Abstract:
The present invention provides for a method for rewinding a web material. The method comprises the steps of: (1) Disposing the web material on a winding spindle, the winding spindle being operatively associated with a winding turret; (2) Cooperatively engaging a contact roll with the winding spindle when the web material is disposed therebetween, the contact roll being operatively associated with the winding turret; and, (3) Adjusting the position of the contact roll upon said winding turret relative to the winding spindle as the web material is being disposed upon the winding spindle.

Description:
FIELD OF THE INVENTION 
     The present invention relates to a process for converting large rolls of wound web material into a finally wound product suitable for use by a consumer. 
     BACKGROUND OF THE INVENTION 
     Web winders are typically used to form large rolls of wound web material, such as paper and polymeric film materials, known as parent rolls. From the parent rolls, rewinders are employed in order to wind the web material into a rolled product. The rolled product is then cut at designated lengths into the finally wound product. The finally wound products typically created by the machines and processes are toilet tissue rolls, paper toweling rolls, paper rolls, polymeric films, and the like. 
     There are essentially two types of techniques known in the art for performing the step of rewinding; that is, winding a web material from a parent roll into a rolled product. The first technique used in winding the web material to form a rolled product is known as surface winding. In surface winding, the web material is wound onto the core via contact with belts and/or rotating rolls. A nip is typically formed between these two or more co-acting belt or roller systems. The belts or rollers of such systems typically travel in opposite directions at different speeds. The reason for having different speeds lies in the fact that the core that is being driven by the opposed belts or rollers will advance in the direction of the faster moving belt or roller. Usually, these belts or rollers are divergent so that the rolled product that is being built upon the core will have enough space to grow in diameter and will be able to maintain contact with the two diverging belts or rollers. Exemplary surface winders are disclosed in U.S. Pat. Nos. 3,630,462; 3,791,602; 4,541,583; 4,723,724; 4,828,195; 4,856,752; 4,909,452; 4,962,897; 5,104,155; 5,137,225; 5,226,611; 5,267,703; 5,285,979; 5,312,059; 5,368,252; 5,370,335; 5,402,960; 5,431,357; 5,505,405; 5,538,199; 5,542,622; 5,603,467; 5,769,352; 5,772,149; 5,779,180; 5,839,680; 5,845,867; 5,909,856; 5,979,818; 6,000,657; 6,056,229; 6,565,033; 6,595,458; 6,595,459; 6,648,266; 6,659,387; 6,698,681; 6,715,709; 6,729,572; 6,752,344; 6,752,345; and 6,866,220. The following international applications also provide exemplary surface winders: International Publication No. 01/16008 A1, 02/055420 A1, 03/074398 A2, 99/02439, 99/42393, and EPO Application No. 0514226 A1. 
     However, such winders can have drawbacks. First, a typical surface winder provides significant contact between the web material and the winding surfaces during winding. This contact during winding can effectively translate winding torque through the web material leading to crushing of embossments that may be disposed upon an embossed material, smudging images disposed upon a web material having an image disposed thereon, and the like. Also, surface winders are known to exhibit winding log instability during the winding of low density products. 
     The second technique used to wind a web material to form a rolled product is known as center winding. In center winding, a core is rotated in order to wind a web material into a roll around a core. Typically, the core is mounted on a mandrel that rotates at high speed at the beginning of a winding cycle and then slows down as the size of the rolled product being wound upon the core increases in diameter. Center winders work well when the web material that is being wound has a printed, textured, or slippery surface. Additionally, center winders can be useful in producing softer rolled products. Exemplary center winders are discussed in U.S. Pat. Nos. 1,040,188; 2,769,600; 3,697,010; 4,588,138; 5,497,959; 5,660,349; 5,725,176; and U.S. Patent Application No. 2002/0130212 A1. 
     However, center winders have drawbacks that are known to those of skill in the art. Known drawbacks include the need to provide a harder “pull” when rolling high density and low density web materials into a high density roll. This “pull” (tension) can provide for a Poisson lateral contraction of the web material resulting in a non-uniformly wound product. Additionally, the application of tension to a perforated web material can cause the web material to rupture at a perforation during processing. This can cause a processing line to shut down. 
     It is clear that the prior art lacks a winder or a rewinder capable of performing both center winding and surface winding in order to take advantage of the positive attributes that both processes enjoy. For example, it would be desirable to provide a winder that is capable of allowing a broader range of finished product roll densities. As would be appreciated by one of skill in the art, this capability, when coupled with known capabilities for imparting perforations at desired intervals and sheet counts in increments of one, can provide for a greatly enhanced product converting flexibility. This, in turn, can allow multiple finished product designs to be achieved using a common substrate. This is believed to provide substantial manufacturing expense savings by reducing change-overs on paper machines and converting lines, thereby avoiding multiple parent roll inventories and the like. Such a desired hybrid winding system can also provide the capability to wind thick, highly embossed web materials into preferred high density finished product rolls having low sheet tension. As would be appreciated by one of skill in the art, this can improve product quality by eliminating sheet elongation and embossment distortion, as well as improving winding reliability by providing fewer web material feed breaks in the winding process. 
     SUMMARY OF THE INVENTION 
     The present invention provides for a method for rewinding a web material. The method comprises the steps of: (1) Disposing the web material on a winding spindle, the winding spindle being operatively associated with a winding turret; (2) Cooperatively engaging a contact roll with the winding spindle when the web material is disposed therebetween, the contact roll being operatively associated with the winding turret; and, (3) Adjusting the position of the contact roll upon said winding turret relative to the winding spindle as the web material is being disposed upon the winding spindle. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a cross-sectional view of an exemplary web winding system and winder at about 0 machine degrees in accordance with the present invention; 
         FIG. 1A  is an expanded view of the region labeled  1 A in  FIG. 1 ; 
         FIG. 2  is a cross-sectional view of the exemplary web winding system and winder shown in  FIG. 1  at about 90 machine degrees; 
         FIG. 2A  is an expanded view of the region labeled  2 A in  FIG. 2 ; 
         FIG. 3  is a cross-sectional view of the exemplary web winding system and winder shown in  FIG. 1  at about 270 machine degrees; 
         FIG. 3A  is an expanded view of the region labeled  3 A in  FIG. 3 ; 
         FIG. 4  is a cross-sectional view of the exemplary web winding system and winder shown in  FIG. 1  at about 350 machine degrees; 
         FIG. 4A  is an expanded view of the region labeled  4 A in  FIG. 4 ; 
         FIG. 5  is a cross-sectional view of an alternative embodiment of the web winding system and winder at about 0 machine degrees; 
         FIG. 5A  is an expanded view of the region labeled  5 A in  FIG. 5 ; 
         FIG. 6  is a cross-sectional view of the exemplary web winding system and winder shown in  FIG. 5  at about 90 machine degrees; 
         FIG. 6A  is an expanded view of the region labeled  6 A in  FIG. 6 ; 
         FIG. 7  is a cross-sectional view of the exemplary web winding system and winder shown in  FIG. 5  at about 270 machine degrees; 
         FIG. 7A  is an expanded view of the region labeled  7 A in  FIG. 7 ; 
         FIG. 8  is a cross-sectional view of the exemplary web winding system and winder shown in  FIG. 5  at about 350 machines degrees; 
         FIG. 8A  is an expanded view of the region labeled  8 A in  FIG. 8 ; 
         FIG. 9  is a cross-sectional view of an alternative embodiment of the web winding system and winder; 
         FIG. 9A  is an expanded view of the region labeled  9 A in  FIG. 9 ; 
         FIG. 10  is a cross-sectional view of the exemplary web winding system and winder shown in  FIG. 9  at about 90 machine degrees; 
         FIG. 10A  is an expanded view of the regional labeled  10 A in  FIG. 10 ; 
         FIG. 11  is a cross-sectional view of the exemplary embodiment of the web winding system and winder shown in  FIG. 9  at about 270 machine degrees; 
         FIG. 11A  is an expanded view of the region labeled  11 A in  FIG. 11 ; 
         FIG. 12  is a cross-sectional view of the web winding system and winder shown in  FIG. 9  at about 350 machine degrees; and, 
         FIG. 12A  is an expanded view of the region labeled  12 A in  FIG. 12 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In the prior art, a winder or reel is typically known as a device that performs the very first wind of that web material generally forming what is known as a parent roll. A rewinder, on the other hand, is generally known as a device that winds the web material from the parent roll into a roll that is essentially the finished product. For purposes of the present application, the words “winder” and “rewinder” are interchangeable with one another in assessing the scope of the present claims. 
     The terms machine direction, cross-machine direction, and Z-direction are generally relative to the direction of travel of a web material or interleaved web segments. The machine direction (MD) is known to those of skill in the art as the direction of travel of the web material or interleaved web segment. The cross-machine direction (CD) is orthogonal and co-planar thereto. The Z-direction is orthogonal to both the machine and cross-machine directions. 
     Referring now to the drawings,  FIG. 1  shows an exemplary web winding system  15  incorporating the new winder  20  of the instant invention. An exemplary but non-limiting web winding system  15  provides for the processing of a web material or interleaved web segments (web material)  22  into a finally wound product  24 . The exemplary, but non-limiting, web winding system  15  can comprise a perforation roll  32 , a web slitter roll  34 , a bed roll  36 , and a chop-off roll  38 . The perforation roll  32 , web slitter roll  34 , bed roll  36 , and chop-off roll  38  are each provided with a longitudinal axis that is generally parallel to the CD of the web material  22 . Such placement can allow for the sequential and/or concurrent processing of web material  22  into a finally wound product  24 . 
     The perforation roll  32  preferably perforates web material  22  upstream of the winder  20 . The web slitter roll  34  can provide for the machine direction slitting of web material  22  into two or more portions. The resulting portions of slit web material  22  can then be processed separately or concurrently by either the same or a plurality of web processing systems as would be known to one of skill in the art. 
     In the exemplary web winding system, as web material  22  travels in direction T, the web material  22  is preferably routed around a portion of the circumference of a bed roll  36  and through a gap disposed between the bed roll  36  and chop-off roll  38 . In a preferred embodiment, the bed roll  36  and chop-off roll  38  are concurrently rotated. In a preferred embodiment, chop-off roll  38  is provided with a plurality of blades. Preferably, the bed roll  36  is provided with a plurality of blades that mesh with the blades disposed upon chop-off roll  38  in the gap disposed between bed roll  36  and chop-off roll  38 . In an exemplary but non-limiting embodiment, the web material  22  is constrained to a path defined by the blades disposed upon each of bed roll  36  and chop-off roll  38 . Applicants believe the web material  22  to be stretched by the relative blade movement and subsequent failure at a line of weakness disposed upon, or within, web material  22  by perforation roll  32 . 
     As would be known to one of skill in the art, after the web material fails at a line of weakness disposed upon, or within, web material  22  by perforation roll  32 , the downstream portion of the web material  22  proceeds through the converting process as the tail of the last separated portion of web material  22 . This web material portion is then wound into a roll forming finally wound product  24 . The upstream portion of the separated web material  22  provides for the leading edge of the web material  22  yet to be processed. 
     Referring again to the drawings,  FIGS. 1 and 1A  depict a cross-sectional view of an exemplary web winding system  15  and winder  20  in accordance with the present invention. The winder  20  is suitable for use in winding a web material  22  to produce the finally wound product  24 . The finally wound product  24  that may be produced by the winder  20  of the present invention can be any number of types of products, such as hand towels, toilet tissue, paper towels, polymeric films, trash bags, and the like. As such, web material  22  can comprise continuous web materials, discontinuous web materials comprising interleaved web segments, combinations thereof, and the like. Exemplary materials suitable for web material  22  of the present invention include, without limitation, metal foils, such as aluminum foil, wax paper, grease-proof paper, polymeric films, non-woven webs, fabrics, paper, combinations thereof, and the like. The web material  22  is depicted as being transported by the web winding system  15  and the winder  20  in the direction indicated by the arrow T. The web winding system  15  transports the web material  22  into contacting engagement with at least a pair of cooperative rollers  26 . Cooperative rollers  26  generally comprise a winding spindle  28  and a contact roll  30 , also disclosed herein as pressure roll  30 . 
     The web material  22  can be transported and/or assisted by the exemplary web winding system  15  into winding contact with at least one winding spindle  28 . In a preferred embodiment, a plurality of winding spindles  28  are disposed upon a winding turret  40  indexable about a center shaft, thereby defining winding turret axis of rotation  42 . The winding turret  40  is preferably indexable or movable about winding turret axis of rotation  42  through an endless series of index positions. For example, a first winding spindle  44  can be located in what may conveniently be called an initial transfer position, and a second winding spindle  46  can be located in what may conveniently be called a final wind position. In any regard, the winding turret  40  is indexable about winding turret axis of rotation  42  from a first index position to a second index position. Thus, the first winding spindle  44  is moved from the initial transfer position into the final wind position. Such indexable movement of the first winding spindle  44  disposed upon winding turret  40  about winding turret axis of rotation  42  may comprise a plurality of discrete, defined positions or a continuous, non-discrete sequence of positions. However, it should be appreciated that contact roll  30  can be brought into proximate contact with winding spindle  28  by any means known to one of skill in the art. Exemplary but non-limiting turrets suitable for use with the present invention (including “continuous motion” turrets) are disclosed in U.S. Pat. Nos. 5,660,350; 5,667,162; 5,690,297; 5,732,901; 5,810,282; 5,899,404; 5,913,490; 6,142,407; and 6,354,530. As will also be appreciated by one of skill in the art, the so-called “open-loop” turret systems would also be suitable for use as a support for the disposition and movement of winding spindles  28  used in accordance with the present invention. An exemplary, but non-limiting, “open-loop” turret system is disclosed in International Publication No. WO 03/074398. 
     If so desired by the practitioner, the contact roll  30  of the present invention may be provided with a relieved surface. In such an embodiment, the relieved portions can be provided as a pattern disposed upon or within the material comprising contact roll  30 . Such a pattern may be disposed upon or otherwise associated with contact roll  30  by laser engraving, mechanical implantation, polymeric curing, or the like. In an exemplary but non-limiting embodiment, such a pattern, relief, or otherwise may correspond to any indicia, embossments, topography pattern, adhesive, combinations thereof, and the like that are disposed upon or disposed within web material  22 . It is believed that such an exemplary pattern associated with a contact roll  30  may be registered with respect to any direction or directions of the web material  22 , particularly the machine and/or cross-machine directions of web material  22 . Such a pattern can be associated with a contact roll  30  and can be provided relative to any indicia, embossments, topography pattern, combinations thereof, or the like associated with web material  22  by any means known to one of skill in the art. Such an embodiment may be useful in preserving desirable features in the web material  22 , such as embossments, or may provide a desired contact force, such as for improved bonding force in discrete and/or desired areas of a two-ply or other multiple-ply product comprising adhesive for joining one ply to another. Similarly, the contact roll  30  can be provided with embossments and/or any other type of topographical pattern corresponding to the portions of a multi-ply type of web material  22  that may have an adhesive or other bonding formulation or structure disposed between the plies forming such a web material  22  structure. A contact roll  30  provided with such embossments and/or any other type of topographical disposed thereon can provide for better adhesion and/or bonding of the plies forming a multi-ply web material  22  by providing additional pressure to the regions sought to be so bonded as would be known to one of skill in the art. Without desiring to be bound by theory, it is believed that such increased bonding can be useful for the prevention of so-called “skinned” rolls when the plies of the multiple ply finally wound product  24  separate during dispensing by the consumer. This is known to those of skill in the art as an undesirable quality defect. 
     In a preferred embodiment of the present invention, the contact roll  30  is driven at a surface speed that corresponds to the speed of the incoming web material  22 . A positioning device (not shown), such as linear actuators, servo motors, cams, links, and the like, known by those of skill in the art as useful to provide such a result, can be provided for control of the position of the longitudinal axis of contact roll  30  relative to the longitudinal axis of a given winding spindle  28 . Such a positioning device (not shown) associated with a contact roll  30  is preferably capable of moving the contact roll  30  in any direction, including, but not limited to, the machine direction, the cross-machine direction, the Z-direction, or any combination thereof. In a preferred embodiment, the movement of contact roll  30  is generally parallel to the Z-direction relative to web material  22 , as the web material  22  is in contacting engagement with a winding spindle  28 . It is believed that in this way the position of the contact roll  30 , when combined with the known diameter growth of the log associated with first winding spindle  44 , can provide the required contact, clearance, and/or pressure between the contact roll and the log associated with first winding spindle  44  having web material  22  being disposed thereon. However, it should be realized that the contact roll  30  can be provided with movement with respect to any direction relative to its longitudinal axis in virtually any direction required to provide the required contact or clearance between the contact roll  30  and the log associated with first winding spindle  44 . Likewise, the contact roll  30  can have virtually any numbers of axes (i.e., at least one) associated thereto, as required, in order to provide the required contact or clearance between the contact roll  30  and the log associated with first winding spindle  44  as web material  22  passes therebetween. 
     If contact between the contact roll  30  through web material  22  to the log associated with first winding spindle  44  is desired, the position of a respective contact roll  30  along an exemplary axis A and/or B can be controlled to a known position in order to provide the desired contact or clearance between the respective contact roll  30  and the respective log associated with the first winding spindle  44  throughout the entire wind, if required. Maintaining a desired contact or clearance throughout the entire wind may be particularly advantageous when winding products having higher densities. Maintaining contact throughout the wind in such an instance is believed to facilitate compaction of all layers of web material  22  within the finally wound product  24 , thereby providing maximum potential density. Maintaining contact throughout the entire wind is also believed to provide product consistency when the web material  22  comprises a structure that is affected by contact force against the contact roll  30 . By way of example, embossed areas disposed upon a web material  22  may have a different appearance or thickness in a region contacted by the contact roll  30  compared to an area of contact roll  30  not so contacted. 
     Alternatively, the position of contact roll  30  can be positioned along any of exemplary axes A, B, or any other desired axes, respectively, in order to regulate the contact force between the contact roll  30  and the respective log associated with either of first or second winding spindles  44 ,  46 . By way of example, in order to provide a low density product roll design upon a finally wound product  24 , there may be minimal or even no contact between the respective contact roll  30  and the log associated with first winding spindle  44 . For medium density product roll designs in a finally wound product  24 , there may be moderate contact or force between the respective contact roll  30  and the log associated with first winding spindle  44 . For providing high density product roll designs in a finally wound product  24 , there may be relatively high contact or force between the respective contact roll  30  and the log associated with first winding spindle  44 . In any regard, it is preferred that the rotational speed of the winding spindles  28  be controlled in order to decelerate at a rate that maintains the same winding surface speed or desired speed differential as the diameter of the log associated with first winding spindle  44  increases. 
     Alternatively, the product density of a finally wound product  24  can be adjusted by adjusting the surface speed of the contact roll  30  and/or the surface speed of the respective log associated with first winding spindle  44 . Without desiring to be bound by theory, it is believed that providing such a speed differential between the surface speed of the contact roll  30  and/or the surface speed of the log associated with first winding spindle  44  can vary the tension present in the web material  22  forming finally wound product  24 . By way of non-limiting example, in order to provide a low density finally wound product  24 , there may be a minimal or even no speed differential between the surface speed of the contact roll  30  and/or the surface speed of the log associated with first winding spindle  44 . However, if a high density finally wound product  24  is desired, there may be relatively high speed differential or bias between the surface speed of the contact roll and/or the surface speed of the log associated with first winding spindle  44 . In any regard, the surface speeds of the contact roll  30  and/or the log associated with first winding spindle  44  can be controlled jointly or severally in order to provide a finally wound product  24  having the desired wind profile. 
     As shown in  FIG. 1 , the winder  20  preferably provides a turret  40  supporting a plurality of winding spindles  28  and contact roll  30 . The winding spindles  28  preferably engage a core (not shown) upon which the web material  22  is wound. The winding spindles  18  are preferably driven in a closed spindle path about the winding turret  40  axis of rotation  42 . Each winding spindle  28  extends along a winding spindle  28  axis generally parallel to the winding turret  40  axis of rotation  42  from a first winding spindle  28  and to a second winding spindle  28  end. The winding spindles  28  are preferably supported at their first ends by the winding turret  40  assembly. The winding spindles  18  are preferably releasably supported at their second ends by a mandrel cupping assembly (not shown). The winding turret  40  preferably supports at least two winding spindles  28 ; more preferably at least six winding spindles  28  and in one embodiment the turret assembly  42  supports at least eight winding spindles  28 . As would be known to one of skill in the art, a winding turret assembly  40  supporting at least eight winding spindles  28  can have a rotatably driven winding turret  40  that is rotated at a relatively low and preferably generally constant angular velocity to reduce vibration and inertial loads while providing increased throughput relative to indexing a winding turret  40  which is intermittently rotated at higher angular velocities. Exemplary winding turret assemblies suitable for use with the present invention are disclosed in U.S. Pat. Nos. 5,690,297 and 5,913,490. 
     A perforation roll  32 , anvil, or other non-contact perforation device known to those of skill in the art can be adapted to provide lines of perforations extending along the cross-machine direction of the web material  22 . Adjacent lines of perforations are preferably spaced apart at a predetermined distance along the length of the web material  22  to provide individual sheets of web material  22  that are joined together at the perforations. The sheet length of the individual sheets of web material  22  is the distance between adjacent lines of perforations. 
     Once the desired number of sheets of web material  22  has been wound onto a log associated with first winding spindle  44  in accordance with the present invention, a web separator  66  can be utilized in order to provide separation of adjacent sheets of perforated web material  22 . In the preferred embodiment, as discussed supra, the web separator  66  is provided as a rotary unit comprising a bed roll  36  and chop-off roll  38  that cooperatively engage web material  22  in a position intermediate to bed roll  36  and chop-off roll  38 . In such a preferred embodiment, the web separator  66  intermittently and/or periodically contactingly engages the web material  22  disposed therebetween. The elements comprising such a semi-continuous web separator  66 , either individually or collectively, can be provided with momentary periods of acceleration or deceleration. As such, the surfaces comprising the bed roll  36  and chop-off roll  38  preferably move along a circular path which has an axis coincident with the axis of rotation. Each element of the web separator  66  is almost tangent to, or makes a slight interference with, the surface of the opposing element of the web separator  66 . 
     Once the desired number of sheets of web material  22  have been wound onto the log associated with first winding spindle  44 , the web separator  66  is moved (i.e., preferably rotated) into a position which facilitates the formation of a nip between the opposing elements (i.e., the bed roll  36  and chop-off roll  38 ) associated with the web separator  66 . Such a nip may comprise the surfaces of the bed roll  36  and chop-off roll  38  having aforementioned blades as well as rollers, pressers, or pads cooperatively associated with the bed roll  36  and chop-off roll  38  associated with the web separator  66 . The movement of the bed roll  36  and chop-off roll  38  comprising the web separator  66  is preferably timed so that the web separator  66  nips the web material  22  disposed between the bed roll  36  and chop-off roll  38  when the perforation at the trailing end of the last desired sheet for the log associated with first winding spindle  44  is located between the bed roll  36  and chop-off roll  38  comprising the web separator  66 . 
     The web material  22  disposed upstream of the nip formed between the bed roll  36  and chop-off roll  38  comprising web separator  66  is then transferred to a new winding spindle  18  which has had an adhesive disposed thereon to form second winding spindle  46 . In a preferred embodiment, a core is disposed upon the new winding spindle  18  that forms second winding spindle  46  and is held securely thereto. The winding turret  40 , comprising the winding spindles  18 , moves the first winding spindle  44  to the finish wind position, either intermittently or continuously, and the winding cycle is repeated. After the wind has been completed, the finally wound product  24  is removed from the first winding spindle  44  disposed upon turret  40  and a new core is preferably disposed upon the now vacant winding spindle  18 . Adhesive can then be applied to the new core prior to the web material  22  transfer. The winding sequence is then repeated as required. 
     As described previously, a preferred embodiment of the present invention includes winding the web material  22  on hollow cores for easy roll mounting and dispensing by the consumer. Additionally, the winder  20  of the instant invention provides for adjustable sheet length capability in order to provide format flexibility and sheet count control in increments of one for such format flexibility. 
     Further, one of skill in the art could provide the winding spindles  18  and/or contact rolls  30  with a speed profile that can allow for an enhanced winding capability. Such enhanced winding capability may be useful or even preferable for low density substrates. Additionally, disposing web material  22  between the first winding spindle  44  and a corresponding and engaged contact roll  30  forming cooperative rollers  26  can provide for an adjustable contact position and/or force upon winding spindle  28  and the web material  22  at the periphery of the log associated with first winding spindle  44 . Providing first winding spindle  44  with an adjustable rotational speed can provide for the ability to apply a force at a point after the web material  22  is disposed upon first winding spindle  44 . This process can provide for a finally wound product  24  having the desired wind profile. 
     For example, finally wound product  24  may be produced as a web material  22  having a perforated sheet length of 250 mm, a 100-sheet count, a finished roll diameter of 130 mm, and be wound upon a core having an outer diameter of 40 mm. Using this information, the theoretical average radial thickness for each layer of web material  22  comprising finally wound product  24  can be calculated to be about 480 μm. In such an exemplary embodiment, the web material  22  may be provided with an initial (i.e., untensioned thickness of 750 μm as web material  22  enters the winding area of winder  20 . In order to provide for the above-described finally wound product  24 , if no contact exists between the log associated with a winding spindle  28  and the corresponding contact roll  30 , the web material  22  must be compressed from the initial thickness of 750 μm to the required theoretical target thickness of 480 μm by only the tension exerted by the winding spindle  28  speed on the incoming web material  22 . Without desiring to be bound by theory, the calculated tension required to decrease the thickness of web material  22  from an initial 750 μm thickness to the required 480 μm thickness is about 50 g per linear centimeter. However, one of skill in the art will appreciate that the web material  22  may separate uncontrollably at the perforations disposed within web material  22  when web material  22  is subject to such a tension (i.e., nominally greater than 350 g per linear centimeter). Such uncontrolled separations can produce an unacceptable finally wound product  24  and potentially result in line/production stoppages. 
     Additionally, the winder  20 , as disclosed supra, may be utilized to provide supplemental compression of the web material  22  being wound upon a winding spindle  28  to produce finally wound product  24 . For example, a contact roll  30  may be loaded against the log associated with the corresponding winding spindle  18  by moving the position of the contact roll  30  along exemplary axes A and/or B relative to a winding spindle  18  in order to achieve the desired finally wound product  24 . For example, a contact roll  30  may be loaded against a log disposed upon a corresponding winding spindle  28  with a force of 100 g per linear centimeter. By calculation, it is believed that such a force may decrease the thickness of the web material  22  from a thickness of 750 μm to a thickness of 500 μm. The calculated required winding tension to further decrease the thickness of web material  22  from a thickness of 500 μm to the required thickness of 480 μm may be provided with as little as 40 g per linear centimeter. This required tension level is well below the known and assumed perforation separation level of 350 g per linear centimeter, thereby allowing reliable production of the desired finally wound product  24 . 
     Additionally, one of skill in the art will understand that the winder  20  disclosed herein can provide contact with the log associated with the first winding spindle  34  throughout the entirety of a wind cycle. Thus, a finally wound product  24  can be provided with heretofore unrealized winding uniformity throughout the entire finally wound product  24 . Further, one of skill in the art will realize that providing winding spindles  28  in a turret system  40  moving in a closed path can provide for continuous winding and removal of finally wound product  24  without the need to interrupt the turret system  40  to load and unload winding spindles  28  or even the cores disposed upon winding spindles  28  from a moving turret system  40  mechanism. 
     PROCESS 
     As used herein, a “machine degree” is equivalent to 1/360 of a complete cycle. With regard to the winder  20  described herein, the 360 machine degrees is defined as a complete rewind cycle; that is, from a first identified index position (such as an initial transfer position or a final wind position) to the next identical and succeeding index position (such as the subsequent or second identical initial transfer position or the subsequent or second identical final wind position). 
     Referring to  FIGS. 1 and 1A , the winder  20  of the present invention is shown at about 0 machine degrees. The web material  22  disposed between first winding spindle  44 /contact roll  30  and third winding spindle  52  has been separated at an identified perforation by the web separator  66  comprising bed roll  36  and chop-off roll  38 . In a preferred embodiment, the bed roll  36  and chop-off roll  38  comprising the web separator  66  are surface speed matched with web material  22 . In such an embodiment, at least one of the bed roll  36  and chop-off roll  38  are provided with at least one blade that is interdigitating and/or nestably related with a corresponding depression, groove, and/or blade, retractable or otherwise, disposed upon the second of the bed roll  36  and chop-off roll  38  comprising the web separator  66 . It is believed that such interdigitating and/or nestable blade assemblies known by those of skill in the art can be adapted to provide such a surface speed matched web separator  66  assembly. By way of non-limiting example, the assemblies discussed in U.S. Pat. Nos. 4,919,351 and 5,335,869 can be adapted to provide such a surface speed matched web separator  66  assembly suitable for use with the present invention. 
     Concurrent with the separation of web material  22  at the identified perforation, the contact roll  30  is movable along an exemplary axis A, as well as a machine direction axis B. In a preferred embodiment, each winding spindle  18  is provided with a core having an adhesive disposed upon the surface thereof to facilitate attachment of the leading edge of the web material  22  to the respective winding spindle  28 . Further, the remaining web material  22  attached to winding spindle  28  forming old log  54  continues to be disposed thereon. It should be realized that contact roll  30  supporting web material  22  can be movable about one or a plurality of exemplary axis (shown as A and B) in order to provide for a desired pressure to be exerted upon new log  56  having web material  22  disposed thereon. It is in this manner that old log  54  and new log  56  can be provided with a desired wind profile during the entirety of the winding process. 
     It should be realized that the position and/or loading force of the contact roll  30  upon any winding spindle  18  can be adjusted such that contact roll  30  maintains the desired contact force or position relative to the winding spindle  18  at all points during the winding cycle. Additionally, the contact roll  30  is initially driven at a surface speed that corresponds to the speed of the incoming web material  22  and the surface speed of the first winding spindle  44 . In a non-limiting embodiment, positioning devices, such as linear actuators, can control the position of the contact roll  30 . In any regard, the position of the contact roll  30 , combined with the known diameter growth of the desired winding log, can determine the contact or clearance between the contact roll  30  and the winding log. If contact is desired, such contact may be controlled to a known position or interference or, alternatively, by regulating the contact force between the contact roll and each respective winding logs  52 ,  54 . By way of non-limiting example, if low density product roll designs are desired, there may be no contact between contact roll  30  and the respective winding logs  54 ,  56 . By further example, if medium density product roll designs are desired, there may be moderate contact or force between the contact roll  30  and the respective winding logs  54 ,  56 . Yet further, if high density product roll designs are desired, there may be relatively high contact or force provided between the contact roll  30  and the respective winding logs  54 ,  56 . 
     In any regard, it is preferred that the contact roll  30  provided herein contact the respective winding logs  54 ,  56  at a point other than the tangent point of the incoming web material  22 . In all cases, the rotational speed of the winding spindle  28  is controlled to decelerate at a rate that maintains the same winding surface speed or desired differential as the winding log diameter increases. It is believed that such profiled mandrel drive systems are well known to those of skill in the art. 
       FIG. 2  depicts the web winding system  15  and winder  20  of the present invention at about 90 machine degrees. As shown, as the new log  56  is indexed by the turret  40  from the initial transfer position to the end of wind position, the contact roll  30  is similarly indexed to maintain the desired contact or pressure with the new log  56 . Preferably, contact and/or pressure exerted upon the new log  56  by the contact roll  30  is maintained throughout the entirety of the winding cycle. However, as would be known to one of skill in the art and as discussed, supra, contact between the new log  56  and the contact roll  30  can be provided as required in accordance to produce a finally wound product  24  having the characteristics desired. For example, the contact position, pressure, and/or force may be controlled to any desired value from the beginning of the wind cycle to the end of the wind cycle as new log  56  progresses from the initial transfer position to the final wind position. As depicted, web material  22  is being disposed upon the winding spindle  18  to form new log  56  as new log  56  progresses from the first initial contact position to the final log winding position. Concurrent with new log  56  growth upon winding spindle  28 , the speed at which winding spindle  28  turns is preferably adjusted to maintain a matched surface speed of new log  56  with incoming web material  22  contacting or disposed upon first winding spindle  44 . Additionally, contact roll  30  can be provided with movement along axes A, B, or any other axes so desired in order to provide the desired contact or pressure upon new log  56  as the diameter of new log  56  increases radially due to deposition of web material  22  thereupon. Further, old log  54  can be removed from the turret  40  and a new core, if required, can be disposed upon the winding spindle  18  previously occupied by old log  54  forming finally wound product  24 . 
       FIGS. 3 and 3A  depict web winding system  15  and winder  20  of the present invention as would be seen at about 270 machine degrees. In this position, the new log  56  continues to display radial growth as web material  22  is rotationally disposed thereupon. It should be realized by one of skill in the art that turret  40  may or may not be indexed between 90 and 270 machine degrees. It is believed that the indexing of turret  40  may be accomplished by those of skill in the art on an as-required basis. Further, as required, the position of contact roll  30  can be adjusted along exemplary axis A, B, or any other axis so desired in order to provide the desired surface pressure upon new log  56  in order to provide for the desired wind profile. As new log  56  progresses orbitally about the turret axis of rotation  42  of turret  40 , old log  54 , having web material  22  disposed thereupon, can be prepared for removal or removed from the turret  40  as a finally wound product  24 . 
       FIGS. 4 and 4A  depict the web winding system  15  and winder  20  of the present invention at about 350 machine degrees. At this point, new log  56  is experiencing radial growth due to the continued deposition of web material  22  thereupon. In a preferred embodiment, the position of contact roll  30  can be adjusted along axes A, B, or any other axes so desired in order to provide the desired contact or pressure of the first contact roll  30  upon new log  56  in order to provide the desired wind profile as the web material  22  is disposed thereupon. However, in an alternative embodiment, the position of contact roll  30  is adjusted in order to provide contactable engagement of the contact roll  30  with the winding spindle  18  that will become second winding spindle  46 . This requires contact roll  30  to leave contacting engagement with first winding spindle  44  forming new log  56  and gain contacting engagement, or become proximate to, second winding spindle  46  forming a second new log (not shown). Additionally, the bed roll  36  and chop-off roll  38  forming the web separator  66  are each moved into a position relative to web material  22  in order to facilitate separation of web material  22  at the desired perforation, as described supra. 
       FIGS. 5 and 5A  depict an alternative embodiment of web winding system  15  and the winder  20 A of the present invention at approximately 0 machine degrees. Winder  20 A provides a turret  40  supporting a plurality of winding spindles  78  and two contact rolls  30 . At this point, first winding spindle  44  is beginning initial radial growth due to the deposition of the web material  22  thereupon. The position of the second contact roll  62  can be adjusted along axes A, B, or any other desired axes in order to provide the desired contact or pressure of the second contact roll  62  upon first winding spindle  44  in order to provide the desired wind profile as web material  22  is disposed thereon. Concurrently, first contact roll  60 , which is in contacting engagement with third winding spindle  52  forming old log  54 , loses contacting engagement with web material  22  disposed upon old log  54  after completion of a wind cycle. In any regard, first contact roll  60  and/or second contact roll  62  are positioned within the turret  40  adjacent to third winding spindle  52  and first winding spindle  44 , respectively, as they are used to apply a force or pressure to the respective winding spindle to control the diameter of the respective winding log. As shown in  FIGS. 5 and 5A , the two contact rolls  60 ,  62  are used to ensure that contact is maintained with each winding log throughout the entirety of the winding sequence. 
     In a preferred embodiment, the position and/or force applied by all contact rolls  30  upon the respective winding spindle  28  is preferably independently adjustable. The position of each contact roll  30  can be adjusted such that each contact roll  30  maintains the desired contact force or position relative to the respective winding log at all points during the winding cycle. To ensure a reliable web transfer to a new core, it is preferred that each contact roll  30  is initially driven at a surface speed that corresponds to the speed of the incoming web and the surface speed of the new core. Positioning devices, such as linear actuators and the like, can control the position of each contact roll  30 . The position of each contact roll  30  combined with the known diameter growth of the respective winding log can determine the contact or clearance between each of the respective contact rolls  30  and the respective winding logs. If contact is desired, such contact can be controlled to a known position or interference or, alternatively, by regulating the contact force between the respective contact roll  30  and the respective winding log. Due to their position (disposed upon turret  40 ), each respective contact roll  30  cannot contact the respective winding log at the point where the incoming web material  22  first contacts the winding log. In other words, the respective contact roll  30  contacts the associated winding log at a point downstream of the point at which the web material  12  first contacts that particular winding log. It is believed that the application of a compressive force upon the winding log by the respective contact roll  30  can still increase the density of the finally wound product  24  disposed upon winding spindle  18 . 
       FIGS. 6 and 6A  depict the web winding system  15  and winder  20 A of the instant invention at approximately 90 machine degrees. In this position, new log  56  is experiencing radial growth due to the continued deposition of web material  22  thereupon. The position of second contact roll  62  is adjusted along axes, C, D, or any other desired axes as required in order to provide the desired contact or pressure of the second contact roll  62  upon new log  56  being formed upon first winding spindle  44 . Concurrently, first contact roll  60  is no longer in contacting engagement with old log  54  and can be adjusted along axes A, B, or any other desired axes required in order to assume a location proximate to new log  56  being wound about first winding spindle  44 . 
       FIGS. 7 and 7A  depict the web winding system  15  and winder  20 A of the instant invention at approximately 270 machine degrees. In this position, new log  56  is experiencing final radial growth due to the continued deposition of web material  22  thereupon. The position of the second contact roll  62  is adjusted along any of axes A, B, or any other desired axes as required in order to provide the desired contact or pressure of second contact roll  62  upon new log  56  in order to provide the desired wind profile as web material  22  is disposed thereon. Concurrently, first contact roll  60  is positioned in contacting engagement with new log  56  by movement of first contact roll  60  along axes, A, B, or any other axes desired. Further, bed roll  36  and chop-off roll  38  forming the web separator  66  assembly are each rotated to a position proximate to web material  22  disposed intermediate therebetween in order to facilitate separation of web material  22  at the desired perforation as described, supra. 
     As shown in  FIGS. 8 and 8A , the web winding system  15  and winder  20 A of the instant invention is depicted at approximately 350 machine degrees. At this point, new log  56  is experiencing final radial growth due to continued deposition of the web material  22  thereupon. The position of first contact roll  60  is adjusted along axes A, B, or any other desired axes in order to provide the desired contact or pressure of the first contact roll  60  upon new log  56  in order to provide the desired wind profile as the web material  22  is disposed thereon. Concurrently, second contact roll  62  is moved proximate to second winding spindle  46  that will form second new log  58 . Second contact roll  62  can be moved along the axes C, D, or any other desired axes in order to provide the desired contact or pressure of the second contact roll upon second winding spindle  46 . Additionally, bed roll  36  and chop-off roll  38  forming the web separator  66  and any peripheral portions associated thereto are moved to a position proximate to or in contacting engagement with web material  22  in order to facilitate separation of web material  22  at the desired perforation as described, supra. As required, old log  54  comprising finally wound product  24  can be removed from turret assembly  40 . 
       FIGS. 9 and 9A  depict an alternative embodiment of a web winding system  15  and winder  20 B at approximately 0 machine degrees. In this embodiment, the turret  40  is provided with a plurality of winding spindles  28 , each having a contact roll  30  cooperatively associated thereto. Each contact roll  30  can be provided with an axis of movement directed along a radial axis disposed from the turret axis of rotation  42 . However, one of skill in the art will realize that each contact roll  30  can be provided with any desired axis of movement in order to provide the desired contact or pressure of the respective contact roll  30  upon associated spindle  28  forming the log that produces finally wound product  24 . In any regard, new log  56  is beginning radial growth due to the deposition of web material  22  thereupon. The position of second contact roll  62 A is adjusted along axis F in order to provide the desired contact or pressure of the second contact roll  62 A upon new log  56  in order to provide the desired wind profile as web material  22  is disposed thereon. Concurrently, third contact roll  64  can be moved to a location proximate to the winding spindle  28  cooperatively associated thereto along exemplary axis G. Likewise, first contact roll  60 A can be moved along exemplary axis E away from old log  54  in order to facilitate removal of old log  54  from the third winding spindle  52 . This can facilitate removal of old log  54  from turret  40  for final processing. 
       FIGS. 10 and 10A  depict the web winding system  15  and winder  20 B at approximately 90 machine degrees. At this point, new log  56  is continuing to experience radial growth due to the continued deposition of the web material  22  thereupon. The position of second contact roll  62 A is adjusted along exemplary axis F in order to provide the desired contact or pressure of the second contact roll  62 A upon new log  56  in order to provide the desired wind profile as web material  22  is disposed thereon. Concurrently, third contact roll  64  is moved along exemplary axis G in order to position third contact roll  64  in a position proximate the associated winding spindle  28 . Likewise, first contact roll  60 A can be moved along exemplary axis E away from old log  54  disposed upon third winding spindle  52  in order to facilitate removal of old log  54  from the turret  40 . 
       FIGS. 11 and 11A  depict the web winding system  15  and the winder  20 B of the present invention at approximately 270 machine degrees. At this point, new log  56  continues to experience radial growth due to the continued deposition of web material  22  thereupon. The position of second contact roll  62 A is adjusted along exemplary axis F in order to provide the desired contact or pressure of the second contact roll  62 A upon new log  56  in order to provide the desired wind profile as web material  22  is disposed thereon. Concurrently, third contact roll  64  is moved to a position proximate to a winding spindle  28  cooperatively associated thereto that will form a new log (not shown) upon the deposition of web material  22  thereupon. Additionally, first contact roll  60 A is moved along exemplary axis E away from old log  54  disposed upon third winding spindle  52  forming finally wound product  24 . Displacement of first contact roll  60 A away from third winding spindle  52  having old log  54  disposed thereon can facilitate removal of old log  54  from turret  40 . 
       FIGS. 12 and 12A  depict the web winding system  15  and the winder  20 B of the instant invention at approximately 350 machine degrees. In this position, new log  56  is experiencing final radial growth due to the continued deposition of web material  22  thereupon. The position of second contact roll  62 A is adjusted along exemplary axis F as required in order to provide the desired contact or pressure of second contact roll  62 A upon new log  56  in order to provide the desired wind profile as the web material  22  is disposed thereon. Concurrently, third contact roll  64  is positioned proximate to a winding spindle  28  cooperatively associated thereto that will form a second new log  58 . Further, the bed roll  36  and chop-off roll  38  forming the web separator  66  are each moved to a position proximate to web material  22  disposed intermediate therebetween in order to facilitate separation of web material  22  at the desired perforation as described, supra. In this regard, the movement of the bed roll  36  and chop-off roll  38  comprising the web separator  66  are timed such that they form a nip through which web material  22  passes and contact the web material  22  when the perforation at the trailing edge of the last desired sheet of web material  22  to be disposed upon first winding spindle  44  is located between the bed roll  36  and chop-off roll  38  comprising the web separator  66 . In other words, concurrent with the nip formation by the bed roll  36  and chop-off roll  38  comprising the web separator  66 , the material comprising web material  22  is provided with an elongate path which therefore causes the perforation located between the bed roll  36  and chop-off roll  38  to break resulting in the formation of the new log  56  having the desired number of sheets disposed thereon. The leading edge of the remaining web material  22  is then affixed to the respective winding spindle  28  that will form second new log  58 . 
     All documents cited in the Detailed Description of the Invention are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention. To the extent that any meaning or definition of a term in this written document conflicts with any meaning or definition of the term in a document incorporated by reference, the meaning or definition assigned to the term in this written document shall govern. 
     The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm”. 
     While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.