U.S. patent number 3,791,603 [Application Number 05/290,268] was granted by the patent office on 1974-02-12 for method and apparatus for improved web transfer.
This patent grant is currently assigned to Kimberly-Clark Corporation. Invention is credited to Gary L. Lenius.
United States Patent |
3,791,603 |
Lenius |
February 12, 1974 |
METHOD AND APPARATUS FOR IMPROVED WEB TRANSFER
Abstract
Improved method and apparatus for obtaining transfer of a web
from a parent roll to sequentially supplied cores for rewinding. A
transfer roll having a deformable surface is utilized in
combination with a piston or the like for urging the individual
cores against the web and the transfer roll surface. The deformable
surface provides increased wrap of the web around the core and
insures smooth web transfer without excessive wrinkling. In a
preferred embodiment a phase shift differential arrangement is
included to adjust the location of sheet or web separation upon
breaking.
Inventors: |
Lenius; Gary L. (Neenah,
WI) |
Assignee: |
Kimberly-Clark Corporation
(Neenah, WI)
|
Family
ID: |
23115239 |
Appl.
No.: |
05/290,268 |
Filed: |
September 18, 1972 |
Current U.S.
Class: |
242/521;
242/532.3; 242/533.5; 242/533.6; 242/541; 242/541.3 |
Current CPC
Class: |
B65H
19/2253 (20130101); B65H 2301/41356 (20130101); B65H
2301/4148 (20130101); B65H 2301/41745 (20130101) |
Current International
Class: |
B65H
19/22 (20060101); B65h 019/20 (); B65h
075/34 () |
Field of
Search: |
;242/64,56A,56R,56.6 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Huckert; John W.
Assistant Examiner: Gerstein; Milton
Attorney, Agent or Firm: Hanlon, Jr.; Daniel J. Herrick;
William D. Miller; Raymond J.
Claims
I claim:
1. Apparatus for transferring a moving web successively onto cores
for rewinding said web comprising,
means for receiving said web,
a transfer roll having a deformable circumferential surface,
means for receiving cores and positioning them sequentially
adjacent said transfer roll,
means for rotating said sequentially positioned core at about the
same circumferential speed as the linear rate of web travel,
means for moving and urging said sequentially positioned core
against said deformable transfer roll surface to pick up said web
and cause it to be wound onto said core, and for moving said core
away from said transfer roll, and
means for removing fully wound cores.
2. The apparatus of claim 1 wherein said deformable surface has a
Shore A hardness in the range of from about 5 to 20.
3. The apparatus of claim 1 further including means to perforate
said web.
4. The apparatus of claim 1 wherein said urging means comprises a
piston adapted to move the means for rotating the cores and the
cores towards said transfer roll.
5. The apparatus of claim 1 wherein said means for rotating said
cores is a driven belt.
6. The apparatus of claim 1 wherein the area contact produced by
said urging means takes place over an arc subtended by an angle of
from 15.degree. to 90.degree. on the core cross section.
7. The apparatus of claim 1 further including means for applying
adhesive to said sequentially supplied cores.
8. An improved method for transferring a moving web successively
onto cores for rewinding said web comprising the steps of,
passing said web into partial wrapping engagement with a transfer
roll having a deformable surface,
positioning cores sequentially adjacent said transfer roll,
rotating said sequentially positioned core,
moving and urging said sequentially positioned core against said
deformable transfer roll surface thereby picking up said web and
causing it to be wound onto said core,
moving said core away from said transfer roll,
removing said core when fully wound.
9. The method of claim 8 further including the step of applying
adhesive to said core prior to urging it against said web.
10. The method of claim 8 wherein said cores are urged against said
deformable transfer roll surface for a period of time required for
about 3 to 4 core revolutions.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The manufacture of consumer-sized rolls of products such as
sanitary bathroom tissue, paper toweling or the like, customarily
involves the rewinding of relatively short lengths from large rolls
produced by paper machines onto cores which are slit into sizes
convenient for home use. In the cases where the product is to
comprise two or more plies or sheets, a corresponding number of
paper machine (parent) rolls are simultaneously unwound so that the
sheets are in a face-to-face position when rewound. If desired, the
plies may be bonded together by use of embossing, light adhesive
application or the like. In order for this winding operation to
work efficiently, it must take place at high speeds and on a
generally continuous basis. This invention is related to
improvements in methods and apparatus for transferring the web to a
new core from a previously completely wound core without causing
excessive wrinkling of the web.
2. Description of the Prior Art
Various apparatus have been devised to provide a continuous
succession of cores for winding in a manner such that the speed of
the parent roll may be continuously maintained at lineal velocities
of up to 1,800 feet per minute and even higher. In most cases, the
web is unwound into partial wrapping engagement with a transfer
roll. Adhesive is usually applied to an empty core, and the sheet
transferred thereto by contact between the core and the sheet on
the transfer roll. In one form of apparatus for obtaining transfer
of the sheet from the transfer roll to a new core, a tucker is
utilized. This tucker is driven very quickly against the web
forcing it outward from the transfer roll into contact with the new
core. This action is usually quite violent and accomplished with a
solenoid-operated hydraulic cylinder at about 600 to 700 p.s.i.g.
line pressure. The very anture of the violent action has caused
missalignment and maintenance problems as well as safety hazards
and noise.
A second commonly used system involves mounting the cores on a
turret and rotating them into position for contact with the web on
the transfer roll. As this necessitates essentially a
point-to-point contact, it has frequently resulted in excessive
wrinkling of the web as it is first transferred to the core.
Reference may be had to U.S. Pat. No. 2,357,976 to Roesen; U.S.
Pat. No. 2,769,600 to Kwitek et al. and U.S. Pat. No. 2,973,158 to
Zernov for specific examples and further description of such
methods and apparatus.
SUMMARY OF THE INVENTION
Briefly, in accordance with the present invention, in both single
ply and multiple-ply operation improved sheet transfer to a new
core is obtained by providing a transfer roll having a deformable
surface combined with a piston or the like for forcing new cores
against the deformable surface. As the web is being transferred to
a new core from a previously fully wound one, the core contacts the
web against this deformable surface and results in a partial wrap
of the web around the core as the surface is deformed. This
maintains the sheet in a smooth condition and insures clean,
substantially wrinkle-free web transfer to the new core when the
web is broken between the new core and the fully wound core. In
this manner, the violent actions required of the tucker blades are
rendered unnecessary since the core may be withdrawn more
gradually, and the point-to-point contact which results from the
use of previous turret-type apparatus and arrangements is also
avoided. In accordance with conventional practice, a knife roll may
be further used to provide perforations, and a phase shift
differential transmission may be utilized to adjust the distance
between the perf blade and the transfer roll, thereby insuring
separation of the web between the cores at a desired line of
perforation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overall perspective view of one form of the transfer
apparatus of the present invention;
FIG. 2 is a schematic side view of the apparatus of FIG. 1 in
combination with one form of a phase shift differential;
FIG. 3 is a detailed partial perspective view of a phase shift
differential transmission;
FIG. 4 is a detailed schematic view of the transfer operation;
FIG. 5 is a partially cut away view showing in perspective the
transfer apparatus including air cyinders for urging the cores into
position; and
FIG. 6 schematically illustrates how the present invention may be
incorporated into an overall winding system.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
While the invention will be described in connection with preferred
embodiments, it will be understood that it is not intended to limit
the invention to those embodiments. On the contrary, it is intended
to cover all alternatives, modifications and equivalents as may be
included within the spirit and scope of the invention as defined by
the appended claims.
Turning first to FIGS. 1 and 2, the improved web transfer apparatus
of the present invention will be described. These drawings
illustrate the winding and transfer assembly immediately prior to
transfer. The overall assembly includes supporting members
generally indicated 10 which have been largely eliminated from the
drawings for clarity but may be of conventional frame design. It
may be divided into phase shift differential transmission section
12, and transfer section 14 both of which have transfer roll 22 in
common. The phase shift differential section includes knife roll 16
(FIG. 2), adjusting gear 18 which includes a differential gear
train (FIG. 3). Timing belt pulleys 20, 21, 23, and 25 tie the
transfer roll in driving relationship with the knife roll. The
transfer section includes transfer roll 22 on shaft 19, which also
has bearing 29 for rotation in support 10 on shaft 80, deformable
surface 24, winding belt assembly 26 including pulleys 28 stepped
for shouldering belts 66 and journalled for rotation by bearing 27
on shaft 31 which has bearings 81. Belt 66 drives cores 30 on core
shaft 78. Air cylinders 32 urge the winding belt assembly and the
core against the transfer roll 22 at timed intervals. An
arrangement such as chain transport 50 is provided as shown in
greater detail in FIG. 6 for moving the cores into and out of
winding positions.
Turning now also to FIGS. 3, 4, and 5 in conjunction with FIGS. 1
and 2, the operation of the method and apparatus for the present
invention will be described in greater detail. Web 38, which may be
slit along lines 39, if desired, is fed to knife roll 16 and then
to transfer roll 22. Cores 30, which are preferably pre-glued and
driven by contact with belt 66 are made of a suitable material such
as cotton-duck backed natural rubber of 40 to 45 Shore A Durometer
hardness, for example. They traverse past the transfer roll 22 at a
rate timed to the number of sheets of web 38 for total web length
required on the completed wound roll 42. Rotation of the cores and
winding of the web 38 results from contact with driven belt 66.
Adjustment of tension of belt 66 is provided by slide block 68
engaged for movement within tracks 70 and threaded adjusting rod 72
including adjusting nut 74 and locking nut 75. The pickup point, or
the location at which the core contacts the transfer roll at
transfer, is generally indicated at 36 (FIG. 2). To initiate the
transfer, the air cylinders 32 connected to support 10 by clevis
bracket 33, pin 35 through eye 37 bracket are activated, pivoting
the winding belt assembly 26 about support pin 76 and connecting
clevis pin 84 having suitable bearings 77, 79 and forcing core 30
against the deformable surface 24 of transfer roll 22 with the web
38 impinged between core 30 and deformable surface 24. Web 38
adheres to the core 30 and wraps around it, applying tension to the
web between the core 30 and the fully wound core 42, eventually
breaking the web at a perforation 40 (FIG. 4) thus completing the
fully wound roll 42 and beginning the wind on new core 30. Core 30
is preferably held in contact with transfer rool 22 for a brief
period, for example 3 to 4 core revolutions, and then is backed
away at a controlled rate to assure good transfer and proper
winding belt pressure.
As is evident from the drawings, the deformable surface of transfer
roll 22 allows the core 30 to impress itself into the surface 24
giving increased surface contact and wrap which aid in the
attachment of web 38 to core 30. Furthermore, deformable surface 24
acts as a shock absorber to cushion the force of the sudden motion
of core 30 into the transfer position, thereby decreasing noise and
increasing the life of the winding belt 66.
The phase shift differential transmission section 12 provides
control of the perforation location at the time web 38 is broken.
This is accomplished by means of the differential gear train
mounted on support 10 (FIG. 3) with external adjustment handle 64
that allows the output shaft 46 to be infinitely adjustable
rotationally with respect to input shaft 48 through timing pulleys
44, 62 while maintaining a constant speed ratio. Drive pulley 82
connected to a suitable power source (not shown) provides the drive
for the winding belt 66. Similarly, the transfer roll 22 may be
driven through a belt and pulley arrangement or by direct drive
(not shown). Additionally, adjustment can be made either statically
or dynamically so that only one sheet of the web will contact core
30 and so that the perforations 40 will be located for most
reliable transfer through increasing or decreasing the distance
between cutting blades 60 on knife roll 16 and transfer roll 22.
Such phase shift differential transmission equipment will not be
described in greater detail as it is known and available, for
example, Model OOPSD from Specon as described in its Phase Shift
Differential Transmission Bulletin No. 205C. With this feature, it
is possible to drive the knife roll by the transfer roll through
the phase shift differential transmission by the pulley arrangement
as generally indicated in FIG. 3.
Knife roll 16 may be any one of a number of conventional
constructions and will not be described in detail. It essentially
includes blades 60 that contact web 38 at selected intervals to
weaken the sheet strength at those locations. The blade 60 normally
need not be sharp and may be serrated in the manner shown, as is
well-known, to provide the desired degree of sheet strength
reduction. Usually it will be desirable to provide an opposing
surface such as an idler roll (not shown) or anvil 88 on support 90
so that the blades 60 may impinge web 38 against a surface for
increased effectivnesss.
Preferably, the drive belt 66 for cores 30 is on the edges only to
avoid contact with adhesives applied to the cores. While a single
drive belt may be used, it is preferred to have at least a drive
belt on each end for balanced operation and others as the length of
the shaft may dictate (FIG. 5). The separation distance between
core 30 and transfer roll 22, prior to contact, is preferably at
least about 3/4 of an inch. The deformable surface is preferably
substantially continuous around the transfer roll cross sectional
circumference and composed of foam rubber such as medium density
Durkee-Atwood open cell natural rubber foam sheeting and may simply
be adhesively attached to the roll surface. Other materials may be
utilized as well. It is preferably about 1/4 inch to 3/4 inch thick
for shock and noise reduction. The preferred hardness of the
deformable layer depends substantially upon the pressure applied by
the piston as transferred to the core. Generally this will be in
the range of from about 2 to about 5 pli for the winding of toilet
tissue or the like. In such cases the Shore A hardness of the
deformable surface may be in the range of from about 5 to about 20
with from 8 to 12 Durometer preferred. Where the applied pressures
are greater or less, it will be recognized that the hardness may
vary outside these ranges. It is important, however, that the core
deform the surfaces sufficiently to produce significant area
contact between the web and the core. Preferably this takes place
over an arc subtended by from about 15.degree. to about 90.degree.
on the core cross section.
Turning to FIG. 6 the application of the invention to improve the
operation of a complete rewinder system will be described. In this
arrangement the cores are supplied by chain link 50 which is driven
counter-clockwise by sprockets 52, powered by a conventional source
(not shown). There are nine core stations 54A to 54I for sequential
operative steps. Cores 30 are provided at 54A, adhesive applied at
54E by a roll coater consisting of dip pan 56 and mist roll 58. At
step 54G sheet 38 contacts core 30 and is transferred from finished
roll 42 by the transfer section 14 as previously described.
Finished roll 42 proceeds to step 54I where it is removed and the
cycle repeated.
The advantages of the present invention include highly reliable web
transfer, increased belt life, quieter operation with less
maintenance, and reduced tendency to form wrinkles at the core.
Means for timing and activating apparatus such as the present
invention are known and will not be described. It is only necessary
that controls be provided that are capable of quick response for
maximum benefits to be derived. However, the selection of any
particular system is not critical and will depend upon the
application involved. For example, core 30 may be forced against
the deformable surface 24 through web 38 without moving the belt
assembly 26. However, it should be recognized that it is usually
desirable to have the core rotating at the same peripheral speed as
the rate of movement of the web. For that reason, it is preferred
that contact between belt 66 and core 30 be maintained.
While the invention has been described in conjunction with specific
embodiments thereof, it is evident that many alternatives,
modifications and variations will be apparent to those skilled in
the art in light of the foregoing description. Accordingly, it is
intended to embrace all such alternatives, modifications and
variations as fall within the spirit and broad scope of the
appended claims.
* * * * *