
to separate the functions for simultaneous execution on separate
rolls provides opportunity for greatly accelerating roll
wrappings productivity.
Moreover, since none of the header capping steps
requires manual manipulation, the entire procedure may be
mechanically sequenced for automatic programming.
Relative to the drawing wherein like reference
characters designate like or similar elements:
FIGURE 1 is a pictorial of the present invention
apparatus;
FIGURE 2 is a partially section elevation of the
present invention;
FIGURE 3 is a sectional detail of the header pan
portion of the present invention;
FIGURE 4 is a pictorial of a paper roll capped with
a square header sheet by the method of the invention; and
FIGURE 5 is a pictorial of a capped paper roll
having the cylindrical surface wrap applied by the method of
the invention.
- llOQ~28
The primary components of the present invention
apparatus are illustrated by the Figure 1 pictorial. These
include an oppositely facing pair of head capping units 100
and 200. Pedestal base 204 of capping unit 200 is rigidly
secured to a floor structure whereas pedestal base 104 of the
capping unit 100 is secured to the floor by means of rails or
guide ways 11 for broad range adjustment of the distance between
the two capping units.
Both capping units 100 and 200 are provided with
header pans 101 and 201, respectively. Such header pans are
secured to the ends of axially shiftable arbor shafts 102 and
202 which slide through frame collars 103 and 203. Any suitable
means such as a ramp or jack may be used to raise a roll R subject
to protective wrapping up to a coaxial level with the header pans
101, 201 and arbor shafts 102, 202. However, the present inven-
tion provides a power operated elevating platform, not shown,
which simultaneously lifts a pair of V-notched stanchions 12 and
13. The elevating platform and associate power equipment are
recessed below floor level to minimize the required energy
output of the equipment and also to keep the work station area
clear of equi~rllent clutter. Both stanchions 12 and 13 extend
through guide slots 14 in the floor above the elevating platform.
Since capping unit 200 is not positionally adjustable,
stanchion 12 may be permanently set for vertical reciprocation.
Stanchion 13, on the other hand, is guided through a
particularly selected slot 14 for convenient adjustment of
the distance between stanchions 12 and 13 respective to the
subject roll length. For changes in roll lengths exceeding
stroke capacity of the capping units 100 and 200, it is
-- 7
Q28
simply necessary to select an appropriate slot 14 for the
movable stanchion 13 and shift the capping unit base 104 on
the rails 11 accordingly.
The partial section of Figure 2 illustrates working
details of the capping units 100 and 200. Further description
of these details will be limited to the movable capping unit
100 since, by association, the same will apply to the fixed
capping unit 200.
Header pan 101 and arbor shaft 102 constitute a
singular structural unit supported by the frame collar 103.
In detail, the collar comprises a fluid pressure cylinder 130
having heads 131 and 132, each provided with slide bearings and
seals 133 and 134, respectively. At opposite axial ends of the
cylinder 130 are provided fluid conduits 135 and 136 from
a four-way control valve 139. An annular piston 121 secured
to the arbor shaft 102 divides the cylinder 130 into two
variable volume chambers 137 and 138.
Also structurally sec~red to the arbor shaft 102
is a ring boss 110 and several gusset plates 111 aligned
radially from the arbor shaft axis A. These gussets 111
provide structural reinforcement for the annular wall 112 of
diaphragm chamber 113. Ring element 114, structurally integral
with the annular wall 112 and gussets 111, constitutes the
radially outer boundary of the chamber 113 and the rim of pan
101 .
The internal volume of chamber 113 is enclosed by
the elastic membrane of diaphragm 115 fabricated from a 0.0625
to 0.125 inch thickness sheet of 30-50 Shore "A" durometer
natural gum rubber having a 600% elongation capacity. In the
preferred embodiment of the invention, the diaphragm 115 is cut
-- 8
ll~Q~28
in the shape of a concentric circle annulus from a sheet of elas-
tomer material having a flat or planar free shape. It is to be
understood that by the description of a flat free shape, it is
meant that the sheet of material from which the diaghragm 115 is
cut has substantially uniform sectional thickness and flat plane
shape when unattached or unbiased to any particular shape. The
outer periphery of diaphragm 115 is wrapped about the projecting
rim of ring element 114 and secured with a clamping ring 117.
Similarly, the inner periphery of the diaphragm annulus is wrap-
ped over the corner edge to the wall 112 and well rim 151 and
secured with compressionring 118. One or more charging conduits
116 serve to inflate and deflate chamber 113.
In an alternative embodiment of the invention notillustrated, the central aperture of the diaphragm 115 is
structurally unattached. The pressure seal at the internal
boundary of chamber 113 is formed by clamping pressure between
the roll R end-face edge and the wall 112. This diaphragm
sealing technique permits pressure in the chamber 113 to be
completely and rapidly vented as a consequence of retracting
the wall 112 when the capping procedure is completed. Obviously,
however, there must be a reasonably accurate axial alignment
between the roll R axis and the wall 112 axis or the internal
pressure seal will not form.
Within the axial center zone of header pan 101 is
provided a recess or platen well 150. The well rim 151 is
secured to the internal periphery of the annular wall 112, to
the gussets 111, and a base wall 152. This well 150 provides
a retraction volume behind the surface plane of annular wall 112
for an axially extensible disk platen 153. A guide shaft
slidably received by a journal 155 set in the end of arbor shaft
102 confines the platen 153 to coaxial alignment with axis A.
Fluid motors 156 provide axial displacement of the platen 153.
g
QZB
In addition to the head capping units 100 and 200
aforedescribed, means should be provided to expeditiously
supply the necessary length of header wrapping material between
the opposite roll end faces and the diaphragm face of the capping
units. Representative of such means, a web supply system is
schematically shown in Figure 2 comprising a pair of powered
pulling rolls 20 and 30 positioned above header pans 101 and
201 for drawing a web of paperboard header material W from
respective supply reels 21 and 31. Preferably, frame and
journal structure for the pulling rolls 20 and 30 is secured
to the respective header pans to provide a fixed relative
position between the out-feed line of the pulling rolls 20
and 30 and the diaphragm face of the respective header pan.
However, the pulling rolls may also be suspended independently
of the header pans so as to be correctly positioned thereover
by manual or automatic means not shown.
Additionally, it is desirable to provide one of the
many, well known web cutting devices such as represented by
the wheel and anvil mechanism 22 and 32 to selectively sever
the web W and separate a discrete header sheet h from the web
continuum.
Using the foregoing equipment, the method of the
invention comprises the preparatory steps of positioning the
movable stanchion 13, capping unit 100, and web pulling rolls
20 relative to the axial length of the roll R to be wrapped.
These steps may be performed manually or automatically as the
result of a control signal characteristic of the roll R length.
Roll R is then positioned and aligned over the
stanchions 12 and 13 to which power is applied for lifting the
roll into centerline alignment with axis A.
-- 10 --
Q28
"~
Either before theroll R is positioned on the
stanchions 12 and 13 or afterward, depending on the application
means and method, bands 15 of adhesive are applied around the
roll circumference near the axial ends. The exact placement
of these bands 15 will depend on the roll diameter and the
width of the wrapping web W. As previously stated, such
adhesive may be either of the flow-on type or double-faced
adhesive tape.
When the roll R is lifted by the stanchions 12 and ~ ;
13, the header pan 101 and 201 will be in the axially retracted
position shown by Figure 2 by virtue of dominant air pressure
in the variable volume chamber 137. Such retracted position
will leave sufficient clearance between the roll R end faces
and the respective diaphragms 115, 215 for web material W to be
draped from the pulling nip of rolls 20 therebetween.
With the apparatus in the condition described and
as illustrated by Figure 2, the platens 153, 253 are extended ~-
by motors 156, 256 to press the draping web W against the roll
end face. With the wrap header sheet h secured relative to
the roll, the sheet h is severed from the supply by cutting
means 22, 32. Valve 139 is then switched to admit fluid
pressure to the chamber 138 and simultaneously exhaust the
chamber 137. The consequent pressure differential across the
piston 121 drives the header pan 101 and arbor shaft 102 along
the axis A against the force of platen motors 156, 256 until
the annular wall 112, 212 of the header pans 101, 201 abuts the
diaphragms 115, 215 against the roll end faces. Since the
rubber of diaphragms 115, 215 will yield as the walls 112, 212
approach final position against the end faces, the header sheets
h will be frictionally drawn radially outward in all directions
thereabout. Altnough no movement of a header sheet h occurs,
such radial friction forces smooth the sheet free of wrinkles
as it is pressed flat with the roll end face. Also due to the
resilience of the diaphragms 115, 215 and the force exerted
by the motor chambers 138, 238, a sharp crease is pressed into
the header sheets h at the roll R end edges.
At this stage of the process, pressurized air is
admitted to the diaphragm chambers 113, 213 to expand the
diaphragms 115, 215 into a toroidal configuration as illustrated
by Figure 3. As the toroids grow, the excess header material
radially beyond the roll R end edges is pressed against the
roll circumferential surface by the rolling, wiping action of
the expanding diaphragms 115, 215. This action presses the
excess head material with a uniformly distributed force firmly
into the adhesive bands 15. Simultaneously, pleats in the
excess header material are formed with a reasonably uniform
distribution around the roll R circumference and sharply creased
to minimize resilient restoration forces within the header
sheet h which would otherwise tend to pull the sheet from the
adhesive of bands 15 when the pressure is released from
chambers 113, 213 and the diaphragms 115, 215 retract.
Due to the firmness and security of the header wrap
by the present invention, the diaphragms 115, 215 may be
immediately retracted and tne header pans 101, 201 withdrawn
by a venting of motor chambers 138, 238 and charging of
chambers 137, 237. A header capped roll such as illustrated
by Figure 4 is the resulting product.
From the foregoing description, it may now be
understood that the cut shape of the header sheet h is largely
irrelevant to the operation and ability of ~he invention to
:~10Q~28
smoothly cap the ends of a roll. Consequently, square or
rectangular header sheets h cut directly from supply rolls 21,
31 may be used with equal facility to a round, die cut header
sheet.
It will be noted that the header sheet h is applied
with undisturbed surface smoothness in the sense that no pre-
formed creases or fold lines are provided to bias the lines along
which the pleat creases are formed. Consequently, the internal
pressure within the motor chamber 113 must be sufficient to press
the randomly occurring pleat crease tightly enough against the
reel surface for a permanent set in the header material.
Also due to the firmness and security of the header
wrap, regardless of header sheet shape, the capped roll may be
immediately removed from the capping station between the units
100, 200 to a rotational station where a circumferential wrap-
ping sheet C is applied over the header pleats as illustrated
by Figure 5.
~ - 13
