Note: Descriptions are shown in the official language in which they were submitted.
'3~ :
-- 1 , .
APPARATUS FOR DISPENSING AND RE-ROLLING
FLOOR COVERING MATERIALS
This invention relates to an appara-tus for dis-
pensing and re-rolling floor covering materials and par-
ticularly but not exclusively carpeting.
Carpeting is delivered and stored in large
rolls which are convenient to mount in rac]cs or even to
lie simply in stacks. Generally in the carpet retailing
industry, a rolled supply of a particular carpet to be
sold is laid on the floor and unrolled across the ~loor ~;
so as to expose the length of carpet which is to be
supplied, following which the carpet is cut at the
~, required length. The remainder of the roll is then
removed and replaced in the rack or on the stack and the
cut carpet is simply rolled up across the floor following
which it may be packaged or tied for delivery purposes.
This technique has disadvantages for a number
of reasons. Firstly a relatively large amount of floor
area must be set aside for unrolliny the carpet since the
floor area must exceed the typical lengths of carpet
which will be suppli.ed in a retail situation. Secondly
the carpet when unrolled on the floor is exposed to dirt
and deterioration. Thirdly the handling of the supply
roll and the re-rolling of the cut carpet is generally a
two person operation and is lengthy, time consuming and
. .
: A
, - . . . ~ ~ . . . .. .. . . .
, ~ ~ .. . . . . . .... . . .
. . . .
.. .
,, . ~ . " ~ . ,
:. . . , , ~ : .
.
1;~8~ 6
- 2 -
,
thus inefficient in personnel cost. Fourthly, the taking
of inventory of a length of carpet rolls remaining in
stock must be handled in basically the same way in that
the carpet must be unrolled manually and then re-rolled
with a measuring taking placing by laying the carpet
across the floor and the use of a tape measure.
Various attempts have therefore been made to
design and manufacture an automated device which will
assist in the dispensing, measuring and re-rolling of
carpet materials which overcomes the above dlsadvantages
of the strictly manual process which is currently ln use
- in almost all carpet retailing stores.
It is one objective of the present invention
therefore to provide an improved device of this general
type for dispensing and re-rolling ~loor coverin~ mate-
rials.
According to the invention there is provided
apparatus Eor dispensing and re-rolling floor covering `~
materlal comprising an elongate base member deEining two
sides and a top surEace and having means for resting of
the base member upon a Eloor surEace, a Eirst cra~le
mounted on the base member a].ong one side thereo and
comprising a plurality of spaced rollers each lying para-
llel to said one side of the base member from an inner-
~ .
.
~1!36~ 6
- 3 - .
most one of the rollers adjacent to an edge of the top
surface with each of the further rollers in turn being
spaced further from the edge oE the top surface, means
supporting the rollers such that their axes lie on an arc
of a circle so as to cradle a roll of floor covering ly-
ing thereon, and means for driving the rotating the
rollers each about its respective axis for rotating the
roll of floor covering, a second cradle mounted on the
base member along an opposed side thereof and comprising
a plurality of spaced rollers each lying parallel to sa1d
opposed side from an innermost one of the rollers adja- :
cent to an opposed edge of the top surface with each of
the further rollers being spaced in turn further from the
opposed edget means supporting the rollers such that
their axes lie on an arc of a circle to cradle a roll of
floor covering lying thereon and means for d~ivingly
rotating the rollers each about its respective axis so as
to rotate the roll of floor covering to form the floor
covering into the roll, means for commonly driving said
first and second cradles such that rotation of the roll
on the flrst cradle causes the floor covering material to
be fed therefrom across said top surface to said roll
forming on said second cradle, a measuring roller mounted
in said top surface for measuring a length of the mate-
A
~ ~. ~ .- .. ;. ..... . . . . .. . . ` . . . ` .
.. . . . . . .
.
~2~16~ii9~;
- 4 -
rial fed there across and a cutting knife member mounted
in said top surface with a knife blade thereof movable
longitudinally the top surface to cut a measured length
of the floor covering.
With the foregoing in view, and other advan-
tages as will become apparent to those skilled .in the art
to which this invention relates as this specification
proceeds, the invention is herein described by reference
to the accompanying drawings forming a part hereof, which
includes a description of the best mode known to the
applicant and of the preferred typical embodiment of the
principles of the present invention, in which~
Figure 1 is an end elevational view of a carpet
dispensing and re-rolling machine according to the inven-
tion.
Figure 2 is a top plan view of the machine of
Figure 1.
Figure 3 is a cross-sectional view along the
lines 3-3 of Figure 2.
Figure ~ is a side elevational view of a detail
of the machine o~ Figure 1 showing the knife construc-
tion.
Figure 5 is a cross-sectional view along the
lines 5-5 of Figure ~.
., , . ' ~.
:, , ' ' ' '
12~ 6
The device as shown in the drawings comprises a
base me~ber generally indicated at 10 which is formed of
a tubular frame structure generally indicated at 11 to
define an undersurEace 12, a pair of vertical sides 13
and 14, a horizontal table top surface 15 and two ends 16
and 17. Each of the sides, ends and table surface is
defined by a sheet metal panel such as to define a clean
outer surface. The frame 11 at the underside 12 carries
castorwheels 18 arranged at four corners o~ the rectang-
ular frame so that the base member can be readily wheeled
manually from place to place as is required for storage
or for operation within an open area.
The width of the table surface 15 is approxi-
mately one~third of the width of the underside with the
side edges of the table surface 15 being defined by elon-
gate structural members 20 and 21. The upper edges of
the sides 13 and 14 are similarly defined by elongate
structurally members 22 and 23 arranged at a height
approximately one-half the distance between the underside
of the top surface so as to define inclined sides of the
devi.ce indicated at 24 and 25. Each of the sides is
formed by a strut 26, 27 which interconnects the struc-
tural beams at the sides and top of -the device with the
area between the struts 26 open as best shown in Figure
'~.
: '
~ A
. .. . . ~ . . . . ..
~L2~36~i~6
-- 6 --
On each inclined side of the device is formed a
separate one of a pair of cradles generally indicated at
28 and 29. Basically each of the cradles is constituted
by four rollers 30 which are arranged in parallel spaced
relationship and extending longitudinally of the frame
structure covering the open sides and extending outwardly
therebeyond to a position slightly outwardly of the sides
13 and 1~.
Each of the rollers 3~ is carried for rotatlon
about its axis in bearings 31. Each of the rollers
carries chain wheel drive members 32 by which it can be
drivingly rotated about its axis defined by the bearings
31. An innermost one of the rollers indicated at 30A is
mounted immediately adjacent the respective side edge of
the top surface 15. For this purpose the respective
bearing of the roller 30A indicated at 31A is mounted in
a strap 33 on an upper surface of the strut 26, 27 so as
to be maintained in fixed positlon at the e~d~e of the top
surface 15 but able to rotate about the axis of the
rol.ler 30A as driven by the chain wheel 32.
A second of the rollers 30B is si~.ilarly
mounted in a strap 33 on the strut 26 at a position down-
wardly and outwardly of the Eirst roller 30A.
.
s~
-- 7 --
A further or third roller indicated at 30C is
carried at a position as sho~n in Figure 1 in which it is
substantially at the same height as the roller 30~ but
spaced outwardly therefrom. A yet further roller indi-
cated at 30D ls positioned outwardly and upwardly rela-
tive to the roller 30C so as to lie at a hei~ht substan-
tially equal to the hei~ht of the roller 30A. In this
way the rollers form a cradle with their axes lying on an
arc of a circle which approximates the size of a roll of
the material. It will of course be appreciated that the
roll will vary in size depending upon the amount of
material remaining but in practice a spacing between the
outer roller 30D and the innermost roller 30A might be of
the order of 18 inches with a diameter of curvature of
the arc defined by the axis of the rollers being of the
order of 24 to 36 inches so as to act as a compromise
between the largest and smallest diameters of roll which
might be accommodated.
While the rollers 30A and 30B are fixed upon
the sides o~ the machine, the rollers 30C and 30D are
pivotally mounted and hence are carried upon levers 3~
and 35 respectively. The cradle 28 of the device which
is intended to act as a roll-up cradle has the levers 34
and 35 formed separately with each defining pivotal move-
,.
A
~ .
. ~ .. ~ .
6~96
-- 8 --
ment of the respective roller 30C and 30D about an axis
parallel to the rollers and spaced inwardly of the
respective roller. Thus the roller 30D is effectively
pivotal about the a~is of the roller 30C on the lever 35
and the roller 30C is in turn pivotal about the axis of
the roller 30B on the lever 34.
In regard to the cradle 29 which is intended to
act as a supply cradle for the supply roll, the levers
- indicated at 34A and 35A are rigidly connected so that
the only pivotal movement allowed of the rollers 30C and
30D of the cradle 29 is about the axis of the roller 30B.
Each of the cradles includes a manually graspable handle
72 extending axially at the outermost roller at a posi.-
tion slightly beyond the end of the lever 35.
In this way both of the cradles 28 and 29 can
be moved from an outward cradling position shown in
respect of the cradle 28 in Figure 1 and shown in respect
of the cradle 29 in Fi~ure 3. In this cradling position,
the outer roller 30~ extends outwardly to the side of the
machine with the axes of the rollers lying on the arc of
the circle to receive resting in the cradle a relatively
large roll. In addition both of the cradles can be
folded inwardly to a folded position shown in respective
of the cradle 28 in Figure 3 and shown in respect of the
. . , . :. - :
.. . .
- : , . : :
: . .
' ; . ~ ' . ~ ` .'' ' '
, .
86596 --
g :.
.
cradle 29 in Figure 1. In these folded-~n positions,
both of the cradles are reduced in width so that the
whole of the machine has a reduced width to the extent
only of the sides 13 and 14. In this way the machine can
be stored in an area of the size of the base section
which in a practical example can be of the ordex of four
feet wide and fourteen feet long.
As shown best in Figure 2, the top table sur-
face 15 defined by the structural members 20 and 21 and
the flat sheet therebetween extends outwardly beyond one
end of the base as indicated at 15A. As the rollers 30 ~-~
have a length substantially equal to the length of a car-
pet roll which is conventionally either four meters or 12
feet. The forward portion 15A of the top surface is in
operation left free of carpet and can act as a table top
for papers of the operative. In addition, the forward
portion 15A carries a display paneI or gauge 40 of a
metering roller 41 mounted within the top surface to be
engaged by carpet mov:Lng across the top surface. The
metering roller ~1 ls received within a recess in the top
surface so that only a portion of the roller ~1 projects
through the recess for engaging the carpet. A nip roller
42 is carried on an arm 43 which is spring biased to form
a nip between the rollers 41 and ~2 to press the carpet
'
:
A
. . ` . . .
. ~ .. .... -. .. - ... . .. . .
.. . . . . . -. . . . . .
.. . . . . . .
: , . .. ~.... ... . . .. .. . . .
. .. . .
1;2E~biS96
- 10 ~
material therebetween. The arm 43 can be lifted against
the spring bias to a retracted position and which it can
latch for example by an over cen-tre arrangement (not
shown).
As shown in Figure 3, a motor 44 is mounted
within the base member for driving the rollers 30 of both
of the cradles 28 and 29. The motor carries a pair of
chain wheels 45 which respectively drive idler sprockets
46 and 47 through chains 48. From the sprocket 46, a
drive train generally indicated at 49 extends to drive
each of the rollers 30 of the cradle 28. For this pur-
pose each of the rollers 30A, 30B, 30C carries a pair of
chain wheels 32 so that the drive can be transmitted each
to the next for common rotation of the rollers about
their respective axes. For purposes o~ safety, the
chains interconnecting the respective chain wheels 32 are
covered by cover plates 50 which prevent an operative's
fingers becoming trapped between the chain and the
respective chain wheel.
Similarly a drive train 51 communicates drive
from the sprocket 47 to each of the rollers 30 of the
cradle 29. A clutch schematically indicated at 52 oper-
able by a lever 53 shown in Figure 1 can disconnect drive
from the motor 44 to the cradle 29 as required by the
-
,
:~2t365~6
operative. The motor can be operated in forward or re-
verse directions by a switch schematically indicated at
54 as shown in Figure 2.
A knife mechanism for cutting the floor cover-
ing material is generally indicated at 55. The knife
mechanism cornprises a chaln 56 which extends along the
full length of the machine and cooperates wi~th chain
wheels 57 at the inward and outward ends respectively so
as to define an upper run of the chain which passes along
the inside of the tubular structural member and a lower
run of the chain which runs along the underside of the
structural member 20. The chain wheel 57 at the inward
end of the machine can be driven to rotate to move the
chain longitudinally of the machine by a hand crank 58
mounted on one side face of the top surface. As an
alternative, a drive motor can be provided within the top
surface for directly driving the chain wheel 57 under
control of a suitably positioned manual switch.
~s best shown in Figures 4 and 5, the chain 56
carries a block 59 on one side of the chaln which
supports Eirstly a utility blade 60 which is of the con-
ventional form to enable ready replacement. The blade 60
projects upwardly through a slot 61 in the upper surface
of the structural member 20 so the blade runs along the
. -
~ ~ .
~2~6Si~
- 12 -
le~gth of the top surface as it is carried longitudinally
by the chain 56. Thus the blade projects upwardly from
the undersurface of the carpet material for cutting
through the bac~lng of the carpet material. To retain
the carpet material in position pressed downwardly onto
the blade, there is provided a pair of wheels 62 which
are mounted on either side of the blade 60 so that the
blade 60 projects into the space bet~een the wheels. The
wheels are mounted upon a common axle 63 which is carried
upon a curved support strut 64 which has a first portion
extending parallel to the chain and a second portion
curving downwardly toward the chain. The axle 63
includes a pin 65 which can be pulled to allow the wheels
to be removed from the support member 64 to allow access
to the blade 60 so that it can be removed for turning to
present a new portion of the blade or for replacement if
the blade is fully worn.
In operation, the support cradle 29 is moved
~rom its folded position shown in Figure 1 into the open
position shown in Figure 3. In this position, a carpet
roll indicated at 70 can be placed upon the cradle. In
order to reduce the stress upon the levers 34A and 35A, a
pair of vertical struts 71 is provided at opposed ends of
the frame which help support the outermost rollers 30C
. . .
- 13 -
and 30D of the cradle 29 when the carpet roll is of the
maximum weight.
The nip roller ~2 is then lifted away from the
top surface 15 and the motor 44 is actuated to commence
the rotation of the rollers of the cradles in a direction
to rotate the roll 70 in a clockwise direction as shown
in Figure 3 so that an edge of the carpet is fed across
the top surface 15 toward the cradle 28. At this point
the knife mechanism is full~ retracted to the drive chain
wheel 57 so that it lies on the extension 15A of ~he top
surface out of the path of the carpet. The carpet can
thus freely pass across the upper surface until the edge
of the carpet reaches the metering roller 41 and the slot
61 of the knife mechanism. The nip roller ~2 is lowered
into place and the gauge 40 is reset to zero. The move-
ment of the rollers 3Q is then recommenced by actuating
the motor 44 so that the edge of the carpet is forwarded
beyond the left hand edge of the top surface 15 onto the
cradle 28. At this point the cradle 28 is Inoved inwardly
by the manually actuable handle 72 in-to the folded posi-
tion shown in Flgure 3. In this posi-tion the carpet edge
passes between the rollers 30A and 30D into a confined
area formed by all of the rollers and particularly the
three rollers 30B, 30C and 30D. In this confined area
':
'
A
~. ... ... ~..... ~ ..... .. .. .... . . .. ..... . . ..... . . . .
. ' '' ' ~" '' ''"''" ''; ''" ''' ' ' '~'~ . ;"'.''; '.' "' ' " '' ' '' " '
~6~
- 14 -
the carpet edge is caused to turn in a clackwise direc-
tion to form a roll of the material. The pressure on the
forming roll can be controlled by the manual actuation of
the handle 72 so that the operative presses down upon the
handle initially to commence the roll and then gradually
releases the pressure as the roll increases in size to a
point where the roll is of sufficient size so it will be -
drlven ~o form a sufficiently tight roll while the cradle
28 is in its fully opened position. The amount o~ force
to be manually applied can be readily gauged by ~he oper-
ative.
In order to assist in drivin~ the ~orming roll
indicated at 75, each of the rollers oE the cradle 28 has
along its length spaced bands 76 of a roughened material
for example emery cloth which is adhesively attached to
the roller to increase the friction between the roller
and the forming roll 75.
Provided the roll 75 is properly and squarely
commenced, the symmetry of the system will ~enerally
cause the supply roll and the forming roll to remain
properly centered. Thus the slot 61 remains directly and
accurately s~uare to the edges of the carpet.
I~ at any time the rolling of the carpet
becomes slightly off-center, the operative can apply
. ,
:
. . . " . ~
.
- 15 -
sufficient force longitudinally of the carpet on the top
surface or table 15 to restore the proper centered roll-
ing of the carpet. If sufficient force cannot be applied
in this way, the machine can be stopped and the centering
restored with the machine halted. ~ -~
When sufficient carpeting has been fed past the
metering roller 41 as indicated by the gauge 40, the
machine can be halted and the knife actuated to cause
slitting of the carpet at the required location. The
knife is actuated b~ operating the hand crank 58 so as to
drive the knife across the width of the carpet to a suit-
able end stop adjacent the outer chain wheel 57. The
controlled cutting provided by the cooperation of the ;
knife blade and the wheels ensures that the carpet is
properly and accurately slit along a straight line with
no opportunity for deviation or fraying. The pressure
applied in the cutting effect can also handle foam backed
carpets which are notoriously difficult to slit without
tearing of the foam.
When the required length has been cut, the
clutch 52 can be operated so that the cradle 29 is main-
tained stationary. The cradle 28 can then be restarted
which will continue to rotate the re-rolled cut length of
the carpet which is required to be delivered. This roll-
A
. - . ~ . . ~ . . . ` . , '
. . . .. - . .
12~3659~
- 16 -
ing action can be used to wrap around the carpet roll a
covering material for example a plastic sheet for pack-
aging the roll and in addition the plastic sheet can be
located in place by suitable tape or string applied
around the roll as the covered roll continues to rotate.
When completed the roll can be simply manually removed
from the cradle and carried on a dolly or forklift for
dispatch.
When the packaged roll has been removed, the
motor 44 can be reversed to rewind the material back onto
the supply roll 70 so the supply roll can be lifted away
from the cradle 29 for return to storage again either on
a suitable dolly or a forklift.
The machine as described above has a number of
advantages as follows:
1. The length of material to be cut is
properly and accurately measured with little or no oppor-
tunity for error.
2. The cut is completely s~uare since the
carpet wi.ll necessarily be properly square acros~ the top
surface 15 provided the rolls are maintained properly
centered.
3. The width of the top surface allows a
portion of the carpet to be available for inspection as
,.
~: . . : - . - - , . , . , : ,
: . , ., , . , . . ~: , .
,
- . , . , ~ .
.
..
- 17 - ~
..~'
it moves across the top surface from the supply roll to
the re-roll.
4. No flooring core is necessary for the
rewinding although one can be used if the retailer or
customer requires.
5. The machine comprises a single simple
devlce which can be rolled from one place to another and
stored in a limited space. It is of a simple nature and
hence can be manufactured at relatively low capital
cost.
6. The device can be operated by a single
- operative with high ef~iciency in some cases enabling
cutting to be carried out at four times the rate possible
with a conventional floor unrolling technique.
7. The controlled knife ensures a clean
accurate cut.
8. The material is maintained in a clean
environment without necessity for ever contacting the
floor.
9. The device can be used for lnventory pur-
pos~s merely re-rolling a supply roll completely from the
cradle 29 onto the cradle 28 and of course m0asuring the
amount of material passing over the metering roll as the
roll is re-rolled.
A
. .
.. - . ~ i. .... .
.. . . .. . ~. . . ~` .:
:. ~ ` . ... . . . . ...
. . . .
