Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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DISPOSABLE/REUSABLE CORE ADAPTERS
Technical Field
[0001] This invention provides both disposable and reusable core
adapters, either of which facilitate mounting a roll wound on a larger
inside diameter core in a reel stand having core chucks designed for use
with a roll wound on a core having a smaller inside diameter. For
example, a paper roll wound on a nominal 6-inch (15.24 cm) inside
diameter core can be mounted in a reel stand having core chucks
designed for use with a paper roll wound on a nominal 3-inch (7.62 cm)
diameter core.
Back rg ound
[0002] Web material such as paper, fabric, plastic film, metal foil,
etc., is commonly wound onto a core. For example, paper rolls, such
as newsprint or soft nip calendered rolls, are produced by winding a
paper web onto a fiber core. Newsprint roll core diameters can vary,
but two are prevalent, namely (nominal) 3-inch and (nominal) 6-inch
inside diameter cores. Press room reel stands are equipped with core
chucks sized to fit either 3-inch or 6-inch diameter cores, but not always
both. Consequently, paper mills commonly supply newsprint wound on
cores sized to fit each customer's unique combination of reel stands.
For example, a customer having some reel stands equipped only with
3-inch core chucks and some reel stands equipped only with 6-inch core
chucks will order some rolls wound on 3-inch cores and some rolls
wound on 6-inch cores. This complicates management of press room
roll inventories and restricts flexible allocation of rolls to reel stands,
since rolls wound on 6-inch cores cannot be mounted on reel stands
equipped only with 3-inch core chucks, and rolls wound on 3-inch cores
cannot be mounted on reel stands equipped only with 6-inch core
chucks.
[0003] Management of paper mill roll inventories is also complex.
For example, a paper mill may need to delay production, until receipt
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of an appropriate combination of customer orders for rolls wound on
3-inch and 6-inch cores, to match the width of the paper machine
winder for efficient production of the ordered rolls. This is because
most winders cannot simultaneously wind sets of rolls on different
diameter cores.
[0004] Prior a:rt 6-to-3 inch core adapters have been used in an
attempt to circumvent the foregoing problems. If such adapters are
fitted into each of the opposed ends of a 6-inch diameter core, a paper
roll wound on that core can be mounted on a reel stand equipped only
with 3-inch core chucks. This allows a paper mill to efficiently wind all
rolls onto 6-inch diameter cores-customers having reel stands equipped
only with 3-inch core chucks can use such adapters to mount the rolls
on those reel stands. This significantly improves press room effi-
ciency-any warehoused roll of paper can be mounted on any reel stand
at any time. Moreover, larger diameter cores are preferable because
they are stiffer and less susceptible to vibration as the roll unwinds,
which allows higher sustained operating speeds and improved
runnability in the press room. Paper mills also benefit because excess
production rolls wound on 6-inch diameter cores can be sold to custom-
ers who only have reel stands equipped with 3-inch core chucks, thus
helping reduce the volume of dead stock in paper mill warehouses and
avoiding expensive rewinding of paper rolls from cores of one diameter
onto different diameter cores.
[0005] A typical prior art adapter is formed as a cylindrical steel
sleeve, with an inside diameter suitable for engaging 3-inch core
chucks. A plurality of ribs extend radially from the sleeve. The ribs
are sized to tightly engage the inside diameter of a 6-inch diameter
paper roll core, when the adapter's ribbed end is driven into the core.
Such adapters usually have a protruding end flange which extends
parallel to the side of the paper roll when the adapter is driven into the
core. The flange necessitates reduction of the roll's width, which is
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undesirable because reduced-width rolls do not fully utilize the reel
stand's width capacity. The protruding flange also precludes safe
stacking, on end, of rolls in which such adapters have been installed.
Such prior art adapters are also heavy, unwieldily, and may not effec-
tively engage the core chuck's fingers, potentially allowing the roll to
slip on the reel stand. Furthermore, installation of such prior art core
adapters in a typical. press room can be laborious and time consuming.
[0006] This invention addresses the shortcomings of such prior art
adapters.
Brief Description of Drawings
[0007] Figure 1 is a partially sectioned isometric view of a dispos-
able core adapter in accordance with the invention, showing the
adapter's studs retracted.
[0008] Figure 2 shows the Figure 1 disposable adapter with its
studs extended.
[0009] Figure 3 is a partially sectioned isometric view of a reus-
able core adapter in accordance with the invention, showing the
adapter's studs retracted.
[0010] Figure 4 shows the Figure 3 reusable adapter with its studs
extended.
[0011] Figure 5A is an outside end elevation view of the Figure 3
and 4 reusable adapter, showing one row of studs in the extended
position.
[0012] Figure 5B is a section view taken with respect to line
5B-5B shown in Figure 5A.
[0013] Figure 6 is a partially sectioned isometric view of a tool for
inserting either the disposable core adapter or the reusable core adapter
into a roll core.
[0014] Figure 7 is a partially sectioned isometric view of a tool for
removing the reusable core adapter from a roll core.
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[0015] Figure 8 is an inward end elevation view, on an enlarged
scale, of either one of the tools depicted in Figures 6 or 7, with the end
cap removed and the locking pins retracted.
[0016] Figure 9 is an inward end elevation view, on an enlarged
scale, of either one of the tools depicted in Figures 6 or 7, with the end
cap removed and the locking pins extended.
[0017] Figure 10 is an inward end elevation view of the drive
flange portion of the Figure 6 tool.
[0018] Figure 11 is an inward end elevation view of the drive
flange portion of the Figure 7 tool.
[0019] Figure 12A is a schematic, partially sectioned, side eleva-
tion assembly view of the Figure 6 adapter insertion tool engaging one
end of a paper roll after insertion of a disposable core adapter into the
roll's core, showing; the insertion tool positioned to commence driving
the disposable adapter's studs into the core.
[0020] Figure 12B depicts the Figure 12A apparatus after actuation
of the adapter insertion tool to drive the disposable adapter's studs into
the core.
[0021] Figure 13 is a partially sectioned isometric view of the
Figure 6 adapter insertion tool engaging one end of a paper roll after
insertion of a reusable core adapter into the roll's core and after actua-
tion of the insertion tool to commence driving the reusable adapter's
studs into the core.
[0022] Figure 14 is a partially sectioned isometric view of the
Figure 7 reusable adapter removal tool engaging one end of a paper roll
core containing a previously inserted reusable core adapter, after
actuation of the removal tool to commence withdrawal of the reusable
adapter's studs froni the core.
[0023] Figure 15A is a schematic, partially sectioned, side eleva-
tion assembly view of the apparatus depicted in Figure 13.
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[0024] Figure 15B is a schematic, partially sectioned, side eleva-
tion assembly view of the apparatus depicted in Figure 14.
Description
[0025] Throughout the following description, specific details are
set forth in order to provide a more thorough understanding of the
invention. However, the invention may be practiced without these
particulars. In other instances, well known elements have not been
shown or described in detail to avoid unnecessarily obscuring the
invention. Accordingly, the specification and drawings are to be
regarded in an illustrative, rather than a restrictive, sense. Although the
invention is described and illustrated in relation to newsprint type paper
rolls, persons skilled in the art will understand that the invention is
readily usable with other core-wound web materials such as fabric,
plastic film, metal foil, etc.
Disposable Core Aclapter
[0026] Figures 1 and 2 depict a disposable core adapter 10 formed
as a flangeless, ribless hollow cylindrical sleeve 12. Adapter 10 can be
made from the same inexpensive fiber material used to make conven-
tional paper roll cores, or made from other suitable material such as
particle board, recycled plastic, rubber, etc. Such disposable adapters
10 are suitable for use in paper mills, where they can be quickly and
economically installed to suit customer core size requirements, before
the paper rolls are shipped to the customer. Such disposable adapters
10 are also suitable for use in a press room.
[0027] A plurality of (e.g. thirty) steel studs 14 are friction-fit
embedded in apertures 13 formed radially in sleeve 12. Each stud 14
has a circular cross--section, a tapered (e.g. conical) spiked tip 16, and a
rounded bottom 18. Tips 16 are initially recessed beneath sleeve 12's
outer cylindrical surface so that bottoms 18 project into sleeve 12's
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hollow core, as shown in Figure 1. Advantageously, each stud 14 has
an overall length of about 1.77 inches (about 4.5 cm) and an external
diameter of about .312 inches (about .794 cm). Each stud 14's conical
tip is about .3 inches (about .762 cm) long.
[0028] Studs 14 are arranged in a plurality of (e.g. six) parallel
rows spaced evenly and circumferentially around sleeve 12. Within
each row, each stud is coplanar with one stud in each one of the other
rows. A plurality of (e.g. five) studs are provided in each row, spaced
evenly along the row. Each stud's longitudinal axis extends substan-
tially perpendicular to sleeve 12's longitudinal axis 20. The outermost
studs in each row are set back a suitable distance (e.g. about 1-inch or
2.54 cm) from sleeve 12's ends 22, 24 to prevent distortion of the roll's
core during use of adapter 10 as explained below.
[0029] Disposable adapter sleeve 12's outside diameter 28 (Figure
1) is sized for light friction-fit insertion into a standard 6-inch inside
diameter paper roll core. Sleeve 12's inside diameter 30 (Figure 2) is
sized to the same tolerances as a standard 3-inch inside diameter paper
roll core. Diameters 28, 30 define notional cylinders which are coaxial
about axis 20. Disposable adapter 10 can have any reasonable length
"LD" (Figure 1-e.g. about 5 inches, or 12.7 cm) to accommodate
different core chuck: designs.
Reusable Core Adapter
[0030] Figures 3, 4, 5A and 5B depict a reusable core adapter 110
formed as a flangeless, ribless hollow cylindrical sleeve 112 from a
resilient material such as DelrinTM synthetic resinous plastic, available
from E. I. du Pont De Nemours and Company, Wilmington, DE. Such
reusable adapters are suitable for use in press rooms, where they can be
efficiently and economically reused as explained below.
[0031] A plurality of (e.g. thirty) steel studs 114 are friction-fit
embedded in apertures 113 (Figures 3, 4, 5A and 5B) formed radially in
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sleeve 112. Each stud 114 has a circular cross-section, a tapered (e.g.
conical) spiked tip 116, a rounded bottom 118, and a central circumfer-
ential groove 115 extending between lower and upper annular rims 117,
119. Tips 116 are initially recessed beneath sleeve 112's outer cylindri-
cal surface so that bottoms 118 project into sleeve 112's hollow core, as
shown in Figure 3. Advantageously, each stud 114 has an overall
length of about 1.77 inches (about 4.5 cm) and an external diameter of
about .312 inches (about .794 cm). Each stud 114's conical tip is about
.3 inches (about .762 cm) long. Groove 115 is about .4 inches (about
1.016 cm) long and about .188 inches (about .478 cm) in diameter.
[0032] Studs 114 are arranged in a plurality of (e.g. six) parallel
rows spaced evenly and circumferentially around sleeve 112. Within
each row, each stud is coplanar with one stud in each one of the other
rows. A plurality of (e.g. five) studs are provided in each row, spaced
evenly along the row. Each stud's longitudinal axis extends substan-
tially perpendicular to sleeve 112's longitudinal axis 120. The outer-
most studs in each row are set back a suitable distance (e.g. about
1-inch) from sleeve 112's outward end 122 to prevent distortion of the
roll's core during use of adapter 110 as explained below. Advanta-
geously, studs 114 are heat treated to extend their durability and longev-
ity. Outward end 122 is clearly labelled "OUTSIDE," as indicated at
121, during manufacture of adapter 110, for example by engraving the
label wording into end 122. Such labelling facilitates correct mounting
of adapter 110 on core adapter insertion tool 140 as explained below.
Pry bar slots 123 are optionally formed in outward end 122 to facilitate
removal of adapter 110 from reusable core adapter removal tool 240
(described below), if adapter 110 becomes jammed on too1240.
[0033] A longitudinal, rectangular cross-sectioned aperture 126 is
formed through sleeve 112 adjacent each row of studs 114, substantially
parallel to axis 120 and intersecting the apertures 113 in which each
stud in the row is embedded. As best seen in Figure 5A, each aperture
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126 is offset by a displacement "0" relative to a notional plane contain-
ing the longitudinal axes of each stud in the row of studs adjacent that
aperture; and the aperture's two side walls are substantially parallel to
that plane. Each aperture 126 is located so that, when studs 114 are
extended from sleeve 12 as shown in Figures 4 and 5B, aperture 126
partially intersects the circumferential groove 115 of each stud in the
row.
[0034] Reusable adapter sleeve 112's outside diameter 128 (Fig-
ures 5A and 5B) is sized for light friction-fit, non-adhesive insertion
into a standard 6-inch inside diameter paper roll core. Reusable adapter
sleeve 112's inside diameter 130 is sized to the same tolerances as a
standard 3-inch inside diameter paper roll core. Reusable adapter 110
can have any reasonable length (e.g. about 5 inches) to accommodate
different core chuck: designs.
[0035] Unlike reusable adapter 110, disposable adapter 10 has no
longitudinal apertures extending between and through sleeve 12's
outward and inward. ends 22, 24 and between outside and inside diame-
ters 22, 30. That is, disposable adapter 10 has no apertures correspond-
ing to reusable adapter 110's apertures 126. Disposable adapter 10's
studs 14 have no central circumferential groove corresponding to
grooves 115 of reusable adapter 110's studs 114. Persons skilled in the
art will understand that studs 114 can, if desired, be used in disposable
adapter 10 although grooves 115 serve no purpose if studs 114 are used
in disposable adapter 10.
Adapter Insertion Tool
[0036] Figure 6 depicts a tool 140 for inserting either one of
disposable core adapter 10 or reusable core adapter 110 into a paper roll
core (not shown in Figure 6). As used herein, "inward" means toward
the right, as viewed. in Figure 6; and "outward" means toward the left,
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as viewed in Figure 6. Tool 140 has a longitudinally apertured, exter-
nally threaded rod 142 which extends through central apertures in each
of DelrinTM spacer plate 144 and stop flange 146 (spacer plate 144 is
optional). The inward end of rod 142 is threaded into the outward end
of adapter mounting mandrel 148 and welded or otherwise fastened to
stop flange 146. The outside diameter of mandrel 148 is slightly less
than sleeve 112's inside diameter 130 to permit easily slidable mounting
of adapter 110 on mandrel 148.
[0037] Lock arm shaft 150 is rotatably mounted in and extends
through rod 142's central longitudinal aperture. Lock arm shaft 150
projects from the inward end of rod 142 and extends through mandrel
148. As best seen in Figures 8 and 9, the inward end of lock arm shaft
150 is fixed to locki:ng pin arm 152 which extends within chamber 154
machined in the inward end of mandrel 148. Locking pins 156, 158 are
pivotally attached, by pivot pins 157, to opposed ends of locking pin
arm 152 and extend, respectively, into apertures 160, 162 machined in
the inward end of mandrel 148. Apertures 160, 162 intersect chamber
154. Lock arm shaf't 150 is selectably rotated as explained below to
move locking pin arm 152 into the position shown in Figure 8 in which
locking pins 156, 158 are retracted within mandrel 148; or, to move
arm 152 into the position shown in Figure 9 in which locking pins 156,
158 project from mandrel 148. Locking pins 156, 158 have wide, flat
outward faces with radiused edges. Mandrel 148 is sized so that its
longitudinal displacement between the inward face of stop flange 146
and the outward edges of locking pins 156, 158 is slightly greater than
the length "LD" (Figure 1) of disposable adapter 10 and slightly greater
than the length "LR" (Figure 4) of reusable adapter 110. 0-rings
surround shaft 150 at spaced intervals, to provide friction-fit engage-
ment between rod 142 and shaft 150 and resist loosening of shaft 150
when tool 140 is operated as explained below.
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[0038] End cap 164 (Figure 6) is fastened to mandrel 148 by
machine screws (not shown) which threadably engage apertures 166
(Figures 8 and 9) in mandrel 148. A plurality of circumferentially
spaced, longitudinally extending channels 168 are machined in mandrel
148. One channel 1.68 is provided for each row of studs 14, 114 in
adapters 10, 110 respectively. Each channel 168 has an inverted-T
cross-sectional shape, as seen in Figures 8 and 9. Optional weight-
reduction channels 170 (Figure 6) can be machined in mandrel 148.
End cap 164 is made sufficiently thick (e.g. about 0.5 inches, or about
1.27 cm) to be capable of securely retaining locking pins 156, 158 when
one of adapters 10 or 110 is driven into a paper roll core as explained
below.
[0039] The outward end of rod 142 extends through a central
keyway aperture 171 (Figure 10) in drive flange 172 and is threaded
into drive nut 174. Keeper plate 176 is diametrically split into two
halves which are fitted over drive nut 174's capture flange 178 and
fastened to drive flange 172 by machine screws 180 which threadably
engage apertures 179 (Figure 10) in drive flange 172. A plurality of
circumferentially spaced slots 181 are machined in drive flange 172.
One slot 181 is provided for each row of studs 114 provided in sleeve
112. Each slot 181 has a rectangular cross-sectional shape, aligned with
a corresponding one of channels 168. The circle (not shown) used to
locate channels 168 machined in mandrel 148 is the same as the circle
(not shown) used to machine slots 181 in drive flange 172. The cir-
cumferential displacement around the circle of channels 168 machined
in mandrel 148 is the same as the circumferential displacement around
the circle of slots 181 machined in drive flange 172. Key 182 extends
into drive flange 172's keyway aperture 183 and into external keyway
184 machined in rod 142, maintaining alignment of drive flange 172
relative to stop flange 146 when drive nut 174 is rotated or counter-
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rotated as explained below. The squared outward end 186 of lock arm
shaft 150 projects outwardly through rod 142's outward end.
[0040] A wedge-tipped bar 194 having an inverted-T cross-sec-
tional shape matching that of channels 168 and slots 181 is provided for
each one of slots 181 (and thus for each row of studs 14 or 114 pro-
vided in sleeves 12 or 112 respectively). The wedge face on each bar
194 has a smooth surface finish to reduce friction and is machined to
gradually merge into the bar's narrow top face, opposite the bar's wider
bottom face. Advaritageously, the wedge face on each bar 194 is heat
treated to increase surface hardness for wear resistance, while preserv-
ing ductility of the remainder of each bar 194 to inhibit breakage. The
inward end of each bar 194 is preferably rounded to prevent the bar
from digging into the non-apertured portion of adapter 10 or 110 during
installation. The outward end of each bar 194 is fastened into one of
drive flange 172's slots 181 by machine screws (not shown) which
threadably engage apertures 193 (Figure 10), care being taken to align
bars 194 substantially perpendicular to the inward face of drive flange
172, with each bar's sloped wedge surface facing radially toward the
outer circumferential rim of drive flange 172 and the bar's wider
bottom face facing radially away from the outer circumferential rim of
drive flange 172. T'he inward (i.e. wedge-tipped) ends of each bar 194
extend through a corresponding one of rectangular apertures 196 ma-
chined in stop flange 146. The circle (not shown) used to locate aper-
tures 196 is the sam.e as the circle (not shown) used to locate channels
168 machined in mandrel 148. The circumferential displacement
around the circle of apertures 196 is the same as the circumferential
displacement around the circle of channels 168 machined in mandrel
148. Consequently, any one of apertures 196 is coaxially alignable with
any one of channels 168. When rod 142 is attached to stop flange 146
as aforesaid, care is taken to maintain coaxial alignment of each one of
apertures 196 with a corresponding one of drive flange 172's slots 181.
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A plurality of (e.g. three) circumferentially spaced set screws 198 are
threadably mounted in and extend through apertures machined in stop
flange 146. Optional weight-reduction apertures 200 can be machined
in stop flange 146. Optional spacer plate 144 assists in guiding bars
194 through apertures 196 when drive nut 174 is rotated or counter-
rotated as explained below. Spacer plate 144 also serves as a cushioned
depth stop for drive flange 172.
Reusable Core Adaz)ter Removal Tool
[0041] Figure '7 depicts a tool 240 for removing from a paper roll
core (not shown in Figure 7) a reusable core adapter 110 previously
inserted into the core by tool 140. Comparison of Figures 6 and 7 will
reveal that tools 140, 240 are structurally similar. Components which
are common to tools 140, 240 bear the same reference numerals in
Figures 6 and 7 and need not be described further. As used herein,
"inward" means toward the right, as viewed in Figure 7; and "out-
ward" means toward the left, as viewed in Figure 7.
[0042] Keeper plate 276 is diametrically split into two halves
which are fitted over drive nut 174's capture flange 178 and fastened to
drive flange 272 by machine screws 280 which threadably engage
apertures 279 (Figuire 11) in drive flange 272. A plurality of circumfer-
entially spaced slots 281 are machined in drive flange 272. One slot
281 is provided for each row of studs 114 provided in sleeve 112. Each
slot 281 has a rectangular cross-sectional shape. The circle (not shown)
used to locate slots 281 machined in drive flange 172 is the same as the
circle (not shown) used to locate apertures 126 formed in adapter 110.
The circumferential displacement of slots 281 around the circle is the
same as the circumferential displacement of apertures 126 around the
circle. Key 182 extends into drive flange 272's keyway aperture 283
and into external keyway 184 machined in rod 142, maintaining align-
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ment of drive flange 272 relative to stop flange 146 when drive nut 174
is rotated or counter-rotated as explained below.
[0043] A wedge-tipped bar 294 having a rectangular cross-sec-
tional shape matching that of apertures 126 and slots 281 is provided for
each one of slots 181 (and thus for each for each row of studs 114
provided in sleeve 112). The wedge tip on each bar 294 has a smooth
surface finish to reduce friction and is machined to gradually merge into
one of the bar's flat sides. Advantageously, the wedge tip on each bar
294 is heat treated to increase surface hardness for wear resistance,
while preserving ductility of the remainder of each bar 294 to inhibit
breakage. The inward end of each bar 294 is preferably rounded to
prevent the bar from digging into the non-apertured portion of adapter
110 during installation. The outward end of each bar 294 is fastened
into one of drive flange 272's slots 281 by one of machine screws 295
which threadably engage apertures 293 (Figure 11), care being taken to
align bars 294 substantially perpendicular to the inward face of drive
flange 272, with each bar's sloped wedge surface facing radially away
from the outer circumferential rim of drive flange 272. The inward
(i.e. wedge-tipped) ends of each bar 294 extend through a correspond-
ing one of rectangular apertures 296 machined in stop flange 146. The
circle (not shown) used to locate apertures 296 is the same as the circle
(not shown) used to locate sleeve 112's apertures 126. The circumfer-
ential displacement of apertures 296 around the circle is the same as the
circumferential displacement around the circle of apertures 126 formed
through sleeve 112. Consequently, any one of apertures 296 is coaxi-
ally alignable with any one of the sleeve 112's apertures 126. When
rod 142 is attached to stop flange 146 as aforesaid, care is taken to
maintain coaxial alignment of each one of apertures 296 with a corre-
sponding one of drive flange 272's slots 281. Each aperture 126 in
sleeve 112 is diametrically sized for snug-fit passage of one of bars 294
through aperture 126 as explained below. Optional spacer plate 244
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assists in guiding bars 294 through apertures 296 when drive nut 174 is
rotated or counter-rotated as explained below. Spacer plate 244 also
serves as a cushioned stop for drive flange 272.
Installation of Disposable Core Adapter
[0044] In operation, a disposable core adapter 10 (with studs 14
retracted as shown in Figure 1) is slidably fitted over tool 140's mandrel
148 by aligning the bottom ends 18 in each row of studs 14 within a
corresponding one of channels 168 to position either one of adapter 10's
ends 22 or 24 flush against the inward face of stop flange 146. A
wrench is then used to rotate lock arm shaft 150's squared outward end
186 clockwise (as viewed from the left side of Figure 6). Such rotation
of lock arm shaft 150 rotates locking pin arm 152 counter-clockwise (as
viewed in Figures 8 and 9), moving locking pin arm 152 and locking
pins 156, 158 into the position shown in Figure 9 in which locking pins
156, 158 project from mandrel 148, thereby snugly capturing disposable
adapter 10 between stop flange 146 and locking pins 156, 158. The
radiused edges of locking pins 156, 158 cam movement of the locking
pins over adapter 10's inward end 24, reducing potential jamming of the
locking pins against the adapter. The locking pins' wide, flat outward
faces bear securely against the adapter's inward end without indenting
that end when the adapter is driven into a paper roll core as explained
below.
[0045] As shown in Figures 12A and 12B, the inward end of core
adapter insertion tool 140 (i.e. the end on which disposable core adapter
10 is captively mounted as aforesaid) is then inserted into one end of
6-inch paper roll core 310, until the inward face of stop flange 146 cir-
cumferentially surrounding adapter 10 is flush against the outward end
of paper roll 312. This action forces the pointed tips of set screws 198
into core 310, preventing rotation of tool 140 and adapter 10 relative to
core 310. Locking pins 156, 158 brace adapter 10's inward end,
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limiting the depth to which adapter 10 can be axially inserted into core
310-if adapter 10's outward end is inserted beyond the outward end of
core 310 it could be difficult to remove adapter 10 from core 310. One
end of a deep sockel: 104 is then fitted over drive nut 174. The socket's
opposite end is coupled to a torque multiplier (not shown). The torque
multiplier is actuated to rotate drive nut 174 so as to threadably advance
drive nut 174 along rod 142 toward the rod's inward end (i.e. toward
the right, as viewed in Figures 12A and 12B). Since drive nut 174's
capture flange 178 is enclosed between drive flange 172 and keeper
plate 176, such advancement of drive nut 174 advances drive flange 172
and keeper plate 176 along rod 142, toward the rod's inward end.
More particularly, such advancement of drive nut 174 drives each one
of bars 194 through a corresponding one of stop flange 146's apertures
196 and into a corresponding one of channels 168. The aforementioned
engagement of key 182 within drive flange 172's keyway 183 and
within rod 142's keyway 184 maintains alignment of drive flange 172
relative to stop flange 146 as bars 194 are driven into apertures 142.
[0046] When the wedge-tipped inward end of a bar 194 reaches
the rounded bottom 18 of the outwardmost one of studs 14 within one of
channels 168, the wedge tip slides easily beneath rounded bottom 18.
As bar 194 is driven further into channel 168, the wedge tip is forced
against rounded bottom 18, driving stud 14 substantially perpendicularly
away from adapter 10's longitudinal axis 20. This in turn drives stud
14's tip 16 into core 310. Operation of the torque multiplier is contin-
ued to simultaneously drive each bar 194 completely into a correspond-
ing one of channels 168, until the inward face of drive flange 172
contacts the outward face of stop flange 146 (or spacer 144-if pro-
vided). The studs 1.4 in each row are thus successively driven into core
310, from the retracted position shown in Figures 1 and 12A into the
extended position shown in Figures 2 and 12B. The studs' penetration
depth into core 310 is determined by the width of bar 194, thus avoid-
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ing over-penetration of the studs which could distort the outer surface of
core 310. As previously explained, within each row, each stud is
coplanar with one stud in each one of the other rows. Accordingly,
simultaneous driving of bars 194 into channels 168 successively drives
each group of coplanar studs simultaneously into core 310, thereby
maintaining concentric alignment of adapter 10 within core 310 to
prevent off-axis rotation of core 310 during high speed unwinding of
material from core 310. Longitudinal and transverse deflection of each
bar 194 relative to i1:s corresponding channel 168 is prevented since the
wide base of each bar 194 is restrained within the wide, lower portion
of the corresponding inverted-T cross-sectionally shaped channel 168.
[0047] After aciapter 10 has been fully installed in core 310 (i.e.
after all of studs 14 have been extended as shown in Figures 2 and 12B)
the torque multiplier is adjusted to reverse its drive direction, then
actuated to rotate drive nut 174 so as to threadably retract drive nut 174
along rod 142 toward the rod's outward end, thereby retracting bars 194
along channels 168 until the bars' wedge tips clear adapter 10's outward
face 22. A wrench is then used to rotate lock arm shaft 150's squared
outward end 186 counter-clockwise (as viewed from the left side of
Figure 6). Such rotation of lock arm shaft 150 rotates locking pin arm
152 clockwise (as v:iewed in Figures 8 and 9), moving locking pin arm
152 and locking pins 156, 158 into the position shown in Figure 8 in
which locking pins 56, 58 are retracted within mandrel 148. Core
adapter insertion tool 140 is then withdrawn from core 310, leaving
disposable adapter 1.0 within core 310. Another disposable adapter 10
is then fitted onto tool 140 and inserted into the opposite end of core
310. That adapter's studs are then driven into core 310 as described
above.
[0048] When driven into core 310 as aforesaid, studs 14 robustly
couple adapter 10 to core 310, so as to withstand core chuck axial thrust
loads and resist acceleration and deceleration torques applied to a paper
CA 02546134 2006-05-05
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roll (not shown) wound on core 310 during typical operation of a press
room reel stand. When the reel stand's core chucks (not shown-there
are many different core chuck configurations) engage core 310, the core
chuck's body butts against the underside of some or all rows of studs
14, preventing retraction of studs 14 from core 310 during unwinding of
the roll. Because disposable adapter 10's sleeve 12 is flangeless, no
protrusions remain after adapter 10 is installed in core 310, so the width
of the paper roll is unaffected by adapter 10. Paper rolls in which
disposable adapters 10 have been installed can also be safely stacked on
end. Core adapter insertion tool 140 facilitates fast, efficient installa-
tion of disposable core adapters 10. Tool 140's simultaneous, symmet-
ric radial engagement of studs 14 ensures concentric installation of each
adapter 10 within core 310. Unlike prior art adapters which must be
recovered from the :spent core after the paper roll is unwound, dispos-
able adapter 10 is discarded with the spent core, avoiding potentially
expensive, time consuming adapter recovery procedures.
Installation of Reusable Core Adapter
[0049] In operation, a reusable core adapter 110 (with studs 114
retracted as shown in Figure 3) is slidably fitted over tool 140's mandrel
148 by aligning the bottom ends 118 in each row of studs 114 within a
corresponding one of channels 168 to position adapter 110's outward
end 122 (i.e. the end bearing "OUTSIDE" label 121) flush against the
inward face of stop flange 146. A wrench is then used to rotate lock
arm shaft 150's squared outward end 186 clockwise (as viewed from the
left side of Figure 6). Such rotation of lock arm shaft 150 rotates
locking pin arm 152 counter-clockwise (as viewed in Figures 8 and 9),
moving locking pin arm 152 and locking pins 156, 158 into the position
shown in Figure 9 in which locking pins 156, 158 project from mandrel
148, thereby snugly capturing reusable adapter 110 between stop flange
146 and locking pins 156, 158. The radiused edges of locking pins
CA 02546134 2006-05-05
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156, 158 cam movement of the locking pins over adapter 110's inward
end 124, reducing potential jamming of the locking pins against the
adapter. The locking pins' wide, flat outward faces bear securely
against the adapter's inward end without indenting that end when the
adapter is driven into a paper roll core as explained below.
[0050] As shocvn in Figures 13 and 15A, the inward end of core
adapter insertion tool 140 (i.e. the end on which reusable core adapter
110 is captively mounted as aforesaid) is then inserted into one end of
6-inch paper roll core 310, until the inward face of stop flange 146 cir-
cumferentially surrounding adapter 110 is flush against the outward end
of paper roll 312. This action forces the pointed tips of set screws 198
into core 310, preventing rotation of tool 140 and adapter 110 relative
to core 310. Lockirig pins 156, 158 brace adapter 110's inward end,
limiting the depth to which adapter 110 can be axially inserted into core
310-if adapter 110's outward end is inserted beyond the outward end
of core 310 it could be difficult to remove adapter 110 from core 310.
One end of a deep socket 104 is then fitted over drive nut 174. The
socket's opposite end is coupled to a torque multiplier (not shown).
The torque multiplier is actuated to rotate drive nut 174 so as to
threadably advance drive nut 174 along rod 142 toward the rod's inward
end (i.e. toward the right, as viewed in Figures 13 and 15A). Since
drive nut 174's capture flange 178 is enclosed between drive flange 172
and keeper plate 176, such advancement of drive nut 174 advances
drive flange 172 and keeper plate 176 along rod 142, toward the rod's
inward end. More particularly, such advancement of drive nut 174
drives each one of bars 194 through a corresponding one of stop flange
146's apertures 196 and into a corresponding one of channels 168. The
aforementioned engagement of key 182 within drive flange 172's
keyway 183 and within rod 142's keyway 184 maintains alignment of
drive flange 172 relative to stop flange 146 as bars 194 are driven into
apertures 142.
CA 02546134 2006-05-05
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[0051] When the wedge-tipped inward end of a bar 194 reaches
the rounded bottom 118 of the outwardmost one of studs 114 within one
of channels 168, the wedge tip slides easily beneath rounded bottom
118. As bar 194 is driven further into channel 168, the wedge tip is
forced against rounded bottom 118, driving stud 114 substantially per-
pendicularly away from adapter 110's longitudinal axis 120. This in
turn drives stud 114's tip 116 into core 310. Operation of the torque
multiplier is continued to simultaneously drive each bar 194 completely
into a corresponding one of channels 168, until the inward face of drive
flange 172 contacts the outward face of stop flange 146 (or spacer
144-if provided). The studs 114 in each row are thus successively
driven into core 310, from the retracted position shown in Figure 3 into
the extended position shown in Figure 4. This is shown in Figures 13
and 15A: the two outwardmost studs have been fully driven into core
310 and the three inwardmost studs are partially driven into core 310.
Specifically, the central stud (i.e. the third stud from the left) is almost
fully driven into core 310, the fourth stud from the left has initially
penetrated core 310 and the inward end of the wedge tip of bar 194 has
just reached the inwardmost stud to commence driving that stud into
core 310. The studs' penetration deptll into core 310 is determined by
the width of bar 194, thus avoiding over-penetration of the studs which
could distort the outer surface of core 310. As previously explained,
within each row, each stud is coplanar with one stud in each one of the
other rows. Accordingly, simultaneous driving of bars 194 into chan-
nels 168 successively drives each group of coplanar studs simulta-
neously into core 31.0, thereby maintaining concentric alignment of
adapter 110 within core 310 to prevent off-axis rotation of core 310
during high speed unwinding of roll 312 from core 310. Longitudinal
and transverse deflection of each bar 194 relative to its corresponding
channel 168 is prevented since the wide base of each bar 194 is re-
CA 02546134 2006-05-05
-20-
strained within the wide, lower portion of the corresponding inverted-T
cross-sectionally shaped channel 168.
[0052] After adapter 110 has been fully installed in core 310 (i.e.
after all of studs 114 have been extended as shown in Figure 4) the
torque multiplier is adjusted to reverse its drive direction, then actuated
to rotate drive nut 174 so as to threadably retract drive nut 174 along
rod 142 toward the rod's outward end, thereby retracting bars 194 along
channels 168 until the bars' wedge tips clear adapter 110's outward face
122. A wrench is then used to rotate lock arm shaft 150's squared out-
ward end 186 counter-clockwise (as viewed from the left side of Figure
13). Such rotation of lock arm shaft 150 rotates locking pin arm 152
clockwise (as viewed in Figures 8 and 9), moving locking pin arm 152
and locking pins 156, 158 into the position shown in Figure 8 in which
locking pins 56, 58 are retracted within mandrel 148. Core adapter
insertion tool 140 is then withdrawn from core 310, leaving reusable
adapter 110 within core 310. Another reusable adapter 110 is then
fitted onto tool 140 and inserted into the opposite end of core 310. That
adapter's studs are then driven into the core 310 as described above.
[0053] When driven into core 310 as aforesaid, studs 114 robustly
couple adapter 110 to core 310, so as to withstand core chuck axial
thrust loads and resist acceleration and deceleration torques applied to
paper roll 312 during typical operation of a press room reel stand.
When the reel stand's core chucks (not shown-there are many different
core chuck configurations) engage core 310, the core chuck's body
butts against the underside of some or all rows of studs 114, preventing
retraction of studs 114 from core 310 during unwinding of roll 312.
Because reusable adapter 110's sleeve 112 is flangeless, no protrusions
remain after adapter 110 is installed in core 310, so the width of paper
rol1312 is unaffected by adapter 110. Paper rolls in which reusable
adapters 110 have been installed can also be safely stacked on end.
Core adapter insertion tool 140 facilitates fast, efficient installation of
CA 02546134 2006-05-05
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reusable core adapters 110. Tool 140's simultaneous, symmetric radial
engagement of studs 114 ensures concentric installation of each adapter
110 within core 310. Moreover, as explained below, adapter 110 is
quickly and easily removed from the spent core after paper roll 312 is
unwound.
Removal of Reusable Core Adapter
[0054] Reusable adapter 110 is removed from the spent core (or
from a non-spent core, should such removal be necessary) with the aid
of reusable core adapter removal tool 240, as shown in Figures 7, 14
and 15B. A wrench is used to rotate lock arm shaft 150's squared out-
ward end 186 counter-clockwise (as viewed from the left side of Fig-
ures 14 and 1513). Such rotation of lock arm shaft 150 rotates locking
pin arm 152 clockwise (as viewed in Figures 8 and 9), moving locking
pin arm 152 and locking pins 156, 158 into the position shown in Figure
8 in which locking pins 56, 58 are retracted within mandrel 148.
[0055] Mandrel 148 is then slidably advanced into the adapter's
sleeve 112 until the inward face of stop flange 146 is flush against the
adapter's outward end 122 (i.e. the end bearing "OUTSIDE" label
121), care being taken to align each one of stop flange 146's apertures
296 over a corresponding one of adapter 110's apertures 126. The
wrench is then used to rotate lock arm shaft 150's squared outward end
186 clockwise, moving locking pin arm 152 and locking pins 156, 158
into the position shown in Figure 9 in which locking pins 156, 158
project from mandrel 148, thereby snugly capturing adapter 110 be-
tween stop flange 146 and locking pins 156, 158. This action forces the
pointed tips of set screws 198 into core 310, preventing rotation of tool
240 and adapter 110 relative to core 310. The radiused edges of lock-
ing pins 156, 158 cam movement of the locking pins over adapter 110's
inward end 124, reducing potential jamming of the locking pins against
the adapter. The locking pins' wide, flat outward faces bear securely
CA 02546134 2006-05-05
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against the adapter's inward end, without indenting that end when the
adapter is removed from core 310 as explained below.
[0056] One end of a deep socket 104 is then fitted over drive nut
174. The socket's opposite end is coupled to an torque multiplier (not
shown). The torque multiplier is actuated to rotate drive nut 174 so as
to threadably advance drive nut 174 along rod 142 toward the rod's
inward end (i.e. toward the right, as viewed in Figures 14 and 15B).
Since drive nut 174's capture flange 178 is enclosed between drive
flange 272 and keeper plate 276, such advancement of drive nut 174
advances drive flange 272 and keeper plate 276 along rod 142, toward
the rod's inward end. More particularly, such advancement of drive
nut 174 drives each one of bars 294 through a corresponding one of
stop flange 146's apertures 296 and into a corresponding one of adapter
110's apertures 126.. The aforementioned engagement of key 182
within drive flange 272's keyway 283 (Figure 11) and within rod 142's
keyway 184 maintains alignment of drive flange 272 relative to stop
flange 146 as bars 294 are driven into apertures 126.
[0057] Figures 4, 5A and 5B illustrate the extended position of
studs 114 after insertion of adapter 110 into core 310 as explained
above. As previously explained, each aperture 126 is located so that,
when a corresponding row of studs 114 is extended from sleeve 112,
the aperture 126 partially intersects the circumferential groove 115 of
each stud in the row, without intersecting the bodies of any of the studs
in the row. When the wedge-tipped inward end of a bar 294 reaches
the groove 115 of the outwardmost one of studs 114 within one of
apertures 126, the wedge tip slides easily over the groove's lower
annular rim 117. As bar 294 is driven further into aperture 126, the
wedge tip is forced against lower annular rim 117, driving stud 114
substantially perpendicularly toward adapter 110's longitudinal axis 120
and retracting stud 114's tip 116 from core 310. The tapered or conical
shape of tip 116 facilitates such retraction.
CA 02546134 2006-05-05
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[0058] Operation of the torque multiplier is continued to simulta-
neously drive each bar 294 completely into a corresponding one of
apertures 126, until the inward face of drive flange 272 contacts the
outward face of stop flange 146 (or spacer 144-if provided). The
studs 114 in each row are thus successively retracted from core 310
(i.e. studs 114 are driven from the extended position shown in Figure 4
into the retracted position shown in Figure 3). This is shown in Figures
14 and 15B: the two outwardmost studs have been fully retracted from
core 310 and the ceritral stud has been partially retracted from core 310.
[0059] After all of adapter 110's studs 114 have been retracted
from core 310 the torque multiplier is adjusted to reverse its drive
direction, then actuated to rotate drive nut 174 so as to threadably
retract drive nut 174 along rod 142 toward the rod's outward end,
thereby retracting bars 294 from apertures 126 until the bars' wedge
tips clear adapter 110's outward face 122. The inward end of tool 240,
with reusable core adapter 110 captively mounted thereon, is then
withdrawn from core 310. A wrench is then used to rotate lock arm
shaft 150's squared outward end 186 counter-clockwise (as viewed from
the left side of Figure 14). Such rotation rotates locking pin arm 152
clockwise (as viewed in Figures 8 and 9), moving locking pin arm 152
and locking pins 156, 158 into the position shown in Figure 8 in which
locking pins 56, 58 are retracted within mandrel 148. Reusable core
adapter 110 is then slidably removed from mandrel 148.
[0060] As previously explained, disposable adapter 10 is ultimately
discarded with the spent roll core. It is accordingly desirable that
adapter 10 be as inexpensive as possible. For example, the components
in disposable adapter 10 can be less durable than the components in
resusable adapter 110 to reduce costs, without compromising the ability
to robustly couple adapter 10 to a roll core. The stud penetration depth
of either adapter 10 or 110 into a roll core may be about 0.300 inches
(about 7.6 mm).
CA 02546134 2006-05-05
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[0061] As will be apparent to those skilled in the art in the light of
the foregoing disclosure, many alterations and modifications are possi-
ble in the practice of' this invention without departing from the spirit or
scope thereof. For example, channels 168 and bars 194 may have
mating cross-sectional shapes other than an inverted-T shape; retention
of bars 194 within cllannels 168 can be achieved with any cross-sec-
tional shape which is wider along a radially inward portion of each bar
and channel and narrower along a radially outward portion of each bar
and channel. Accordingly, the scope of the invention is to be construed
in accordance with the substance defined by the following claims.
