U.S. patent application number 12/820232 was filed with the patent office on 2010-12-23 for in-line formed core supporting a wound web.
This patent application is currently assigned to CATBRIDGE MACHINERY, LLC. Invention is credited to William Christman, Michael Pappas.
Application Number | 20100320302 12/820232 |
Document ID | / |
Family ID | 42668217 |
Filed Date | 2010-12-23 |
United States Patent
Application |
20100320302 |
Kind Code |
A1 |
Pappas; Michael ; et
al. |
December 23, 2010 |
In-Line Formed Core Supporting a Wound Web
Abstract
A web is wound onto an in-line core instead of a separate core.
At the start of the winding process, a core-forming substrate
attached to the leading edge of the web is wound into an in-line
core. The web is wound around the in-line core. For streaming
operation, a composite substrate-web stream comprising an
alternating sequence of attached core-forming substrate segments
and web segments is produced. The first core-forming substrate
segment is wound into a first in-line core, and the first web
segment is wound around the first in-line core. The composite
substrate-web stream is cut. The second core-forming substrate
segment is wound into a second in-line core, and the second web
segment is wound around the second in-line core. The composite
substrate-web stream can be slit longitudinally to produce multiple
composite substrate-web stream strips. Multiple composite
substrate-web stream strips can be wound in parallel on a single
mandrel.
Inventors: |
Pappas; Michael; (Denville,
NJ) ; Christman; William; (Rockaway Township,
NJ) |
Correspondence
Address: |
WOLFF & SAMSON, P.C.
ONE BOLAND DRIVE
WEST ORANGE
NJ
07052
US
|
Assignee: |
CATBRIDGE MACHINERY, LLC
Parsippany
NJ
|
Family ID: |
42668217 |
Appl. No.: |
12/820232 |
Filed: |
June 22, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61219428 |
Jun 23, 2009 |
|
|
|
Current U.S.
Class: |
242/160.1 ;
242/525; 242/526; 242/532; 242/532.3 |
Current CPC
Class: |
B65H 29/008 20130101;
B65H 2301/4148 20130101; B65H 39/14 20130101; B65H 19/2207
20130101; B65H 2701/5112 20130101; B65H 75/50 20130101; B65H
2301/414325 20130101 |
Class at
Publication: |
242/160.1 ;
242/532; 242/532.3; 242/525; 242/526 |
International
Class: |
B65H 19/22 20060101
B65H019/22; B65H 19/28 20060101 B65H019/28; B65H 19/26 20060101
B65H019/26; B65H 35/02 20060101 B65H035/02; B65H 35/04 20060101
B65H035/04; B65H 18/28 20060101 B65H018/28 |
Claims
1. A method for winding a web having a leading edge and a trailing
edge, the method comprising the steps of: attaching a core-forming
substrate to the leading edge of the web; winding the core-forming
substrate into an in-line core; and winding the web around the
in-line core.
2. The method of claim 1, wherein the step of attaching a
core-forming substrate to the leading edge of the web comprises the
step of: attaching the core-forming substrate to the leading edge
of the web with an adhesive.
3. The method of claim 2, wherein the adhesive is at least one of:
an open adhesive disposed on at least a portion of a surface of the
core-forming substrate; an applied adhesive disposed on at least a
portion of a surface of the core-forming substrate; an open
adhesive disposed on at least a portion of a surface of the web;
and an applied adhesive disposed on at least a portion of a surface
of the web.
4. The method of claim 1, wherein the web comprises an open
adhesive disposed on a surface of the web, and wherein the
core-forming substrate is a first core-forming substrate, further
comprising the step of: attaching a second core-forming substrate
to the trailing edge of the web, wherein the second core-forming
substrate covers a portion of the open adhesive in the proximity of
the trailing edge of the web.
5. The method of claim 1, wherein the web is a non-adhesive web,
and wherein the core-forming substrate is a first core-forming
substrate, further comprising the step of: attaching a second
core-forming substrate to the trailing edge of the web; and
attaching the second core-forming substrate to a surface of a
portion of the previously wound web.
6. The method of claim 1, further comprising the step of: applying
graphics on a surface of the core-forming substrate.
7. A method for winding a web having a leading edge and a trailing
edge, the method comprising the steps of: attaching a core-forming
substrate to the leading edge of the web; slitting the web and the
attached core-forming substrate along at least one longitudinal
slit line to produce a plurality of substrate-web strips, each
substrate-web strip comprising a strip of the core-forming
substrate attached to the leading edge of a strip of the web; and
for each substrate-web strip: winding the strip of the core-forming
substrate into an in-line core; and winding the strip of the web
around the in-line core.
8. The method of claim 7, further comprising the step of: applying
graphics on a surface of the core-forming substrate.
9. A method for winding a plurality of webs, the method comprising
the steps of: producing a composite substrate-web stream comprising
an alternating sequence of attached core-forming substrate segments
and web segments, wherein each core-forming substrate segment has a
leading edge and a trailing edge and wherein each web segment has a
leading edge and a trailing edge; winding at least a portion of a
first core-forming substrate segment into a first in-line core;
winding a portion of a first web segment around the first in-line
core, wherein the first web segment is disposed between the
trailing edge of the first core-forming substrate segment and the
leading edge of a second core-forming substrate segment; and
cutting the composite substrate-web stream along a first cut
line.
10. The method of claim 9, wherein the first cut line is disposed
along the leading edge of the second core-forming substrate
segment, further comprising the step of: winding the remaining
portion of the first web segment around the first in-line core.
11. The method of claim 10, further comprising the steps of:
winding the second core-forming substrate segment into a second
in-line core; winding a portion of a second web segment around the
second in-line core, wherein the second web segment is disposed
between the trailing edge of the second core-forming substrate
segment and the leading edge of a third core-forming substrate
segment; cutting the composite substrate-web stream along a second
cut line disposed along the leading edge of the third core-forming
substrate; and winding the remaining portion of the second web
segment around the second in-line core.
12. The method of claim 9, wherein the first cut line is disposed
between the leading edge and the trailing edge of the second
core-forming substrate segment, further comprising the step of:
winding the remaining portion of the first web segment and a first
portion of the second core-forming substrate segment around the
first in-line core, wherein the first portion of the second
core-forming substrate segment is disposed between the leading edge
of the second core-forming substrate segment and the first cut
line.
13. The method of claim 12, further comprising the steps of:
winding a second portion of the second core-forming substrate
segment into a second in-line core, wherein the second portion of
the second core-forming substrate segment is disposed between the
first cut line and the trailing edge of the second core-forming
substrate segment; winding a portion of a second web segment around
the second in-line core, wherein the second web segment is disposed
between the trailing edge of the second core-forming substrate
segment and the leading edge of a third core-forming substrate
segment; cutting the substrate-web composite stream along a second
cut line disposed between the leading edge and the trailing edge of
the third core-forming substrate segment; and winding the remaining
portion of the second web segment and a first portion of the third
core-forming substrate segment around the second in-line core,
wherein the first portion of the third core-forming substrate
segment is disposed between the leading edge of the third
core-forming substrate and the second cut line.
14. The method of claim 9, wherein the step of producing a
composite substrate-web stream comprises the step of: attaching a
plurality of spaced-apart core-forming substrates on a surface of a
continuous web.
15. The method of claim 9, wherein the step of producing a
composite substrate-web stream comprises the step of: attaching a
plurality of spaced-apart core-forming substrates to a plurality of
spaced-apart webs in alternating sequence.
16. The method of claim 9, further comprising the step of: applying
graphics to a core-forming substrate segment.
17. A method for winding a plurality of webs, the method comprising
the steps of: producing a composite substrate-web stream comprising
an alternating sequence of attached core-forming substrate segments
and web segments, wherein each core-forming substrate segment has a
leading edge and a trailing edge and wherein each web segment has a
leading edge and a trailing edge; slitting the composite
substrate-web stream along at least one longitudinal slit line to
produce a plurality of composite substrate-web stream strips, each
composite substrate-web stream strip comprising an alternating
sequence of attached core-forming substrate segment strips and web
segment strips, wherein each core-forming substrate segment strip
has a leading edge and a trailing edge and wherein each web segment
strip has a leading edge and a trailing edge; and for each
composite substrate-web strip: winding at least a portion of a
first core-forming substrate segment strip into a first in-line
core; winding a portion of a first web segment strip around the
first in-line core, wherein the first web segment strip is disposed
between the trailing edge of the first core-forming substrate
segment strip and the leading edge of a second core-forming
substrate segment strip; and cutting the composite substrate-web
stream strip along a first cut line.
18. The method of claim 17, wherein for each composite
substrate-web strip the first cut line is disposed along the
leading edge of the second core-forming substrate segment strip,
further comprising the steps of: for each composite substrate-web
stream strip: winding the remaining portion of the first web
segment strip around the first in-line core.
19. The method of claim 18, further comprising the steps of: for
each composite substrate-web stream strip: winding the second
core-forming substrate segment strip into a second in-line core;
winding a portion of a second web segment strip around the second
in-line core, wherein the second web segment strip is disposed
between the trailing edge of the second core-forming substrate
segment strip and the leading edge of a third core-forming
substrate segment strip; cutting the composite substrate-web stream
strip along a second cut line disposed along the leading edge of
the third core-forming substrate strip; and winding the remaining
portion of the second web segment strip around the second in-line
core.
20. The method of claim 17, wherein for each composite
substrate-web stream strip the first cut line is disposed between
the leading edge and the trailing edge of the second core-forming
substrate segment strip, further comprising the steps of: for each
composite substrate-web stream strip: winding the remaining portion
of the first web segment strip and a first portion of the second
core-forming substrate segment strip around the first in-line core,
wherein the first portion of the second core-forming substrate
segment strip is disposed between the leading edge of the second
core-forming substrate segment strip and the first cut line.
21. The method of claim 20, further comprising the steps of: for
each composite substrate-web stream strip: winding a second portion
of the second core-forming substrate segment strip into a second
in-line core, wherein the second portion of the second core-forming
substrate segment strip is disposed between the first cut line and
the trailing edge of the second core-forming substrate segment
strip; winding a portion of a second web segment strip around the
second in-line core, wherein the second web segment strip is
disposed between the trailing edge of the second core-forming
substrate segment strip and the leading edge of a third
core-forming substrate segment strip; cutting the substrate-web
composite stream strip along a second cut line disposed between the
leading edge and the trailing edge of the third core-forming
substrate segment strip; and winding the remaining portion of the
second web segment strip and a first portion of the third
core-forming substrate segment strip around the second in-line
core, wherein the first portion of the third core-forming substrate
segment strip is disposed between the leading edge of the third
core-forming substrate strip and the second cut line.
22. The method of claim 17, wherein the step of producing a
composite substrate-web stream comprises the step of: attaching a
plurality of spaced-apart core-forming substrates on a surface of a
continuous web.
23. The method of claim 17, wherein the step of producing a
composite substrate-web stream comprises the step of: attaching a
plurality of spaced-apart core-forming substrates to a plurality of
spaced-apart webs in alternating sequence.
24. The method of claim 17, further comprising the step of:
applying graphics to a core-forming substrate segment.
25. An apparatus for winding a web having a leading edge and a
trailing edge, the apparatus comprising: means for attaching a
core-forming substrate to the leading edge of the web; means for
winding the core-forming substrate into an in-line core; and means
for winding the web around the in-line core.
26. The apparatus of claim 25, wherein the means for attaching a
core-forming substrate comprises: means for attaching the
core-forming substrate to the leading edge of the web with an
adhesive.
27. The apparatus of claim 25, wherein the web comprises an open
adhesive disposed on a surface of the web, and wherein the
core-forming substrate is a first core-forming substrate, further
comprising: means for attaching a second core-forming substrate to
the trailing edge of the web, wherein the second core-forming
substrate covers a portion of the open adhesive in the proximity of
the trailing edge of the web.
28. The apparatus of claim 25, wherein the web is a non-adhesive
web, and wherein the core-forming substrate is a first core-forming
substrate, further comprising: means for attaching a second
core-forming substrate to the trailing edge of the web; and means
for attaching the second core-forming substrate to a surface of a
portion of the previously wound web.
29. The apparatus of claim 25, further comprising: means for
applying graphics on a surface of the core-forming substrate.
30. An apparatus for winding a web having a leading edge and a
trailing edge, the apparatus comprising: means for attaching a
core-forming substrate to the leading edge of the web; means for
slitting the web and the attached core-forming substrate along at
least one longitudinal slit line to produce a plurality of
substrate-web strips, each substrate-web strip comprising a strip
of the core-forming substrate attached to the leading edge of a
strip of the web; and for each substrate-web strip: means for
winding the strip of the core-forming substrate into an in-line
core; and means for winding the strip of the web around the in-line
core.
31. The apparatus of claim 30, further comprising: means for
applying graphics on a surface of the core-forming substrate.
32. A streaming winding system comprising: a substrate inserter
module configured to: receive a web; and produce a composite
substrate-web stream comprising an alternating sequence of attached
core-forming substrate segments and web segments, wherein each
core-forming substrate segment has a leading edge and a trailing
edge and wherein each web segment has a leading edge and a trailing
edge; and a winder module configured to: receive the composite
substrate-web stream; wind at least a portion of a first
core-forming substrate segment into a first in-line core; wind a
portion of a first web segment around the first in-line core,
wherein the first web segment is disposed between the trailing edge
of the first core-forming substrate segment and the leading edge of
a second core-forming substrate segment; and cut the composite
substrate-web stream along a first cut line.
33. The streaming winding system of claim 32, wherein the winder
module is further configured to: position the first cut line along
the leading edge of the second core-forming substrate segment; and
wind the remaining portion of the first web segment around the
first in-line core.
34. The streaming winding system of claim 33, wherein the winder
module is further configured to: wind the second core-forming
substrate segment into a second in-line core; wind a portion of a
second web segment around the second in-line core, wherein the
second web segment is disposed between the trailing edge of the
second core-forming substrate segment and the leading edge of a
third core-forming substrate segment; cut the composite
substrate-web stream along a second cut line disposed along the
leading edge of the third core-forming substrate; and wind the
remaining portion of the second web segment around the second
in-line core.
35. The streaming winding system of claim 32, wherein the winder
module is further configured to: position the first cut line
between the leading edge and the trailing edge of the second
core-forming substrate segment; and wind the remaining portion of
the first web segment and a first portion of the second
core-forming substrate segment around the first in-line core,
wherein the first portion of the second core-forming substrate
segment is disposed between the leading edge of the second
core-forming substrate segment and the first cut line.
36. The streaming winding system of claim 35, wherein the winder
module is further configured to: wind a second portion of the
second core-forming substrate segment into a second in-line core,
wherein the second portion of the second core-forming substrate
segment is disposed between the first cut line and the trailing
edge of the second core-forming substrate segment; wind a portion
of a second web segment around the second in-line core, wherein the
second web segment is disposed between the trailing edge of the
second core-forming substrate segment and the leading edge of a
third core-forming substrate segment; cut the substrate-web
composite stream along a second cut line disposed between the
leading edge and the trailing edge of the third core-forming
substrate segment; and wind the remaining portion of the second web
segment and a first portion of the third core-forming substrate
segment around the second in-line core, wherein the first portion
of the third core-forming substrate segment is disposed between the
leading edge of the third core-forming substrate and the second cut
line.
37. The streaming winding system of claim 32, wherein the substrate
inserter module is further configured to: attach a plurality of
spaced-apart core-forming substrates on a surface of a continuous
web.
38. The streaming winding system of claim 32, wherein the substrate
inserter module is further configured to: attach a plurality of
spaced-apart core-forming substrates to a plurality of spaced-apart
webs in alternating sequence.
39. The streaming winding system of claim 32, wherein the substrate
inserter module is further configured to: apply graphics to a
core-forming substrate segment.
40. A streaming winding system comprising: a substrate inserter
module configured to: receive a web; and produce a composite
substrate-web stream comprising an alternating sequence of attached
core-forming substrate segments and web segments, wherein each
core-forming substrate segment has a leading edge and a trailing
edge and wherein each web segment has a leading edge and a trailing
edge; and a winder module configured to: receive the composite
substrate-web stream; slit the composite substrate-web stream along
at least one longitudinal slit line to produce a plurality of
composite substrate-web stream strips, each composite substrate-web
stream strip comprising an alternating sequence of attached
core-forming substrate segment strips and web segment strips,
wherein each core-forming substrate segment strip has a leading
edge and a trailing edge and wherein each web segment strip has a
leading edge and a trailing edge; and for each composite
substrate-web stream strip: wind at least a portion of a first
core-forming substrate segment strip into a first in-line core;
wind a portion of a first web segment strip around the first
in-line core, wherein the first web segment strip is disposed
between the trailing edge of the first core-forming substrate
segment strip and the leading edge of a second core-forming
substrate segment strip; and cut the composite substrate-web stream
strip along a first cut line.
41. The streaming winding system of claim 40, wherein the winder
module is further configured to: for each composite substrate-web
stream strip: position the first cut line along the leading edge of
the second core-forming substrate segment strip; and wind the
remaining portion of the first web segment strip around the first
in-line core.
42. The streaming winding system of claim 41, wherein the winder
module is further configured to: for each composite substrate-web
stream strip: wind the second core-forming substrate segment strip
into a second in-line core; wind a portion of a second web segment
strip around the second in-line core, wherein the second web
segment strip is disposed between the trailing edge of the second
core-forming substrate segment strip and the leading edge of a
third core-forming substrate segment strip; cut the composite
substrate-web stream strip along a second cut line disposed along
the leading edge of the third core-forming substrate strip; and
wind the remaining portion of the second web segment strip around
the second in-line core.
43. The streaming winding system of claim 40, wherein the winder
module is further configured to: for each composite substrate-web
stream strip: position the first cut line between the leading edge
and the trailing edge of the second core-forming substrate segment
strip; and wind the remaining portion of the first web segment
strip and a first portion of the second core-forming substrate
segment strip around the first in-line core, wherein the first
portion of the second core-forming substrate segment strip is
disposed between the leading edge of the second core-forming
substrate segment strip and the first cut line.
44. The streaming winding system of claim 43, wherein the winder
module is further configured to: for each composite substrate-web
stream strip: wind a second portion of the second core-forming
substrate segment strip into a second in-line core, wherein the
second portion of the second core-forming substrate segment strip
is disposed between the first cut line and the trailing edge of the
second core-forming substrate segment strip; wind a portion of a
second web segment strip around the second in-line core, wherein
the second web segment strip is disposed between the trailing edge
of the second core-forming substrate segment strip and the leading
edge of a third core-forming substrate segment strip; cut the
substrate-web composite stream strip along a second cut line
disposed between the leading edge and the trailing edge of the
third core-forming substrate segment strip; and wind the remaining
portion of the second web segment strip and a first portion of the
third core-forming substrate segment strip around the second
in-line core, wherein the first portion of the third core-forming
substrate segment strip is disposed between the leading edge of the
third core-forming substrate strip and the second cut line.
45. The streaming winding system of claim 40, wherein the substrate
inserter module is further configured to: attach a plurality of
spaced-apart core-forming substrates on a surface of a continuous
web.
46. The streaming winding system of claim 40, wherein the substrate
inserter module is further configured to: attach a plurality of
spaced-apart core-forming substrates to a plurality of spaced-apart
webs in alternating sequence.
47. The streaming winding system of claim 40, wherein the substrate
inserter module is further configured to: apply graphics on a
surface of a core-forming substrate.
48. A streaming winding system comprising: means for receiving a
web; means for producing a composite substrate-web stream
comprising an alternating sequence of attached core-forming
substrate segments and web segments, wherein each core-forming
substrate segment has a leading edge and a trailing edge and
wherein each web segment has a leading edge and a trailing edge;
means for winding at least a portion of a first core-forming
substrate segment into a first in-line core; means for winding a
portion of a first web segment around the first in-line core,
wherein the first web segment is disposed between the trailing edge
of the first core-forming substrate segment and the leading edge of
a second core-forming substrate segment; and means for cutting the
composite substrate-web stream along a first cut line.
49. The streaming winding system of claim 48, further comprising:
means for positioning the first cut line along the leading edge of
the second core-forming substrate segment; and means for winding
the remaining portion of the first web segment around the first
in-line core.
50. The streaming winding system of claim 49, further comprising:
means for winding the second core-forming substrate segment into a
second in-line core; means for winding a portion of a second web
segment around the second in-line core, wherein the second web
segment is disposed between the trailing edge of the second
core-forming substrate segment and the leading edge of a third
core-forming substrate segment; means for cutting the composite
substrate-web stream along a second cut line disposed along the
leading edge of the third core-forming substrate; and means for
winding the remaining portion of the second web segment around the
second in-line core.
51. The streaming winding system of claim 48, further comprising:
means for positioning the first cut line between the leading edge
and the trailing edge of the second core-forming substrate segment;
and means for winding the remaining portion of the first web
segment and a first portion of the second core-forming substrate
segment around the first in-line core, wherein the first portion of
the second core-forming substrate segment is disposed between the
leading edge of the second core-forming substrate segment and the
first cut line.
52. The streaming winding system of claim 51, further comprising:
means for winding a second portion of the second core-forming
substrate segment into a second in-line core, wherein the second
portion of the second core-forming substrate segment is disposed
between the first cut line and the trailing edge of the second
core-forming substrate segment; means for winding a portion of a
second web segment around the second in-line core, wherein the
second web segment is disposed between the trailing edge of the
second core-forming substrate segment and the leading edge of a
third core-forming substrate segment; means for cutting the
substrate-web composite stream along a second cut line disposed
between the leading edge and the trailing edge of the third
core-forming substrate segment; and means for winding the remaining
portion of the second web segment and a first portion of the third
core-forming substrate segment around the second in-line core,
wherein the first portion of the third core-forming substrate
segment is disposed between the leading edge of the third
core-forming substrate and the second cut line.
53. The streaming winding system of claim 48, further comprising:
means for attaching a plurality of spaced-apart core-forming
substrates on a surface of a continuous web.
54. The streaming winding system of claim 48, further comprising:
means for attaching a plurality of spaced-apart core-forming
substrates to a plurality of spaced-apart webs in alternating
sequence.
55. The streaming winding system of claim 48, further comprising:
means for applying graphics on a surface of a core-forming
substrate.
56. A streaming winding system comprising: means for receiving a
web; means for producing a composite substrate-web stream
comprising an alternating sequence of attached core-forming
substrate segments and web segments, wherein each core-forming
substrate segment has a leading edge and a trailing edge and
wherein each web segment has a leading edge and a trailing edge;
means for slitting the composite substrate-web stream along at
least one longitudinal slit line to produce a plurality of
composite substrate-web stream strips, each composite substrate-web
stream strip comprising an alternating sequence of attached
core-forming substrate segment strips and web segment strips,
wherein each core-forming substrate segment strip has a leading
edge and a trailing edge and wherein each web segment strip has a
leading edge and a trailing edge; and for each composite
substrate-web stream strip: means for winding at least a portion of
a first core-forming substrate segment strip into a first in-line
core; means for winding a portion of a first web segment strip
around the first in-line core, wherein the first web segment strip
is disposed between the trailing edge of the first core-forming
substrate segment strip and the leading edge of a second
core-forming substrate segment strip; and means for cutting the
composite substrate-web stream strip along a first cut line.
57. The streaming winding system of claim 56, further comprising:
for each composite substrate-web stream strip: means for
positioning the first cut line along the leading edge of the second
core-forming substrate segment strip; and means for winding the
remaining portion of the first web segment strip around the first
in-line core.
58. The streaming winding system of claim 57, further comprising:
for each composite substrate-web stream strip: means for winding
the second core-forming substrate segment strip into a second
in-line core; means for winding a portion of a second web segment
strip around the second in-line core, wherein the second web
segment strip is disposed between the trailing edge of the second
core-forming substrate segment strip and the leading edge of a
third core-forming substrate segment strip; means for cutting the
composite substrate-web stream strip along a second cut line
disposed along the leading edge of the third core-forming substrate
strip; and means for winding the remaining portion of the second
web segment strip around the second in-line core.
59. The streaming winding system of claim 56, further comprising:
for each composite substrate-web stream strip: means for
positioning the first cut line between the leading edge and the
trailing edge of the second core-forming substrate segment strip;
and means for winding the remaining portion of the first web
segment strip and a first portion of the second core-forming
substrate segment strip around the first in-line core, wherein the
first portion of the second core-forming substrate segment strip is
disposed between the leading edge of the second core-forming
substrate segment strip and the first cut line.
60. The streaming winding system of claim 59, further comprising:
for each composite substrate-web stream strip: means for winding a
second portion of the second core-forming substrate segment strip
into a second in-line core, wherein the second portion of the
second core-forming substrate segment strip is disposed between the
first cut line and the trailing edge of the second core-forming
substrate segment strip; means for winding a portion of a second
web segment strip around the second in-line core, wherein the
second web segment strip is disposed between the trailing edge of
the second core-forming substrate segment strip and the leading
edge of a third core-forming substrate segment strip; means for
cutting the substrate-web composite stream strip along a second cut
line disposed between the leading edge and the trailing edge of the
third core-forming substrate segment strip; and means for winding
the remaining portion of the second web segment strip and a first
portion of the third core-forming substrate segment strip around
the second in-line core, wherein the first portion of the third
core-forming substrate segment strip is disposed between the
leading edge of the third core-forming substrate strip and the
second cut line.
61. The streaming winding system of claim 56, further comprising:
means for attaching a plurality of spaced-apart core-forming
substrates on a surface of a continuous web.
62. The streaming winding system of claim 56, further comprising:
means for attaching a plurality of spaced-apart core-forming
substrates to a plurality of spaced-apart webs in alternating
sequence.
63. The streaming winding system of claim 56, further comprising:
means for applying graphics on a surface of a core-forming
substrate.
64. A wound web roll comprising: an in-line core formed from a
core-forming substrate; and a web wound around the in-line core,
wherein the web has a leading edge and a trailing edge and the
leading edge of the web is attached to the core-forming
substrate.
65. The wound web roll of claim 64, wherein the core-forming
substrate is a first core-forming substrate, further comprising: a
second core-forming substrate attached to the trailing edge of the
web.
66. The wound web roll of claim 64, further comprising: graphics
applied on a surface of the core-forming substrate.
67. A wound web roll produced by the steps of: attaching a
core-forming substrate to a leading edge of a web; winding the
core-forming substrate into an in-line core; and winding the web
around the in-line core.
68. The wound web roll of claim 67, wherein the step of attaching a
core-forming substrate to a leading edge of a web comprises the
step of: attaching the core-forming substrate to the leading edge
of the web with an adhesive.
69. The wound web roll of claim 67, further produced by the step
of: applying graphics to a surface of the core-forming substrate.
Description
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/219,428 filed Jun. 23, 2009, which is
incorporated herein by reference.
CROSS-REFERENCE TO RELATED APPLICATION
[0002] This application is related to U.S. patent application Ser.
No. ______ (Attorney Docket No. 11356.0009), entitled Enveloper
Assembly for Winding Webs, which is being filed concurrently
herewith and which is herein incorporated by reference in its
entirety.
BACKGROUND OF THE INVENTION
[0003] The present invention relates generally to winding of webs,
and more particularly to an in-line formed core that supports a
wound web.
[0004] Many products are supplied as a flexible, elongated sheet
referred to as a web. Examples of webs include sheet paper, sheet
fabric, plastic film, and metal foil. Webs are commonly wound into
a roll for storage, shipping, processing, and consumption. In
typical practice, webs are wound onto a separate component, a core
formed from a rigid material such as cardboard, wood, plastic, or
metal. The core serves as a support structure for initiating the
winding process and for maintaining the structural integrity of the
web during shipping and handling. The core also serves as a
mechanism for dispensing the web during further processing and
during end-user applications.
[0005] Separate cores, however, suffer from several disadvantages.
For example, they incur additional costs associated with their
purchase, shipping, and storage; and the additional steps required
to load the separate cores onto winding mandrels increase
manufacturing complexity, with attendant additional manufacturing
costs. Separate cores, furthermore, add to the waste stream, since
the cores are typically discarded once the web has been consumed.
Various coreless winding methods have been developed; however, they
are typically tailored to specific materials and require
complicated steps to initiate the winding. In some instances, the
final roll does not maintain sufficient structural integrity as the
web is consumed; consequently, the last portions of the web are
wasted. What are needed are methods and apparatus that wind webs
formed from a wide range of materials, reduce manufacturing costs,
and reduce waste material.
BRIEF SUMMARY OF THE INVENTION
[0006] A web is wound around an in-line core. A core-forming
substrate is attached to the leading edge of the web. The
core-forming substrate can be attached to the web with adhesive.
The core-forming substrate is wound into an in-line core, and the
web is wound around the in-line core. For streaming operation, a
composite substrate-web stream comprising an alternating sequence
of attached core-forming substrate segments and web segments is
produced. The first core-forming substrate segment is wound into a
first in-line core, and the first web segment is wound around the
first in-line core. The composite substrate-web stream is then cut.
The second core-forming substrate segment is wound into a second
in-line core, and the second web segment is wound around the second
in-line core. The composite substrate-web stream can be slit
longitudinally to produce multiple composite substrate-web stream
strips. Multiple composite substrate-web stream strips can be wound
in parallel on a single mandrel.
[0007] These and other advantages of the invention will be apparent
to those of ordinary skill in the art by reference to the following
detailed description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1A and FIG. 1B show a reference geometry for a
core-forming substrate attached to a web;
[0009] FIG. 2A-FIG. 2D show various configurations for attaching a
core-forming substrate to a web;
[0010] FIG. 3A-FIG. 3E show a sequence of steps for forming an
in-line core;
[0011] FIG. 4A-FIG. 4C show different segmentations of a
core-forming substrate and a web;
[0012] FIG. 5A-FIG. 5H show different configurations for attaching
a core-forming substrate to a web;
[0013] FIG. 6 shows a schematic of a manufacturing system for
streaming production of wound web rolls with in-line cores;
[0014] FIG. 7A-FIG. 7S show schematics of steps for producing a
sequence of webs and core-forming substrates;
[0015] FIG. 8A-FIG. 8R show schematics of steps for producing wound
web rolls with in-line cores;
[0016] FIG. 9A and FIG. 9B show end tabs on finished wound web
rolls;
[0017] FIG. 10 shows strips of web segments and core-forming
substrate segments with graphics imprinted on the core-forming
substrate segments; and
[0018] FIG. 11 shows the placement of adhesive to avoid adhesive on
the inner surface of a wound web roll.
DETAILED DESCRIPTION
[0019] In embodiments of the invention, an in-line core-forming
substrate is attached to the leading edge of a web. At the start of
the winding process, the in-line core-forming substrate is wound
into a core. The web is then wound onto the in-line formed core
(for simplicity, an in-line formed core is also referred to as an
in-line core). Note that the term "substrate" is sometimes used as
a synonym for "web". Herein, a "web" refers to the product of
interest (such as paper towels, cloth strips, photographic film,
masking tape, and metal foil). As discussed above, in general, a
web refers to a flexible, elongated sheet. Web materials can be
homogeneous or heterogeneous, including composites and laminates.
Webs can have surface coatings, including adhesives. The body of a
web can be uniform or can have geometrical features such as
perforations and corrugations. The surface of a web can be smooth
or textured, including features such as corrugations.
[0020] "Core-forming substrate" refers to a component used to
produce an in-line formed core (as described in detail below). A
wide range of materials can also be used for substrates, including
paper, plastic, and metal. In some instances, the substrate
material can be similar to the web material. For example, the web
can be thin paper, and the substrate can be a heavier weight,
stiffer paper. As another example, the web can be thin plastic
film, and the substrate can be a thicker plastic film or a more
rigid plastic film. Substrate materials can be homogeneous or
heterogeneous, including composites and laminates. Substrates can
have surface coatings, including adhesives. The body of a substrate
can be uniform or can have geometrical features such as
perforations and corrugations. The surface of a substrate can be
smooth or textured, including features such as corrugations.
[0021] FIG. 1A (View A) and FIG. 1B (View B) show a reference
geometry for winding operations. In the example shown, web 104,
with a width 141 and a length 143, is unwound from a web supply
roll 102. Note: To simplify the figures, a roll with multiple
windings is depicted as a series of concentric circles; in actual
practice, a web is wound as a continuous spiral. Web 104 is then
rewound for further processing (such as slitting into narrower
widths) or end-user application (such as retail rolls of masking
tape). To simplify the terminology, "rewinding" is referred to as
"winding". The final product is referred to as a wound web roll.
Note that web 104 can also be supplied as an individual flat sheet,
instead of being unwound from a web supply roll 102. Web 104 has a
leading edge 130, a trailing edge 132, a longitudinal axis 121, and
a transverse axis 123. In an embodiment of the invention,
core-forming substrate 106 is attached to the leading edge 130 of
web 104.
[0022] Details of the highlighted region 150 are shown in FIG.
2A-FIG. 2D (View B only) for several examples of attachment
geometries. Shown is a portion of web 104 with leading edge 130.
Web 104 has a surface 210 and a surface 212. Web 104 has a
thickness 201. Core-forming substrate 106 has a leading edge 202, a
trailing edge 204, a surface 206, and a surface 208. Core-forming
substrate 106 has a length 211 and a thickness 213. In FIG. 2A, the
leading edge 130 of web 104 is butted against the trailing edge 204
of core-forming substrate 106. In FIG. 2B, a portion of surface 208
of core-forming substrate 106 is facing a portion of surface 210 of
web 104. The overlap distance 215 is the distance between the
leading edge 130 of web 104 and the trailing edge 204 of
core-forming substrate 106. The overlap distance 215 can range from
0 to length 211. In FIG. 2C, a portion of surface 212 of web 104 is
facing a portion of surface 206 of core-forming substrate 106. The
overlap distance 217 is the distance between the leading edge 130
of web 104 and the trailing edge 204 of core-forming substrate 106.
The overlap distance 217 can range from 0 to length 211. In FIG.
2D, a portion of web 104 is inserted into a portion of core-forming
substrate 106. The insertion distance 219 is the distance between
the leading edge 130 of web 104 and the trailing edge 204 of
core-forming substrate 106. The insertion distance 219 can range
from 0 to length 211.
[0023] In some embodiments, a third component can be used to attach
core-forming substrate 106 to the leading edge 130 of web 104. For
example, in the configuration shown in FIG. 2B, component 220 is
disposed along leading edge 130 and contacts a portion of surface
208 of core-forming substrate 106 and a portion of surface 212 of
web 104 in the proximity of leading edge 130. Similarly, in the
configuration shown in FIG. 2C, component 220 is disposed along
leading edge 130 and contacts a portion of surface 206 of
core-forming substrate 106 and a portion of surface 210 of web 104
in the proximity of leading edge 130. In one embodiment, component
220 is a strip of single-sided adhesive tape that sticks to both
the core-forming substrate and the web. In another embodiment,
component 220 is a strip of thermoplastic that can be thermally
fused to both the core-forming substrate and the web. More examples
of attachment configurations are discussed below.
[0024] Herein, core-forming substrate 106 is attached to leading
edge 130 of web 104 if core-forming substrate 106 is attached to at
least one of leading edge 130, a portion of surface 210 of web 104
in the proximity of leading edge 130, and a portion of surface 212
of web 104 in the proximity of leading edge 130. Similarly, a
core-forming substrate is attached to the trailing edge of the web
if the core-forming substrate is attached to at least one of the
trailing edge and a portion of at least one surface of the web in
the proximity of the trailing edge.
[0025] Web 104 can be attached to core-forming substrate 106 by a
variety of means. For example, they can be attached with an
adhesive. The adhesive can be disposed on web 104, core-forming
substrate 106, or both web 104 and core-forming substrate 106. The
adhesive can be a thermally-activated adhesive. In another
embodiment, web 104 is attached to core-forming substrate 106 with
double-sided adhesive tape disposed between web 104 and
core-forming substrate 106. In another embodiment, as discussed
above, web 104 is attached to core-forming substrate 106 with
single-sided adhesive tape. In another embodiment, web 104 is
attached to core-forming substrate 106 by thermal fusion. As
discussed above with reference to FIG. 2B and FIG. 2C, web 104 can
be thermally fused to core-forming substrate 106 with the use of a
thermoplastic strip, component 220. Web 104 can also be thermally
fused directly to core-forming substrate 106. One skilled in the
art can devise other means for attaching web 104 to core-forming
substrate 106, including mechanical crimping. More details of
methods for attaching web 104 to core-forming substrate 106 are
discussed below, with reference to FIG. 5A-FIG. 5H.
[0026] FIG. 3A-FIG. 3E (View B only) illustrate the basic process
of forming an in-line core and winding a web onto the in-line core.
FIG. 3A shows the initial stage with web 104 attached to
core-forming substrate 106. The leading edge 202 of core-forming
substrate 106 is depicted as a ball for illustration purposes only.
In FIG. 3B, winding of core-forming substrate 106 is initiated. In
FIG. 3C, winding of core-forming substrate 106 continues. In FIG.
3D, winding of core-forming substrate 106 is completed, and an
in-line core 302 is formed. In FIG. 3E, web 104 is wound onto the
in-line core 302 to form wound web roll 304.
[0027] In the example shown in FIG. 3D, the in-line core 302 is
formed from one complete revolution of core-forming substrate 106.
In general, an in-line core can be formed from part of a
revolution, one revolution, or multiple revolutions of core-forming
substrate 106.
[0028] FIG. 4A-FIG. 4C (View A only) illustrate geometrical
configurations for streaming production of wound web rolls with
in-line cores. In FIG. 4A, webs and core-forming substrates are
attached in alternating sequence: core-forming substrate 410A, web
420A, core-forming substrate 410B, web 420B, core-forming substrate
410C, web 420C, core-forming substrate 410D, . . . . During later
processing, segments are cut off. The segments can be cut off in
different configurations. In a first configuration, the segments
are cut off along cut line 430A-cut line 430D. In a second
configuration, the segments are cut off along cut line 440A-cut
line 440D.
[0029] FIG. 4B shows a representative segment according to the
first configuration. Core-forming substrate 410C is attached to the
leading edge of web 420C. FIG. 4C shows a representative segment
according to the second configuration. Core-forming substrate
410A-1 is attached to the leading edge of web 420A, and
core-forming substrate 410B-2 is attached to the trailing edge of
web 420A.
[0030] As shown in FIG. 9A and FIG. 9B (View B only), core-forming
substrate 410B-2 can be used as finishing tabs on the finished
wound web rolls. In FIG. 9A, core-forming substrate 410B-2 is used
as a pull tab 902 to release an adhesive web 904 (such as adhesive
tape) from a finished wound web roll 906. For illustration, web 904
is partially unwound from wound web roll 906. In FIG. 9B,
core-forming substrate 410B-2 is used as a sealing tab 912 to seal
a non-adhesive web 914 (such as plastic film) to prevent the
finished wound web roll 916 from unwinding. For illustration, web
914 is partially unwound from wound web roll 916.
[0031] FIG. 5A-FIG. 5H (View B only) show different composite
structures of a core-forming substrate attached to a web. The
composite structures are pre-configured and pre-attached in
upstream processes, as described below with reference to the
substrate inserter assembly shown in FIG. 7A-FIG. 7S. The figures
depict the stage in which a first wound web roll 502 with an
in-line core 504 is being completed, and a second in-line core is
being started. In FIG. 5A-Fig. E, web 514 is an open-adhesive web
such as adhesive tape. Herein, an open adhesive refers to adhesive
that is already present on the material as supplied. Web 514 has a
surface 510 and a surface 512. As supplied, web 514 has open
adhesive 516O disposed on surface 510. Core-forming substrate 524
has a surface 520 and a surface 522. Bare mandrel 506 corresponds
to mandrel 804 described below with reference to the turret winder
assembly shown in FIG. 8A-FIG. 8Q.
[0032] In FIG. 5A, web 514 is continuous, and core-forming
substrate 524 is applied in parallel with web 514. Core-forming
substrate 524 extends from reference line 551 to reference line
557. Open adhesive 516O sticks surface 522 of core-forming web 524
to surface 510 of web 514. Applied adhesive 526A is applied on
surface 520 of core-forming substrate 524 from reference line 555
to reference line 557. Herein, an applied adhesive is an adhesive
that is applied to a material during processing; an applied
adhesive is disposed on the surface on which it has been applied.
Applied adhesive 526A can be applied either along the longitudinal
axis or along the transverse axis. Applied adhesive 526A causes
core-forming substrate 524 to adhere to itself as it is wound. No
adhesive is applied on surface 520 between reference line 551 and
reference line 555. The distance between reference line 551 and
reference line 555 is approximately equal to the circumference of
bare mandrel 506 so that the first wrap of the in-line core does
not have exposed adhesive on the inner diameter. More details of
the geometry of adhesive placement are described below with
reference to FIG. 11A-FIG. 11E.
[0033] Reference line 557 is the demarcation line between the
trailing edge of core-forming substrate 524 and the leading edge of
web 514 for the next wound web roll. Reference line 553 is the cut
line that demarcates the end of wound web roll 502 and the start of
the in-line core for the next web roll. If a pull tab for wound web
roll 502 is desired, reference line 553 is offset from reference
line 551. If no pull tab is desired, reference line 553 coincides
with reference line 551.
[0034] FIG. 11A-FIG. 11E show in more detail the geometry of
adhesive placement. Refer to FIG. 11A. The core-forming substrate
has a section 1102 and a section 1104. The surfaces of both
sections are referenced as surface 1120 and surface 1122. There is
no adhesive on either surface of section 1102. Adhesive 1126 is
disposed on surface 1120 of section 1104. Section 1102 has leading
edge 1101. Section 1104 is attached to the leading edge of web
1130.
[0035] In FIG. 11B, winding of section 1102 is initiated. In FIG.
11C, winding of section 1102 is completed. The length of section
1102 is sufficient for at least one complete revolution. Note that
the inside surface of the first wrap is surface 1120, which has no
adhesive disposed on it. In FIG. 11D, winding of section 1104 is
initiated. As section 1104 is wound onto section 1102, adhesive
1126 causes section 1104 to stick onto section 1102. In FIG. 11E,
winding of section 1104 is completed. In the example shown, the
length of section 1104 is sufficient for two revolutions. In
general, multiple revolutions can be used. As section 1104 is
wound, adhesive 1126 causes it to stick to a previously wound
portion of section 1104.
[0036] In the embodiment shown in FIG. 11E, the finished in-line
core 1140 is a core formed from multiple wraps of a core-forming
substrate bonded together with adhesive. One skilled in the art can
develop other means for bonding, such as thermal fusion. The
finished in-line core 1140 has a wall thickness 1141, which is the
difference between the outside radius and the inside radius.
[0037] The inner wrap is formed from section 1120, which has no
adhesive, and the outer wraps are formed from section 1104, which
has adhesive disposed on one surface. The inside surface of the
finished in-line core 1140 is therefore surface 1120, which has no
adhesive disposed on it. In many applications, it is desirable to
have no adhesive on the inside surface. For example, exposed
adhesive would attract dirt, interfere with loading the finished
wound web roll onto a dispensing spindle, and interfere with
handling by a user (that is, exposed adhesive would stick to
fingers). In FIG. 11E, winding of web 1130 onto the finished
in-line core 1140 can then proceed, as previously shown in FIG.
3E.
[0038] The configuration shown in FIG. 5B is similar to that shown
in FIG. 5A (core-forming substrate applied in parallel with web),
except that core-forming substrate 524 has open adhesive 526O
disposed on surface 520. Non-adhesive liner 534 is disposed on open
adhesive 526O between reference line 551 and reference line 559.
The length of non-adhesive liner 534 (distance between reference
line 551 and reference line 559) is approximately equal to the
circumference of bare mandrel 506 so that the first wrap of the
in-line core does not have exposed adhesive on the inner diameter.
Note that non-adhesive liner 534 can be applied to a portion of
core-forming substrate 524 that is initially not covered by any
non-adhesive liner. Alternatively, core-forming substrate 524 can
initially be completely covered by a non-adhesive liner, and a
portion of the non-adhesive liner can be stripped away and removed
to leave behind non-adhesive liner 534. Non-adhesive liner 534 can
be applied or stripped away along the longitudinal axis or along
the transverse axis.
[0039] In the configuration shown in FIG. 5C, the web is
discontinuous, and the core-forming substrate is applied in series
with the web. The web includes two segments, web 514A and web 514B.
Open adhesive 516O sticks surface 510 of web 514A to surface 522 of
core-forming substrate 524 between reference line 551 and reference
line 553. Open adhesive 516O sticks surface 510 of web 514B to
surface 522 of core-forming substrate 524 between reference line
557 and reference line 561. As in the configuration shown
previously in FIG. 5A, applied adhesive 526A is applied on surface
520 of core-forming substrate 524 between reference line 555 and
reference line 557.
[0040] The configuration shown in FIG. 5D is similar to that shown
in FIG. 5C (core-forming substrate applied in series with web),
except that core-forming substrate 524 has open adhesive 526O
disposed on surface 520. Non-adhesive liner 534 is disposed on open
adhesive 526O between reference line 551 and reference line 559.
The length of non-adhesive liner 534 (distance between reference
line 551 and reference line 559) is approximately equal to the
circumference of bare mandrel 506 so that the first wrap of the
in-line core does not have exposed adhesive on the inner
diameter.
[0041] The configuration shown in FIG. 5E is similar to the
configuration shown in FIG. 5C (core-forming substrate applied in
series with web), except core-forming substrate 524 has open
adhesive 528O disposed on surface 522. Open adhesive 516O on
surface 510 of web 514A and open adhesive 528O stick surface 510 of
web 514A to surface 522 of core-forming substrate 524 between
reference line 551 and reference line 553. Open adhesive 516O and
open adhesive 528O stick surface 510 of web 514B to surface 522 of
core-forming substrate 524 between reference line 557 and reference
line 561. Note that, instead of having open adhesive 528O on
surface 522, an applied adhesive can be applied to surface 522.
[0042] In FIG. 5F-FIG. 5H, web 514 is a non-adhesive web (for
example, bare plastic film). In FIG. 5F and FIG. 5G, the web is
continuous, and the core-forming substrate is applied in parallel
with the web. In FIG. 5H, the web is discontinuous, and the
core-forming substrate is applied in series with the web.
[0043] In the configuration shown in FIG. 5F, core-forming
substrate 524 has open adhesive 528O on surface 522. Applied
adhesive 526A is applied on surface 520 between reference line 555
and reference line 557. If a sealing tab on wound web roll 502 is
desired, applied adhesive 526A is also applied on surface 520
between reference line 551 and reference line 553. Note that,
instead of having open adhesive 528O on surface 522, an applied
adhesive can be applied to surface 522.
[0044] The configuration shown in FIG. 5G is similar to the one
shown in FIG. 5F, except core-forming substrate 524 has open
adhesive 526O on surface 520 and open adhesive 528O on surface 522
(double-sided adhesive). Non-adhesive liner 534 is disposed on open
adhesive 526O between reference line 553 and reference line 559.
The length of non-adhesive liner 534 (distance between reference
line 553 and reference line 559) is approximately equal to the
circumference of bare mandrel 506 so that the first wrap of the
in-line core does not have exposed adhesive on the inner diameter.
If a sealing tab on wound web roll 502 is desired, reference line
553 is offset from reference line 551. If a sealing tab on wound
roll 502 is not desired, reference line 553 coincides with
reference line 551. Note that, instead of having open adhesive 528O
on surface 522, an applied adhesive can be applied to surface
522.
[0045] In FIG. 5H, the web is discontinuous: the web includes two
segments, web 514A and web 514B. Core-forming substrate 524 has
open adhesive 528O on surface 522. Open adhesive 528O sticks
surface 510 of web 514A to surface 522 of core-forming substrate
524 between reference line 551 and reference line 553. Open
adhesive 528O sticks surface 510 of web 514B to surface 522 of
core-forming substrate 524 between reference line 557 and reference
line 561. If a sealing tab on wound roll 502 is desired, applied
adhesive 526A is applied on surface 520 of core-forming substrate
524 between reference line 551 and reference line 553.
[0046] For streaming production, the sequence of core-forming
substrate/web/core-forming substrate/web . . . is repeated. Herein,
a composite substrate-web stream comprises an alternating sequence
of attached core-forming substrate segments and web segments. Each
core-forming substrate segment has a leading edge and a trailing
edge, and each web segment has a leading edge and a trailing edge.
To simplify geometrical descriptions herein, a core-forming
substrate segment includes a core-forming substrate and any portion
of web overlapping it or inserted into it.
[0047] For example, in FIG. 2B, a core-forming substrate segment
includes core-forming substrate 106 and the portion of web 104
between leading edge 130 of web 104 and the trailing edge 204 of
core-forming substrate 106. In FIG. 5A, core-forming substrate 524
is attached in parallel to continuous web 512. A core-forming
substrate segment then includes core-forming substrate 524 and the
section of web 512 between the leading edge 551 and the trailing
edge 557 of core-forming substrate 524. In FIG. 5D, core-forming
substrate 524 is attached in series between web 514A and web 514B.
A core-forming substrate segment then includes core-forming
substrate 524, the section of web 514A between leading edge 551 of
core-forming substrate 524 and the trailing edge 553 of web 514A,
and the section of web 514B between trailing edge 557 of
core-forming substrate 524 and leading edge 561 of web 512.
[0048] Under this geometrical terminology, a web segment is
attached to a core-forming substrate segment. The trailing edge of
a core-forming substrate segment also serves as the demarcation
line for the leading edge of the attached web segment. FIG. 4A then
can also be viewed as a composite substrate-web stream comprising
an alternating sequence of core-forming substrate segments
410A-410D and web segments 420A-420C.
[0049] FIG. 6 (View B only) illustrates an embodiment of a
manufacturing system (streaming winding system) for streaming
production of wound web rolls with in-line cores. The streaming
winding system includes three main modules: web supplier module
602, substrate inserter module 604, and winder module 606. Web 514
is unwound from web supply roll 610 mounted in web supplier module
602. Web 514 is fed into substrate inserter module 604, passed
around roller 622, and fed into substrate inserter assembly 620,
which inserts core-forming substrate 524 onto web 514 (either in
parallel or in series). A continuous sequence of core-forming
substrate 524/web 514 is outputted from substrate inserter assembly
620, passed around roller 624, and fed into roller assembly 636 in
winder module 606.
[0050] One skilled in the art can assemble the modules in various
physical configurations. For example, all modules can be housed in
a single frame. In another example, the winder module and the
substrate inserter module can be housed in one frame, and the web
supplier module can be housed in a second frame. In another
example, the three modules can each be housed in individual frames.
One skilled in the art can also group functions in various
configurations. For example, the slitting operation (described
below) can be grouped with the winding module or with the substrate
module; the slitting operation can also be performed in an
independent module.
[0051] Various components such as rollers and turrets are driven by
drive systems such as electrical motors. The drive systems and the
overall sequence of operations are controlled in response to
commands issued by a control unit. The control unit, for example,
can be a computerized control unit or a programmable logic
controller control unit.
[0052] In the embodiment shown in FIG. 6, winder module 606
operates in a duplex mode, with twin turret winder assemblies,
turret winder assembly 630 and turret winder assembly 634, which is
a duplicate of turret winder assembly 630. In another embodiment,
winder module 606 operates in a simplex mode, with a single turret
winder assembly 630. Duplex and simplex operation are discussed in
more detail below.
[0053] More details of substrate inserter assembly 620 are shown in
FIG. 7A-FIG. 7S below. More details of turret winder assembly 630
are shown in FIG. 8A-FIG. 8R below.
[0054] FIG. 7A-FIG. 7S (View B only) show a sequence of operations
in substrate inserter assembly 620. FIG. 7A-FIG. 7L show a sequence
of operations for applying a core-forming substrate in parallel to
a web. FIG. 7A shows a schematic of the basic setup. Web 514 is fed
from roller 622 (see FIG. 6) and is fed around drive roller 702 and
drive roller 704. Core-forming substrate 524 is fed from
core-forming substrate supply roll 720 and is fed around roller 722
and roller 724. The free end of core-forming substrate 524 is
initially held in place by clamp 740. In embodiments in which a
non-adhesive liner is used, non-adhesive liner 534 is guided by
liner peel-off roller 732 and rewound onto liner rewinder 730. In
this example, non-adhesive liner is stripped away from core-forming
substrate. In embodiments in which an adhesive is applied, glue
head 750 is installed. In embodiments in which graphics are printed
on the core-forming substrate 524, print head 760 is installed.
Printing is described in further detail below with reference to
FIG. 10. The functions of gripper 708, nip roller 706, and table
710 are described below. Additional components can be installed;
for example, a heat source for activating thermally-activated
adhesive or a heat source for fusing a core-forming substrate onto
a web.
[0055] In FIG. 7B, the jaws of gripper 708 are opened and
positioned around the free end of core-forming substrate 524. In
FIG. 7C, the jaws of gripper 708 are closed onto the free end of
core-forming substrate 524. In FIG. 7D, clamp 740 is opened. In
FIG. 7E, gripper 708 pulls a user-specified length of core-forming
substrate 524 over table 710. In FIG. 7F, clamp 740 closes, and
cut-off knife 742 cuts off a section 524A of core-forming substrate
524. In addition to a knife, other means for cutting can be used;
for example, a laser. The length of core-forming substrate 524A can
be varied to produce a user-specified wall thickness of the
subsequent in-line formed core. In FIG. 7G, the jaws of gripper 708
are opened. In FIG. 7H, gripper 708 is retracted, and core-forming
substrate 524A lies on table 710. In FIG. 7I, table 710 is inclined
to position the leading edge of core-forming substrate 524A onto
web 514 at drive roller 704. Nip roller 706 is lowered to nip the
leading edge of core-forming substrate 524A onto web 514. In FIG.
7J, web 514 and core-forming substrate 524A are fed through drive
roller 704 and nip roller 706 to form an adhesive bond between
core-forming substrate 524A and web 514. Core-forming substrate
524A is attached in parallel to web 514.
[0056] FIG. 7K and FIG. 7L show an alternate feeding mechanism for
the core-forming substrate 524. Refer to FIG. 7K. Instead of the
gripper 708 and clamp 740 shown in FIG. 7A, the free end of
core-forming substrate 524 is gripped by nipped drive rollers 770
and 772. In FIG. 7L, nipped drive rollers 770 and 772 feed a
user-specified length of core-forming substrate 524 over table 710.
A section 524A of core-forming substrate 524 is cut off (not
shown), and the process then continues as in FIG. 7I and FIG.
7J.
[0057] FIG. 7M-FIG. 7S show a sequence of operations for applying a
core-forming substrate in series with a web. The basic setup is
shown in FIG. 7M. Components common to FIG. 7A-FIG. 7L are labelled
the same. Core-forming substrate 524 is fed by nipped drive rollers
770 and 772. Web 514 is fed by drive roller 704 and nip roller 706.
Web 514 is supported by hinged table 780 and fixed table 782.
[0058] In FIG. 7N, cut-off knife 784 cuts a section 514A from web
514. Fixed table 782 helps support web 514A during and after the
cutting operation. In FIG. 7O, table 780 is inclined to provide
clearance, and web 514 is held against drive roller 702 by nip
roller 786. Table 710 is inclined, and the leading edge of
core-forming substrate 524 is fed onto the trailing edge of web
514A between drive roller 704 and nip roller 706. Fixed table 782
helps direct the leading edge of core-forming substrate 524 into
the proper position. In FIG. 7P, cut-off knife 742 cuts a section
524A from core-forming substrate 524. The length of core-forming
substrate 524A can be varied to produce a user-specified wall
thickness of the subsequent in-line formed core.
[0059] In FIG. 7Q, core-forming substrate 524A continues to be fed
through drive roller 704 and nip roller 706. In FIG. 7R, table 710
and table 780 are returned to horizontal. The trailing edge of
core-forming substrate 524A is positioned on top of the leading
edge of web 514B (new section) and clamped by clamp 788 to form an
adhesive bond. Fixed table 782 helps support the trailing edge of
core-forming substrate 524A during the bonding operation. In FIG.
7S, clamp 788 is released. Core-forming substrate 524A is thus
attached in series to web 514A and web 514B.
[0060] In the embodiment of the substrate inserter assembly 620
shown in FIG. 7A-FIG. 7S, the core-forming substrate is fed along
the longitudinal axis of the web. In another embodiment, the
core-forming substrate is fed along the transverse axis.
[0061] FIG. 8A-FIG. 8R (View B only) show a sequence of operations
in turret winder assembly 630 (see FIG. 6). FIG. 8A shows a turret
802 on which are mounted two mandrels: mandrel 806 and mandrel 804.
As discussed below, the diameter of a mandrel can increase and
decrease. For example, a mandrel can contain an air bladder that
can be inflated to increase the diameter and deflated to decrease
the diameter. Other means for increasing and decreasing the
diameter can be used. At this stage, mandrel 806 is bare, and an
in-line core 820 (formed from a core-forming substrate) has been
wound on mandrel 804. The process for forming in-line core 820 is
described in detail below. Web 514 is fed from roller assembly 636
(see FIG. 6). Lay-on roller 808 nips web 514 to in-line core
820.
[0062] In FIG. 8B, mandrel 804 rotates. A user-specified length of
web 514 is wound onto in-line core 820 to produce wound web roll
830. In FIG. 8C, lay-on roller 808 retracts. In FIG. 8D, turret 802
is indexed 180 degrees clockwise. Wound web roll 830 is transferred
to the unload position, and mandrel 806 is transferred to the wind
position. In FIG. 8E, core-forming substrate 524 is fed from roller
assembly 636 (as described above, substrate inserter module 604
feeds a continuous sequence of core-forming
substrate/web/core-forming substrate/web . . . to winder module
606). Lay-on roller 808 nips core-forming substrate 524 to mandrel
806. Winding of web 514A (a segment of web 514) resumes until
core-forming substrate 524 advances to a user-specified
position.
[0063] In FIG. 8F, support arm 870 is swung around articulated
joint 860 into operational position. Articulated joint 860 is
coupled to a support infrastructure (not shown). Refer to FIG. 8R.
Enveloper assembly 880 includes support arm 870, support arm 872
coupled to support arm 870 by articulated joint 862, support arm
874 coupled to support arm 872 by articulated joint 864, and
enveloper roller 846 coupled to support arm 874. Also coupled to
support arm 870 are wipedown assembly 890 and web support bar 842.
Wipedown assembly 890 includes support arm 876 coupled to support
arm 870 by articulated joint 866 and wipedown roller 844 coupled to
support arm 876. To simplify the drawings, in FIG. 8F-FIG. 8Q, the
dashed rectangle representing enveloper assembly 880 and the dashed
rectangle representing wipedown assembly 890 are not shown;
however, the individual components of enveloper assembly 880 and
wipedown assembly 890 are called out.
[0064] In FIG. 8F, enveloper roller 846 nips core-forming substrate
524 against mandrel 806 at nip position 881. In FIG. 8G, wipedown
roller 844 nips against wound web roll 830. In FIG. 8H, cut-off
knife 850 severs core-forming substrate 524 at a user-specified
position into segment 524A and segment 524B. If a pull tab or
sealing tab (see FIG. 9A and FIG. 9B) is desired, a segment 524B of
core-forming substrate is left attached to the trailing edge of web
514A. If a pull tab or sealing tab is not desired, cut-off knife
850 severs core-forming substrate 524 at the leading edge of
core-forming substrate 524 (no segment 524B). In FIG. 8I, web 514A
and segment 524B are wound onto wound web roll 830, which is now
completely finished. Leading edge 527 is now the new leading edge
of core-forming substrate 524.
[0065] In FIG. 8J, enveloper roller 846 sweeps core-forming
substrate 524 around mandrel 806. Enveloper roller 846 nips
core-forming 524 against mandrel 806; the nip position follows the
surface of mandrel 806 from nip position 881 to nip position 883.
In FIG. 8K, mandrel 806 rotates until a user-specified length of
core-forming substrate 524 is wound for the tucking operation. Tail
tucker 850 is brought into position. In FIG. 8L, tail tucker 850
nips core-forming substrate 524 against mandrel 806 in close
proximity to lay-on roller 808. In FIG. 8M, mandrel 806 rotates,
and leading edge 527 of core-forming substrate 524 is guided into
the nip between mandrel 806 and lay-on roller 808.
[0066] In FIG. 8N, tail tucker 850 and support arm 870 retract from
their operational positions. Mandrel 804 deflates to allow wound
web roll 830 to be removed. In FIG. 8O, wound web roll 830 has been
removed, and mandrel 804 is now bare. Mandrel 806 expands to hold
core-forming substrate 524 as winding begins, and a new in-line
core is started. In FIG. 8P, core forming is complete when the
trailing edge of core-forming substrate 524 is wound onto mandrel
806. A pre-attached leading edge of web 514 follows and roll
formation begins. This is the stage previously shown in FIG. 8A
with mandrel 804 as the winding mandrel. In FIG. 8Q, the winding
process continues until the desired roll size is achieved. This is
the stage previously shown in FIG. 8B with mandrel 804 as the
winding mandrel. The sequence described above then repeats.
[0067] In the example shown in FIG. 8A-FIG. 8Q, a single wound web
roll was produced on a single mandrel. In general, multiple web
rolls can be produced in parallel on a single mandrel. FIG. 10
shows a section of a composite substrate-web stream 1000 which has
been slit along longitudinal slit line 1040 and longitudinal slit
line 1050 to produce three composite substrate-web stream strips:
composite substrate-web stream strip 1014, composite substrate-web
stream strip 1024, and composite substrate-web stream strip 1034.
Each composite substrate-web stream strip comprises an alternating
sequence of attached core-forming substrate segment strips and web
segment strips. Composite substrate-web stream strip 1014 includes
core-forming substrate segment strip 1012A, web segment strip
1010A, core-forming substrate segment strip 1012B, and web segment
strip 1010B. Composite substrate-web stream strip 1024 includes
core-forming substrate segment strip 1022A, web segment strip
1020A, core-forming substrate segment strip 1022B, and web segment
strip 1000B. Composite substrate-web stream strip 1034 includes
core-forming substrate segment strip 1032A, web segment strip
1030A, core-forming substrate segment strip 1032B, and web segment
strip 1030B. In general, the number of composite substrate-web
stream strips that can be slit from a single composite
substrate-web stream is user-specified.
[0068] Multiple wound web rolls can be produced in parallel on a
single mandrel in a single turret winder assembly 630 (see FIG. 6).
A composite substrate-web stream 524/514 is received by winder
module 606 from substrate inserter module 604. Composite
substrate-web stream 524/514 is fed by roller system 636, details
of which are not discussed. Slitting knife 650 can be brought into
position to slit composite substrate-web stream 524/514 into two
composite substrate-web stream strips. In general, multiple
slitting knives can be used in parallel to slit a composite
substrate-web stream into a user-specified number of composite
substrate-web stream strips. In addition to a slitting knife, other
means for slitting can be used; for example, a laser. In general,
the slitting operation can be performed at a user-specified
position after the substrate insertion operation and before the
winding operation.
[0069] Refer to FIG. 8A-FIG. 8Q. Multiple composite substrate-web
stream strips can be wound in parallel on a single mandrel.
Enveloper roller 846 can be a single full-width roller that
processes multiple composite substrate-web stream strips; multiple
shorter enveloper rollers mounted on a common axis can also be
used. Similarly, tail tucker 850 can have a single roller or
multiple rollers mounted at the end of a single pair of arms.
[0070] In one embodiment, winder module 606 can outfitted with a
single turret winder assembly, such as turret winder assembly 630
(simplex mode). All composite substrate-web stream strips are
processed in parallel on mandrel 804 and mandrel 806 (see FIG. 8A).
In the embodiment shown in FIG. 6, winder module 606 is outfitted
with dual turret winder assemblies (duplex mode). Turret winding
assembly 630 and turret winding assembly 640 are duplicates. In
duplex mode, multiple composite substrate-web stream strips are fed
alternately to turret winding assembly 630 and turret winding
assembly 640. For example, assume that composite substrate-web
stream 524/514 is slit into four composite substrate-web stream
strips, labelled strip 1, strip 2, strip 3, strip 4. Then strip 1
and strip 3 are fed to turret winding assembly 630, and strip 2 and
strip 4 are fed to turret winding assembly 640. In the simplex
mode, the multiple strips loaded onto a single mandrel are close
together. In some instances, one strip can interfere with the
winding of an adjacent strip (for example, if they rub against each
other). In the duplex mode, the multiple strips loaded onto a
single mandrel are spaced further apart.
[0071] As discussed above, auxiliary operations such as printing
can be performed during the substrate insertion operation in
substrate inserter module 604. In FIG. 10, graphics, including text
and images are applied to the core-forming substrate segment strips
(1012A, 1012B, 1022A, 1022B, 1032A, and 1032B). Examples of
graphics include manufacturer's name and logo, product name,
product identification number, lot number, manufacturing date, and
bar code. In the finished in-line core, the graphics would be
visible on the inner surface (surface 1120 in FIG. 11E). The
graphics can be applied by printing directly onto the core-forming
substrate via a print head (such as print head 760 in FIG. 7A).
Graphics can also be applied by other means; for example, sticking
a printed label onto a core-forming substrate.
[0072] The foregoing Detailed Description is to be understood as
being in every respect illustrative and exemplary, but not
restrictive, and the scope of the invention disclosed herein is not
to be determined from the Detailed Description, but rather from the
claims as interpreted according to the full breadth permitted by
the patent laws. It is to be understood that the embodiments shown
and described herein are only illustrative of the principles of the
present invention and that various modifications may be implemented
by those skilled in the art without departing from the scope and
spirit of the invention. Those skilled in the art could implement
various other feature combinations without departing from the scope
and spirit of the invention.
* * * * *