US 3553055 A
Description (OCR text may contain errors)
Jan. 5, 1971 s. A. JANlK 3,553,955
APPARATUS FOR ADHERING AN OUTER TAIL PORTION OF A WOUND ROLL To AN UNDERLYING CONVOLUTION 5 Sheets-Sheet 1 Filed Feb. 6, 1968 INVENTOR. STANLEY JANIK Jan. 5, 1971 5, JANIK 3,553,055
APPARATUS FOR ADHERING AN OUTER TAIL PORTION OF A WOUND ROLL. TO AN UNDERLYING CONVOLUTION Filed Feb. 6, 1968 5 Sheets-Sheet 2 49" ,aa /'l22 47 INVENTOR.
mil STANLEY JANIK BY 66 Jan. 5, 1971 5 JANIK 3,553,@55
APPARATUS FOR ADHERING AN OUTER TAIL PORTION OF A WOUND ROLL TO AN UNDERLYING CONVOLUTION Filed Feb. 6, 1968 5 Sheets-Sheet 3 I N VB NTOR. STANLEY JANIK ATTY.
Jan. 5, 1971 5 JANIK 3,553,355
APPARA'IUS POP. ADHERING AN OUTER TAIL PORTION OF A WOUND ROLL TO AN UNDERLYING CONVOLUTION Filed Feb. 6, 1968 5 Sheets-Sheet 4 IN VENTOR. STANLEY JAN 1 K Jan. 5, 1971 s. A. JANIK 3,553,055
APPARATUS FOR ADHERING AN OUTER TAIL PORTION OF A WOUND ROLL TO AN UNDERLYING CONVOLUTION Filed Feb. 6, 1968 5 Sheets-Sheet 5 INVENTOR. STAN LEY JANI K lay/ ATTY.
"nited States US. Cl. 156450 Claims ABSTRACT OF THE DISCLOSURE After a wound tissue roll leaves a roll-forming station in a winding machine, the roll is rotated about its own longitudinal axis in an unwinding direction to extend a tail portion of the roll a predetermined distance into a vacuum box where the tail is temporarily halted while an adhesive applicator is moved along a trackway to apply adhesive to an exposed portion of the roll along a line parallel to the longitudinal axis of the roll. The tail is then completely rewound on the roll to sandwich the adhesive between the tail and an underlying convolution, and the roll is removed from the winding machine.
BACKGROUND OF THE INVENTION The present invention relates to a method and apparatus for adhering an outer tail portion of a wound roll of flexible material to an underlying convolution on the roll. While reference will primarily be made hereinafter to the invention as applies to rolls of tissue, such as toilet tissue, it is to be understood that the invention also has application to tail securing of rolls of other flexible material.
In the manufacturing of wound rolls of paper for household use, such as rolls of toilet tissue or towels, it is conventional to first wind a roll (commonly called a log or cant) which is of the same diameter, but longer than the final roll product which is sold to the consumer. Such cant is then cut transversely into sections of desired final roll product length. If the tail portion of the cant is not firmly secured to an underlying convolution, the tail may extend outwardly of the cant and interfere with proper transverse cutting of the cant. Furthermore, the consumer-length roll is often packaged in a transparent Wrapper. If the tail extends outwardly of the roll in the package, the appearance is unsightly which may be detrimental to consumer acceptance of the package. In addition, an unsecured tail may contribute to causing wrapping machinery to malfunction with consequent loss of productions and requiring extra manual labor to index and reposition the cant.
In view of the above, it can be seen that it is desirable to provide an apparatus and method which is effective in adhering the tail portion of a wound roll product to an underlying convolution. In the design of a suitable mode of accomplishing this, there are several factors that must be taken into consideration. One such factor, or problem, to be solved, is that the tail will remain adhered while a cant or roll is severed into consumer-length rolls, but the adherence should not be of such a nature as will make it difficult for the consumer to unwind the rolled product from the roll when desired. Another factor, or problem to be considered, is that the adherence should be close enough to the outer end of the tail so that no unsightly flap will still remain unadhered. Another factor is a matter of economics in that it is desirable to adhere the tail at a station which is combined with the equipatent O Patented Jan. 5, 1971 ice ment used for winding the roll rather than utilizing equipment at a station remote from the winding equipment.
SUMMARY It is therefore an object of the present invention to provide a method and apparatus wherein a tail is effectively secured to an underlying convolution on a roll along a longitudinal line of adherence located a predetermined short distance from the end edge of the tail so as to hold the tail in place until the consumer receives the product, but which does not unduly interfere with the consumer finally unwinding the wound product from the roll.
Another object is the provision of a method and apparatus wherein effective tail securing on a wound roll is accomplished before the roll is removed from the winding equipment which is used to form the roll.
In accordance with one aspect of the present invention, a tail portion of a wound roll is extended a prede termined distance from the Wound roll, and the extended tail is halted While adhesive is applied as a bead along a longitudinal line to an exposed surface portion of the wound material on the roll which is unexposed when the roll is completely wound. Then the tail is rewound on the roll to sandwich the adhesive line between the tail and an underlying convolution. Because the tail extension length is fixed at a predetermined distance, and because the position where the adhesive applied is at a predetermined, fixed location, the location of the line of adhesive can be chosen so that it will be a fixed, predetermined short distance fromv the end of the tail. Furthermore, the adhesion being only along a narrow line facilitates removal of the product from the roll by the consumer.
Another aspect of the present invention resides in combining the tail-securing apparatus and method with the winding equipment so that the tail may be adhered along a line longitudinally of the formed roll before the roll is removed from the winding equipment.
Still other aspects reside in the particular structure which is used for unwinding the tail, detecting a predetermined length, and rewinding the tail after application of an adhesive line.
BRIEF DESCRIPTION OF THE DRAWINGS An embodiment of the present invention is illustrated in the accompanying drawings in which:
FIG. 1 is a front foreshortened elevational view, with parts broken away for clarity, of the apparatus of the present invention;
FIG. 2 is a side sectional view taken on line 22 of FIG. 1, but with additional parts of the winder illustrated in outline;
FIG. 3 is a sectional view taken on line 3-3 of FIG. 1;
FIG. 4 is a sectional plan view taken on line 44 of FIG. 1 but with parts removed for clarity;
FIG. 5 is a foreshortened perspective view, partly diagrammatic, illustrating a roll at the roll-removing station with adhesive being applied thereto; and
FIG. 6 is a schematic electrical circuit diagram illustrating control circuitry for establishing a predetermined length tail extension as a part of the present invention.
GENERAL DESCRIPTION The present invention, in a preferred embodiment thereof, forms a combination with winder equipment 10 used to wind tissue, such as toilet tissue, from a large parent roll to smaller diameter (e.g. 4 inch) rolls or cants. It will be helpful, at this point, to generally describe such winder equipment.
First referring especially to FIGS. 1, 2 and 5 of the drawing, there is illustrated a plurality of mandrels 11 in the form of spaced, longitudinally extending rods or tubes, and the longitudinal axis of each mandrel is substantially parallel to the longitudinal axis of each other mandrel. One end 12 of each of the mandrels is conventionally supported for rotation on a common turret 13. The turret 13 is movable in a clockwise direction (as viewed at FIG. 2), and, as the mandrels are carried by the turret, the mandrels 11 are sequentially indexed in an orbital path to various stations. The mandrels are supported in such a manner, however, as to be capable of being individually rotated about their own longitudinal axis. At two of the stations (core-receiving station and roll-removing station) end 14 of the mandrel opposite from the turret (see FIG. 5) is free so that a core 15, such as a cardboard core used in toilet tissue rolls, can be received from this end 14 longitudinally on the mandrel 11, and so that a wound roll 16 can be removed from the mandrel. It is conventional to use a pivotal cap member which is pivoted into lace to support the end 14 of the mandrel at other stations occupied by the mandrels 11 during their step-wise movement in an orbital path. Support at both ends 12 and 14 of the mandrel during high speed rotation thereof while a roll 16 is being wound is especially desirable. As seen at FIG. 5, the end 14 of each mandrel is pointed so as to facilitate receipt of a core thereon.
Turning again to FIG. 2, the numeral 17 indicates a station where a core 15 is received on the mandrel 11. After positioning the core 15, it is held in place so that the core will not move relative to the mandrel, and this may be accomplished in any conventional manner such as by using retractable pins or wedges which are adapted to be projected a slight distance from the exterior surface of the mandrel 11 to Wedgingly engage the inner surface of the core 15. The pins may be retracted when it is desired to remove the core from the mandrel.
Considering the station 17 to be the first station to be occupied by each mandrel in its orbital path (clockwise, as viewed at FIG. 2), each mandrel 11 then moves to a second station 18 and then to a third station 19. At the third station 19, glue is applied in a conventional manner to the external surface of core 15 to facilitate subsequent receipt of the leading edge of tissue to be Wound on the core.
After passing through a fourth station 20, each mandrel 11 is sequentially advanced to fifth or roll-forming station 21 Where the leading edge of the material to be wound on the core is adhered to the core 15 and then the mandrel carrying the core is rapidly rotated about its own longitudinal axis to wind the material on the core. It is to be understood that a web 22 of material is led from a parent roll (not shown) through suitable tensioning rolls, over a perforation-applying roll 23 and cutoff roll 24. The cut-off roll 24 functions in a conventional manner to sever the web 22 after the roll 16 or cant being formed at station 21 has reached a predetermined desired diameter. From station 21, the turret advances each mandrel 11 sequentially to a sixth or rollremoving station 25. At the station 25, the pins or wedges are released so that the core 15 with the roll 16 of tissue wound thereon may be removed from the mandrel. The mandrel 11 then is advanced from the roll-removing station 25 .to the core-receiving station 17 to begin another cycle. The time each mandrel spends at each of the stations mentioned above will vary depending on the prodnot formed, this time being dictated primarily by the amount of time it takes to form a wound roll 16 at the roll-forming station 21. It may, for example, take about 10 seconds to form a 4-inch diameter roll of toilet tissue. It is to be understood that as soon as each mandrel 11 has been indexed from the first station 17 to the second station 18 another mandrel is available at the first station for receipt of a core 15.
What has just been described under the heading General Description is conventional. What the present in- 4 vention is concerned with a method and apparatus which is operative on the roll 16 and mandrel 11 after leaving the roll-forming station 21 to adhere the outer tail portion of a formed roll to an underlying convolution of the roll 16 before the roll or cant is removed from the mandrel.
Braking means As mentioned above, each mandrel is rapidly rotated about its own axis to wind a roll 16 at the roll-forming station 21. Immediately upon leaving station 21, the mandrel 11 and roll 16 are free wheeling and so they are still rapidly rotating. Because the present invention contemplates turning the mandrel 11 and its attached roll 16 in an unwinding direction before the mandrel reaches the roll-removing station 25, it is desirable to provide means to brake the free wheeling before such unwinding takes place. Referring to FIG. 3, a piston-actuated brake 26 is illustrated in phantom outline engaging a roll 16 immediately after the roll leaves roll-forming station 21 to brake the free wheeling of the roll (in a counterclockwise direction) about the rolls own longitudinal axis.
In further description of the braking means, and referring to FIGS. 2, 3 and 4, a pair of cylinders 27 and 28 each has one end pivotally connected to respective vertical support posts 29 and 30. A piston is reciprocably received in each cylinder, and each piston has a piston rod 31 and 32 respectively connected thereto, the piston rods extending from the cylinders. A common connector bar 33 extends generally in a horizontal direction, and the bar 33 is pivotally connected to the outer end of each of the piston rods 31 and 32. The upper surface of the connector bar 33 has a plate 34 connected thereto, such as by welding, and one side edge of the plate has ears 35 and 36 extending downwardly therefrom. The ears 35 and 36 are respectively pivotally connected to support posts 29 and 30 by pivot pins 37 and 38. A flat strip 39 of felt or other suitable flexible material is clamped to the upper surface of plate 34, and the strip 39 extends slightly past the free edge 40 of the plate. Inlets 41 and 42 at the base of each cylinder permit hydraulic or pneumatic fluid under pressure to be inserted to each cylinder. The braking means is so positioned that in the position of FIG. 2 and the solid line position of FIG. 3, the strip 39 is free of any engagement with the roll 16. When, however, fiuid is admitted to inlets 41 and 42, the piston rods 31 and 32 move outwardly of the cylinder to move the strip 39 into the path of travel of a formed roll 16 as the roll is advanced between the roll-forming station 21 and the roll-removing station 25 (phantom outline of FIG. 3). Such frictional engagement brakes the free wheeling movement of the formed roll.
Unwinding and winding means As regards further treatment of the formed roll 16 after it leaves the roll-forming station 21 and before the roll is removed from mandrel 11, an outer tail portion 43 at the end of the roll is first extended or unwound from the roll 16 to expose a surface portion 44 which is unexposed when the roll is completely wound. Adhesive is then. applied to the exposed portion along a line 45 extending generally parallel to the axis of the roll 16. Then, the tail 43 is rewound to sandwich the adhesive line 45 between the tail and an underlying convolution to adhere the tail to the roll.
A common belt 46 (FIG. 2) is utilized to enforce both unwinding and winding movement on the mandrel 11 and roll 16, movement of the belt 46 being derived from a reversible motor 47 so that the belt may be driven selectively in either of opposite directions. The belt is of the double-V type. In other words, the lower half 48 of the belts surface is generally V-shaped in cross section so that the belt may be engaged with suitable drive and supporting sheaves to advance the belt. The
upper half 49 of the belts surface has a generally inverted V-shaped cross section so that this upper belt surface may engage a drive sheave 50. Each mandrel 11 has a drive sheave 50 connected thereto so that movement of the belt 46 may be enforced on the mandrel 11 to turn the roll 16.
As is perhaps clearest at FIG. 2., the belt 46 is entrained about a belt drive sheave 51 which is secured to a drive shaft 52 which derives its motion from motor 47. A first vertical run 53 of the belt extends to a support sheave 54 which is supported for rotation from a main machine frame member. From sheave 54, the belt has a drive run 55 which extends in a direction from sheave 54 generally toward, but beneath, the roll-forming station 21 of the winding apparatus. It is along run 55 that the belt engages the sheave 50 on the mandrel. A sheave 56 which is supported on an arm 57 attached to main machine frame member 58 defines the opposite end of run 55 from sheave 54. The belt 46 extends around sheave 57 and returns along a lower run 5-9 generally parallel to run 55, thence around another guiding and supporting sheave 60 which is also supported for rotation from the machine frame. From sheave 60 the belt returns along run 61 to the motor sheave 61; however, in this latter run 61, an additional sheave 62 engages the belt 46 to assure that the belt remains in positive contact with the other sheaves in the drive system. The sheave 62 is mounted at one end of the arm 63, the other end of arm 63 being pivotally connected to main machine frame member 64. A tension spring 65 has one end connected to the arm 63, and the other end of the spring 65 is connected to a fixed, horizontally extending main support member 66. The :spring 65 therefore urges the arm 63 toward member 66 which urges belt run 61 away from run 53, and therefore assurance is gained that proper tension is maintained on the belt. The belt 46 may be made of leather, composition or any other suitable flexible material commonly used for drive belts.
So that the operations may take place in the shortest possible period of time, it is desirable that unwinding of the tail 43 from the roll 16 be initiated immediately after brake 26 has performed its function, and while the roll is being advanced between roll-forming station 21 and the roll-removing station 25. To accomplish this, the belt 46 should be in contact with sheave 50 on mandrel 11 along an extended distance of the top run 55 of the belt. Such extended engagement is assured by providing biasing means 67 which biases the run 55 of the belt upwardly. In preferred form, this biasing means includes a roller or sheave 68 which is supported at the free end of an arm 69, the opposite end of the arm 69 being pivotally connected to frame member 70. A tension spring 71 has one end connected to an ear 72 on arm 70, and the other end of the spring is connected to fixed frame member 73 (FIG. 4). The spring 71 therefore resiliently urges the sheave 68 in a counterclockwise direction (as viewed at FIG. 2) so that a resilient upward biasing force is exerted on the run 55 of belt 46, and the belt is thereby urged into engagement with a sheave 50 during the extended path. The belt is still in driving engagement with sheave 50 when the sheave reaches roll-removing station 25.
In order to aid in releasing and unwinding the tail portion 43 from the roll 16, a plurality of air nozzles 74 (FIG. 5) are mounted in a position to supply a generally tangential air blast to the surface of the roll, as the roll moves from station 21 to station 25. As is clearest at FIG. 3, this blast of air enters between the tail 4.3 and an underlying convolution, and tends to lift the tail from the roll.
As a further aid in extending the tail from the roll, antistatic means are preferably provided to remove static electricity which may have built up in the roll and the air surrounding the roll while the material is being wound.
The antistatic means simply comprises a grounded electrical conductor 75 which has exposed wires 76 extendling toward the roll in the path of travel of the rolls 16 between stations 21 and 25.
In preferred practice of the present invention, still further means, in the form of a vacuum box 77, is provided to aid in proper unwinding of the tail 43, and which also includes a detection device to accurately assure that a predetermined length tail extends from the roll when adhesive is applied. Such vacuum box and detection means will now be described in detail.
Vacuum box and length detection means The vacuum box 77 is firmly secured to the main machine framework and is positioned beneath the path of travel of the roll 16- between the roll-forming station 2 1 and the roll-removing station 25. The box includes opposed side walls 78 and 79, end walls 80 and 81 and bottom wall 82. The top of the box opens toward the path of travel of the roll 16 between the two stations 21 and 25 just mentioned; however, an inclined baflle plate 83 is positioned so as to extend across the greater portion of the top of the box. An edge 84 of the baffie together with side wall 79 defines a relatively narrow opening 85 leading from the top into the box 77 for admission of the tail portion 43 of the roll 16 as the roll is unwound. The baffle 83 permits pressure to be reduced to a greater degree in the box 77 than would be permitted without the baflle. A vacuum hose 86 is in communication with the bottom of the box 77 to permit air to be withdrawn from the box in aiding the proper unwinding of the tail. Side wall 78 of the box has a transparent window 87 therein, and side Wall 79 also has a window 88 directly across from win dow 87. A tubular light source 89 is positioned outside of side wall 78 immediately adjacent window 87 and so a light path 90 from the source 89 passes through window 87, across the interior of the box 77, and through window 88. A photoelectric cell 91 is positioned outside of side wall 79 immediately adjacent the window 88 so that the photoelectric cell 91 receives light from the source 89. It is the light source .89 and the photoelectric cell 91 that provide detection means for detecting when the tail 43 is at a predetermined length.
At FIG. 3, the tail 43- from roll 16 is illustrated as extending a predetermined distance from the roll. This has exposed a surface 44 of the web which is unexposed when the roll is completely wound, and this newly exposed surface 44 is adapted to receive adhesive along line 45 parallel to the longitudinal axis of the wound roll 16 so that the adhesive may be sandwiched between the tail and an underlying convolution when the tail is rewound on the roll. Before describing the manner of applying adhesive, however, it will be helpful to describe the manner in which the predetermined length tail extension 43 is accomplished. For this, reference should also be made to the schematic circuit diagram of FIG. 6. The condition of the circuit as exemplified at FIG. 6 may be just after a roll 16 has been completed at the roll-forming station, and the turret 13 has begun rotation to move mandrel 11 and formed roll 16 to the roll-forming station 25. It will be understood that a suitable rotary actuator (not shown) may begin one complete revolution just at the time the web 22 is cut and the roll 16 is formed at station 21, so as to automatically actuate various switches in its path of travel between 0 and 360 of movement of the actuator. By the time the actuator reaches 360, one cycle has been completed, and another roll 16 has been formed at station 21 ready to start another cycle.
Now, again assuming a roll 16 has just been formed and referring to FIG. 6, it is seen that switch 92 has tfirst been closed which establishes an electrical circuit across power lines 106 and 107 through a control 93 for withdrawing air from the vacuum box 77 so that reduced pressure is established in the box. This switch 92 may be closed, if desired, at all times when the winding machine is running. Now, for example, when the rotary actuator reaches a position of 2, the switch 94 will close to establish a circuit through a solenoid 95 which admits fluid pressure to cylinders 27 and 28 to operate the brake 26. The switch 94 may be opened at, for example, a position of the rotary actuator, and the roll 16 has by this time traversed a path of about one-half the distance between the station 21 and the station 25. Now, also, the upper run of belt 46 is in contact with mandrel sheave 50, and the sheave 50 is linked to the mandrel 11 so that rotation of the sheave also rotates the mandrel and the core 17 and roll 16 mounted on the mandrel. When the rotary actuator reaches a position of, say, 40, the switch 96 is closed and the switch 97 is opened because of a mechanical link 98 between switches 96 and 97. Now, a circuit can be traced through switch 96, through photocell relay switch 99 and through a starter 100 which starts the motor 47 moving in an unwinding direction (unwinding the tail 43 from the roll 16). A circuit also is completed through solenoid 101 which operates the air jet nozzles 74. Photocell relay 102 is, however, adapted to open switch 99 when the light path 90 is interrupted. Therefore, when the tail 43 interrupts the light path 90, the switch 99 opens to cut oif power to the motor 47 in the unwinding direction. Prior to power cut-off, however, the motor 47 will have had a chance to get up to speed and so there will be a slight over-shoot of the tail 43 past the position of FIG. 3. In other words, the tail 43 will be extended, at this point, a greater length than the predetermined length of FIG. 3. Also of the above has been accomplished while the roll 16 has been moving between stations 21 and 25. At this point, however, the roll 16 has arrived at station 25 (solid line position of FIG. 3). Now, the rotary actuator has moved to perhaps at which position switch 97 is automatically closed and switch 96 is opened. Another photocell relay 103 is of the type that will close switch 104 when the light path is interrupted, but will open the switch '104 when there is a path for the light. Because when the tail is extending greater than the predetermined distance the light path is blocked, the relay 103 closes switch 104 to establish a circuit through motor starter 105 which starts the motor 47 in a direction tending to wind the tail 43 onto the roll 16. This winding will only be for a very short distance, however, because as soon as the tail 43 clears the light path 90, the switch 104 opens to stop the motor 47. During this short travel, the motor 47 will not have developed a great inertia, and so the winding is stopped substantially instantaneously. The tail 43 will now extend the predetermined length from the roll 16 as seen in FIG. 3. Of course, separate photoelectric cells could be used for each of the relays 102 and 103. The circuit of FIG. 6 is simply to illustrate schematically an arrangement for obtaining a predetermined length tail. While tail 43 is halted at such a position, adhesive is applied to the exposed portion 44 of this roll along line 45 substantially parallel to the axis of the roll, and a preferred form of an adhesive applicator will now be described in detail.
Adhesive applicator The adhesive applicator comprises a glue gun 107 which is positioned on the opposite side of the roll 16 from the vacuum box 77 when the roll is at the rollremoving station 25. Actually, since adhesive is applied when the roll 16 is at station 25, the station 25 may also be said to be a tail-adhering station. It is to be understood that the tail is adhered to an underlying convolution at this station 25 before the roll 16 is removed from the mandrel 11.
The glueor adhesive-applying gun 107 includes a nozzle 108 which is directed toward the exterior surface of roll 16 so that when adhesive is forced under pressure from the nozzle as the gun is moved longitudinally of the roll, a head of adhesive will be applied along a line 45. The bead is preferably no more than about A; inch wide when applied. The exact type of adhesive is not important so long as it is of a consistency capable of being forced from the adhesive gun and forming an adhesive bead line on the roll 16. The tip of the nozzle is located about 1% inches from the surface of the roll. Further, the nozzle is preferably located in such a position relative to the free end of the tail that the adhesive bead will be no more than about A; inch from the end of the tail when the tail has been rewound.
One end of a flexible supply line 109 is attached in communication with the glue gun 107 through the medium of a suitable electrically controlled valve 110 which controls the flow of adhesive. The other end of the supply line 109 receives adhesive under pressure from a suitable adhesive container.
As mentioned above, the adhesive applicator is desirably movable longitudinally in a direction parallel to the axis of roll 16, and so the gun 107 is secured to a movable plate 111. A plurality of rollers, including two upper rollers 112 and two lower rollers 113 are rotatably supported from the plate. In order to support the adhesive applicator for such movement, an upper trackway 114 receives rollers 112, and a lower trackway 115 receives rollers 113 for movement therealong. In preferred practice, the lower trackway 115 is formed by cutting a groove in a longitudinally extending horizontal plate 116 which is Welded or otherwise secured to a main supporting frame member 117, and upper trackway 11-4 is formed by cutting a groove in another horizontal plate 118 which is also secured to member 117.
As is clearest at FIGS. 1 and 5, one end of a drive chain 119 is secured to the plate 111 near one edge thereof, and the other end of the chain 119 is secured to the opposite edge of the plate 111. The chain 119 is suitably entrained about a series of guide sprockets 120 and also around a drive sprocket (not shown) secured to the shaft of a reversible drive motor. The plate 111 and glue gun 107 can therefore be advanced along the trackways 114 and 115 in either of opposite directions depending on the direction of rotation of the drive motor shaft.
When the tail 43 is halted at the position of FIG. 3, the gun 107 is at one end of the roll 16. Now, the drive motor for the chain may be actuated and, at the same time, the valve 110 for the glue gun is opened to drive the glue gun 107 along the trackway and deposit adhesive on the exposed portion of the roll along line 45 substantially parallel to the longitudinal axis of the roll 16. If desired, the valve 110 may be intermittently actuated so the adhesive line 45 will be periodically interrupted. Once the adhesive line 45 has been applied, the glue gun 107 may be halted (such as by contacting a limit switch at the end of its path of travel), and the drive motor for the glue gun may then be reversed to return the gun to its starting position.
As soon as adhesive has been applied to the roll 16, the drive motor 47 for the belt 46 is again actuated to turn the roll 16 in a winding direction to wind the tail 43. After the tail is completely rewound on the roll 16, the adhesive line 45 is sandwiched between the tail 43 and an underlying convolution on the roll so that the tail 43 is adhered to the roll 16.
It is desirable that the glue line 45 be as close to the outer end 121 of the tail as possible. This is accomplished effectively by the present invention because the predetermined length of tail extension 43 as at FIG. 3 is just long enough to barely overlap the adhesive line 45 which has been applied by the adhesive applicator. As mentioned previously, it is preferable that the adhesive line be no more than /2 inch from the end of the tail. Vertical adjustability of the trackways 114 and 115 permits the position of the adhesive line 45 to be adjusted. Such adjustability is accomplished by providing vertical slots 121 (FIG. 1) in the ends of frame member 117. The frame member is secured to main vertical support posts 122 by bolts 123 which have shanks passing through slots 121. When the bolts 123 are loosened, the frame 117 may be adjusted vertically, as desired, and such vertical movement also changes the vertical position of the trackways 114 and 115 and adhesive applicator 107.
A brush 124 or strip of flexible material is inserted in a groove 125 adjacent the roll 16 at station 25 and the free end of the brush bears resiliently against the roll 16 to assure that the tail will be brought into full contact with the adhesive bead when the tail is rewound.
Once the tail has been rewound about the adhesive line 45, the roll 16, with the tail portion adhered thereto, may be removed from the mandrel 11 by suitable rollremoving means.
Roll-removing means In preferred form, the roll-removing means 126 comprises an endless fiat belt 127 having an upper run 128 which extends beneath and along the length of the formed roll 16 at the roll-removing station 25. This upper run 128 is spaced slightly from the exterior surface of the formed roll. The belt 127 is mounted for rotation about a plurality of guide and support rolls, three of such rolls 129 through 131 being illustrated in the drawing. It is to be understood that the belt will also extend about a motor-driven roll (not shown in the drawing) similar to the guide rolls so that the belt 127 may be moved as desired by the motor. One of the guide rolls 129 is adjustable horizontally so that the tension on the belt 127 may be adjusted. Such adjustability is accomplished by mounting one end of a supporting shaft 132 for support roll 129 in a plate 133 which is horizontally adjustable with respect to the main frame. The adjustability of the plate 133 is realized by providing horizontal slots 134 (see FIG. 1) in the plate. Bolts 135 extend through the slots 134 and are threadably received in apertures in a main frame plate 58 (FIG. 3). By loosening the bolts 135 the plate 133 can be moved to the left or right as desired and held in the adjusted position by retightening the bolts 135. The opposite end of the roll shaft 132 is, of course, also horizontally adjustable. In this regard, an aperture is formed through end 136 of the shaft 132 which accommodates a threaded rod 137 through the aperture (FIG. 1). The rod 137 extends between and is secured to vertical posts 138 and 139, which posts are, in turn, firmly fastened to rigid frame member 117. A nut 140 is threaded on the rod 137, and the nut 140 is adapted to engage end portion 136 of the shaft 132 to move the shaft along the rod 137 by rotating the nut 140.
The belt 127 includes a plurality of cleats 141 which extend a sufiicient distance from the upper surface of the belt so as to engage end 142 of a formed roll 16 (FIG. 1). The cleats 141 are spaced from each other a greater distance than the length of a formed roll 16. Once a roll 16 has been formed it is only necessary to rotate the belt 127 in a counterclockwise direction (as viewed at FIG. 1) to completely remove the roll from the mandrel, assuming, of course, that pins wedging the core to the mandrel have first been released. As soon as a cleat 141 contacts end 142 of the roll, the cleat carries the roll with it in a direction longitudinally of the mandrel 11 to remove the roll 16. The roll 16, once removed, is supported on belt 127 which may carry the roll to another station, such as a station where the roll is severed transversely into consumer-size rolls.
It wi l now be helpful to summarize the operational steps performed on the roll 16 between the time the roll is formed at roll-forming station 21 and the time the roll is removed by belt 127.
Summary of operation After a roll 16 has been wound at station 21 and severed from web 22, movement of the roll toward station 25 is begun. The roll is still free wheeling in a winding direction and so a brake 26 is applied to halt the roll. Then, while the roll is being moved by the turret 13 in an orbital path toward station 25, a sheave 50 on one end of mandrel 11 contacts the upper run 55 of drive belt 46. The belt 46 rotates the roll in an unwinding direction which, with the aid of an air blast from jets 74, carries the tail portion 43 of the roll 16 into vacuum box 77. The tail 43 is unwound to a length greater than a predetermined length, and then rewound to extend a predetermined length from the roll 16 in a manner set forth above. By this time, the roll 16 has arrived at station 25 with the tail halted and extending a predetermined distance into vacuum box 77 Then, an adhesive applicator is utilized to apply adhesive to an exposed portion of the roll along a line 45 substantially parallel to the longitudinal axis of the roll 16. After applying adhesive, rewinding of the tail 43 continues until the tail is completely rewound on the roll 16 with the adhesive line 45 being sandwiched between the tail and an underlying convolution. Then, the roll 16 is removed from the mandrel 11. By this time, another roll 16 has been formed at station 21, and the cycle is repeated.
While the foregoing specification has set forth an embodiment of the present invention in considerable detail for purposes of making a complete disclosure thereof, various other embodiments and modifications will occur to those skilled in the art, but Will fall within the spirit and scope of the invention defined in the following claims.
What is claimed is:
1. In an apparatus for winding a web of flexible material onto a core from a parent roll and adhering an outer tail portion of the wound web to an underlying convolution of the web, said apparatus including a plurality of mandrels each having a longitudinal axis extending substantially parallel to the other mandrels, the mandrels each being connected to a rotary turret for moving each mandrel sequentially in an orbital path from a core-receiving station through a rollforming station to a ro lremoving station, wherein the improvement comprises tail-handling and tail-adhering means operative sequentially on formed rolls after the rolls have been severed from the parent roll and before each roll is removed from a mandrel for adhering a tail portion of the wound roll to an adjacent underlying convolution, said tail-handling and tail-adhering means comprising:
(a) means for unwinding a tail portion from the formed roll while the roll is on the mandrel and after the formed roll has been severed from the parent roll to expose a portion of the web material surface which is unexposed when the roll is completely wound;
(b) an adhesive applicator located at a position along the path of travel of the mandrels adjacent the roll removing station for applying adhesive to said exposed surface along a line substantially parallel to the axis of the mandrel and formed roll after the tail has been unwound from the formed roll; and,
(c) means for rewinding the tail on the roll while the roll is on the mandrel to sandwich the adhesive line between the tail and an underlying convolution of the material.
2. Apparatus as set forth in claim 1 wherein each of said mandrels includes a sheave operatively connected thereto for enforcing rotation on an associated mandrel, and said winding means includes an endless drive belt positioned to drivingly engage each said sheave sequentially after each sheave leaves the roll-forming station, and means for driving said drive belt to rotate said mandrel and wound roll about their common axis.
3. The apparatus as set forth in claim 2 which further includes means for biasing the belt into engagement with the sheaves during an extended portion of the path of travel of the sheave between the roll-forming station and the roll-removing station.
4. The apparatus as set forth in claim 3 wherein said biasing means includes a pivotable roller, which is springbiased into contact with said endless drive belt.
5. The apparatus as set forth in claim 2 wherein said means for driving said belt is reversible to aid in unwinding the tail in one direction of movement of said drive means, and wind the tail in the other direction of movement of said drive means.
6. The apparatus as set forth in claim 1 which further includes a vacuum box located below the path of travel of the mandrels and positioned to receive the tail when the tail is unwound from the roll, and means for withdrawing air from said vacuum box to aid unwinding of the tail from the roll.
7. The apparatus as set forth in claim 6 which further includes detection means located in the path of movement of said tail into the vacuum box for detecting when the tail is at a predetermined length.
8. The apparatus as set forth in claim 1 which further includes a trackway for supporting the adhesive applicator for movement in a direction substantially parallel to the axis of the wound roll.
9. The apparatus as set forth in claim 8 wherein the trackway is located at a position adjacent the roll-removing station.
12 10. The apparatus as set forth in claim 1 which further includes brake means operative on the formed roll and positioned immediately beyond the roll-forming station to initially stop said roll prior to unwinding the tail therefrom.
References Cited UNITED STATES PATENTS CARL D. QUARFORTH, Primary Examiner 20 G. SOLYST, Assistant Examiner US. Cl. X.R.