Note: Descriptions are shown in the official language in which they were submitted.
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METHOD AND APPARATUS FOR CORELESS WINDING -~
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~ BACKGROUND AND SUMMARY OF INVENTION:
¦ This invention relates to a method and apparatus for
coreless winding and more particularly including the
stabilization of the interior portion of a coreless wound log of
paper or the like. A "log" has the same diameter as the
commercial sized roll (toilet tissue, toweling, etc.) but is
much longer. Current practice is to transver~ely cut the log
into rolls, viz., in the U.S. 4-1/2" long for toilet tissue and
11" long for kitchen toweling.
A few coreless wound products have been in existence
for the last 10 or 15 years. These can be separated into t~ree
categories. First, there is the large diameter tissue and towel -
rolls made to dispense from the center and exemplified by U.K.
Patent 1,554~619. Second, there are tissue rolls with very
small "core" diameters made to dispense either from special,
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barbed shafts or without the use of any dispensing shaft but
rather using a cradle~ The use of these two categories has been
generally confined to Europe. Third, there is a category which
is frequently discussed but has never caught on. Exemplary of
this is a bathroom tissue roll for a standard home dispenser but
without the core. One of the obstacles in developing such a
product is the instability of the interior of the coreless log.
Without a core the center of the log is subject to collapse or
unwinding from the interior. This causes problems first at the
log saw -- wherein the elongated "log" is transversely cut into
retail size lengths or rolls, and also during packaging and
I shipping and finally when the user attempts to install it on the
dispenser shaft.
According to the invention, the problems associated
t with the third category is solved through stabilizing the loginterior by applying a fixing agent to the inside plies. In a
sense, this could be considered analogous to tail sealing (see
U.S. Patent 3,044,532 to Ghisoni) except that it works on the
inside tail.
More particularly, the invention contemplates winding a
web in convolute fashion on a "bare" mandrel and applying the
stabilizing agent prior to complete removal of the wound log
from the mandrel. In one embodiment, the stabilizing or fixing
agent can be applied during the course of the log winding -- as
by delivering the agent through axially or spirally spaced ports
in the mandrel. Alternatively, the stabilizing agent can be
applied prior to or during the "stripping" of the log from the
mandrel. This is achieved through the use of a discharge
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orifice means adjacent the end of the mandrel from which the log
is removed.
The invention also provicles a variety of means and
steps for maintaining the web in contact with the mandrel,
particularly during the initial stages. This can be done
through the use of a vacuum -- as in the same axially or
spirally, i.e., longitudinally, spaced ports used to deliver the
stabilizing agent.
Advantageously, the stabilizing agent has adhesive
characteristics such as starch/water mixtures, tail seal
adhesives, polyvinyl alcohol and the like. Even heated water or
steam may be employed to provide bonding of the inner plies.
Where the stabilizing agent may include liquids or liquids
atomized into droplets and dispersed in air, it can be employed
to pressurize the log and additionally help reduce the force
required to strip the log from the mandrel. Also, the
operations may be combined by using a two-part adhesive
procedure -- as in the well-known epoxy materials. For example,
the first part may be applied during winding throughout the
length of the mandrel and the second part is sprayed at the end
of the mandrel during the stripping operation.
Other objects and advantages of the invention may be
seen in the details of construction and operation set forth in
the ensuing specification.
¦ BRIRF DESCRIPTION OF DRAWING:
¦ The invention is described in conjunction with the
¦ accompanying drawing, in which --
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FIG. 1 is a side elevational view (somewhat schematic)
of a winder which can be employed to advantage in the practice
of the invention;
FIG. 2 is a fragmentary end elevational view
(essentially schematic) of the winder of FIG. 1;
FIG. 3 is a fragmentary end elevational view of another
embodiment of mandrel employed in the practice of the invention;
~ FIG. 4 is a fragmentary side elevational view,
I partially in section of another form of turret useful in the
practice of the invention and particularly with the mandrel of
FIG. 3; and
FIG. 5 is an enlarged fragmentary view of the central
portion of FIG. 4.
DETAILED DESCRIPTION:
In the illustration given in FIG. ~, the numeral 10
designates generally a frame which is conventional in winders --
very often referred to as "rewinders". This term stems from the
fact that the web is "rewound" from an already wound parent roll
of sizeable length and diameter into retail sized logs or
rolls.
More particularly the frame 10 includes a pair of
longitudinally extending side frames, one of which is
illustrated generally schematically at 10a in FIG. 2. The frame ~
provides an elongated path and supports a number of rolls ~;
therebetween in rotatable fashion.
Returning to FIG. 1, the numerals 11 and 12 at the
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upper left hand portion of the view designate pull rolls or draw
rolls which operate to advance a web W from a parent roll (not
shown). The web is further advanced by a perforator bedroll ~3
and a transfer bedroll 14. Cross perforations are provided in
the web by the knife-equipped perforator bedroll 13 operating
against a stationary anvil 15. The widely used perforator is
seen in co-owned, expired Patent No. 2,870,840.
The web in proceeding along the path defined by the
frame 10 is in partial wrapping relation with the transfer
bedroll 14. The numeral 16 designates a kni~e roll which
cooperates with the bedroll 14 for the cutoff and impalement of
the free leading edge of the web W. This feature is described
in co-owned, expired Patent No. RE. 28,353.
Still referring to FIG. 1, the numeral 17 designates
generally a mandrel-equipped turret which is mounted for
rotation in the rewinder frame 10 and which is disposed in
parallel, side-by-side relation with the bedroll 14. In the
illustration given, the turret 17 is equipped with six mandrels
as at 18, the mandrels being arranged for sequential movement
through an orbit into web-contacting relation. In the operation
of the turret 17, the mandrel 18 is moved from station A through
stations B and C with no operations being performed. When the
mandrel reaches station D, the rotation of the mandrel is
started via drive belts 19 as described in more detail in
co-owned, expired Patent No. 3,116,890. One of the belts
operates to raise the rotational speed of the mandrel 18 to
exactly transfer speed at the time of actual transfer. In the
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station D, the mandrel 18 is engaged with the accelerating
driving belt and is accelerated to web speed as pointed out
above. As the mandrel 18 moves toward station E, transfer
occurs.
During movement from station E to station F, the :
mandrel 18 continues moving down and increasingly away from the
bedroll 14. It also is now in contact with the decelerating
driving belt. Prior to reaching station F, a discrete
predetermined length of the web has been wound and cut off,
after which the mandrel arrives in station F, which is the
finished roll-removing station.
Finished roll removal is achieved at station F by a
mechanism such as is seen in co-owned, expired Patent No.
2,769,600. Reference may be had thereto for details of
I construction and operation not set forth herein. For example,
¦ the operation of the turret 17 is achieved through a Geneva gear
and other suitable mechanism (not shown) which indexes the
turret.
Construction Details
7 20 Referring now to FIG. 2, the numeral 20 designates the ~::
mandrel drive pulleys for the mandrel 18. These pulleys receive
7 the accelerating and decelerating belts 19 referred to above.
In FIG. 2, the details of construction for practicing the
~ inventive method are shown. For example, each of the mandrel~
.~ 18 has an axially extending passage 21 for applying both vacuum
~ for adhering the web and pressure for delivering the stabi1iz ing
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fluid. For this purpose, each mandrel 18 is equipped with a
plurality of ports 22 connected to the passage 21. As
illustrated, these ports are disposed in a spiral arrangement
but other arrangements can be employed. It is advantageous to
have the ports spaced axially, i.e., longitudinally, so as to
insure thorough coverage of the interior plies of the web roll
being developed in the rewinder.
In the practice ~f the invention according to the
embodiment of FIGS. 1 and 2, vacuum is applied first to the
ports 22 to maintain the leading edge of the severed web in
~ contact with the surface of the mandrel. Once this is achieved,
¦ winding progresses so that the vacuum can be terminated. Then
¦ the passage 21 and ports 22 are available for use in delivering
the stabilizing f luid.
For this purpose, the turret is equipped with a
subframe as at 23 and which necessarily rotates with the turret
17 and therefore the mandrels 18. Provided as part of the frame
10a and thus not rotatable is a vacuum valve 24 which is
generally horseshoe shaped. This applies vacuum only at a
predetermined or preselected portion of the rotation of the
turret, i.e., only during a portion of the orbit of each mandrel
18. For example, this would occur just shortly before transfer
as when a mandrel is approaching station E. Vacuum is developed
by a vacuum reservoir 25 coupled to a vacuum pump 25a and which
is coupled to the stationary vacuum valve 24 by means of vacuum
line 26. Thus, as illustrated in FIG. 2, the vacuum is
connected to chamber 22 associated with mandrel 18.
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The drive shaft for the turret subframe 23 is
designated 27 -- see the central part of FIGS. 1 and 2.
Provided at a point offset from tha drive shaft 27 and
associated drive (not shown) is the means for supplying the
stabilizing fluid. This includes a source 28, a pump 29 and a
reservoir 30. Fluid is discharged through line 31 to a pressure
fluid valve 32. More particularly, pressurized adhesive from
source 28 is mixed with air flow at 33 using a venturi or
atomizing nozzle.
It will be appreciated that the subframe 23 has a
plurality of conduits therein ~or selective coupling with the
valves 24, 32. As illustrated in FIG. 2, there is a chamber or
conduit 34 coupling the vacuum in valve 24 with the upper
mandrel while the chamber 35 couples the lower mandrel to the
valve 32.
More particularly, each mandrel 18 is coupled to a
chamber or conduit 34, 35 which in one position of the turret is
coupled to the horseshoe vacuum valve 24 and in another rotated
position to the pressure adhesive valve 32. Thus, at the
beginning of the wind, vacuum is applied so as to adhere the
leading edge of the web to the mandrel and after winding has
progressed enough to develop a few convolutions or turns of the
web on the mandrel, the vacuum is removed from the passage 21 by
virtue of the rotation of the turret 17 and thus brings the
conduit aligned with the particular mandrel into the position `
wherein it is coupled to the pressure system for applying
adhesive or fixing material to the inner plies.
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Embodiment of FIGS. 3-5
This embodiment as illustrated first in FIG. 3 again
has an axially extending passage 121 but instead of a plurality
of ports 22 disposed along its length has a plurality of
radially aligned ports 127 located adjacent the discharge or
cantilevered end of the mandrel. For example, in station F of
FIG. 1, the end of the mandrel from which the log is to be
stripped is unclamped from its location within the turret and
provides a free, cantilevered end so that the stripping
mechanism can operate.
This embodiment also utilizes a different way of
maintaining the leading edge of the severed web against the
mandrel 118. Essentially, this is "envelopment", thereby
avoiding the need for vacuum. An advantageous means for
achieving this is seen in co-owned, expired patent 3,679,010 and
express reference is made for details of constructions and
operation not set forth herein. However, the principal features
are described in connection with FIGS. 4 and 5.
The condition of the machine 110 in FIG~ 4 corresponds
to the time in the winding cycle when the web has just been cut
and the leading edge L (see FIG. 5) is about to be blown into
~ the nip defined by the mandrel 118 and the main rider roll 137.
¦ This is achieved through the air assist delivery from the member
136. Once this is achieved, a winding cycle is initiated
relative to the mandrel 118.
Shortly after transfer, the air-assist member 136 is
retracted by downward movement of the arm 138 to the position
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138'. This is achieved by the cylinder and piston rod unit 139
operating through linkage 140. The member 136 remains in the
retracted position -~ as at 138' throughout the major portion of
the winding cycle. This shifting of the member 136 permits the
mandrel 118 to be moved out of the winding position to make room
for a subsequent mandrel.
At the same time the member 136 is retracted (by virtue
of the actuation of the cylinder and piston rod unit 139), arms
141 are moved upwardly to the dotted line position in FIG. 4 and
designated 141'. This is achieved through the actuation of the
cylinder and piston rod unit 142. Thus, the knife assembly ~43
and the idling roll 144 are moved out of the orbital path which
will be described by the next mandrel when it moves into the
winding position previously occupied by the mandrel 118.
When the web has been wound to a predetermined amount
on the mandrel 118, the turret (not shown herein) begins to
index and the rider roll 137 is retracted by the actuation of
the cylinder and piston rod unit 145. This clears the orbital
path. As the indexing is completed, air is delivered to the
cylinder unit 13~.
This results in the elevation of the air-assist member
136 to the position indicated in FIG. 6. When the air-assist
member 136 reaches the uppermost position, the cylinder 146 is
actuated to trigger the knife arc and slice the web W. For this
purpose, the machine 110 is equipped with a microswitch (not
shown) which is actuated by the air-assist member 136 hen it is
in its uppermost position -- this delivering a signal for
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actuating the cylinder and piston rod unit 146. This same
signal is employed to open a valve (not shown) associated with
air delivery pipe so as to create the air jets in the passages
148 (see FIG. 5). The air jets are employed for driving the
leading edge L into the nip defined by mandrel 11~ and the rider
roll 137.
Thus, the air-assist member 136 develops the desired
enveloping action of the web W relative to the mandrel 118.
More particularly, the air-assist member 136 does this in
conjunction with cutoff. For this purpose, the member 136 is
equipped with a slot 149 into which the knife 147 moves for
cutoff. At this time the web is supported on each side of the
slot 149. The air jet emanating from the passage 148 on the
right side of the slot 149 (as seen in FIG. 5) urges the leading
edge L into the nip between rider roll 137 and mandrel 118 to
wrap itself around mandrel 118.
The foregoing arrangement avoids the need for vacuum to
hold the web against the mandrel and thus frees the pas~age 121
¦ in the mandrel 118 for the delivery of the stabilizing fluid,
i.e., the adhesive.
SU~ARY :
The invention is practiced in making coreless
convolutely wound web rolls by first transferring the leadin~
¦ edge portion of a web to a mandrel and maintaining the web in
contact with the mandrel ultimately to provide a hollow axially
extending interior in the wound roll. Winding is continued
I until a predetermined diameter log has been achieved. Then the -~
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log is removed from the mandrel by means of a stripping
mechanism such as that seen at 37 ln FIG. 1 -- just below
station F.
In its broadest aspect, the interior of the log has a
' stabilizing agent applied thereto sometime prior to the complete
removal of the log from the mandrel. This can be done either
during the wind as illustrated in FIG. 2 or after the wind and
incident to the stripping as seen in FIG. 3.
While in the foregoing specification, a detailed
description of the invention has been set down for the purpose
of illustration, many variations in the details hereingiven may
be made by those skilled in the art without departing from the
spirit and scope of the invention.
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