Abstract:
A container is reconfigurable between a shipping configuration in which a roll of material is enclosed therein and a dispensing configuration in which an access passageway is exposed. A free edge portion of the roll may be withdrawn through the passageway in the dispensing configuration. A container sidewall door portion is pivotally attached to the container body and pivots between an open position to expose the passageway in the dispensing configuration and a closed position in the shipping configuration to close off the passageway. The door portion enclosing the passageway is substantially horizontal in the open position and supported by at least one leg, whereby forming a worktable. The free end of the roll may be drawn across the worktable and scored at an appropriate location. The side wall portion and the support leg may be pivoted against the container in storage positions when the container is transported between field sites.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates generally to a container for shipping and dispensing rolled material and, specifically, to a conveyor belt field splicing dispensing container.  
         BACKGROUND OF THE INVENTION  
         [0002]    Conveyor belts are commonly used as a means to move material from one location to another. In large mining operations, the conveyor belt is generally formed of a rubber body embedded with steel cords or strands or textile reinforcement. A cover compound can be used at the surface wherein the material is to be conveyed. Generally the compound is abrasions and cut resistant and of sufficient thickness to prevent the rocks being conveyed from tearing the belt. A pulley compound can be used on the interior surface and is ideally suited for improved wear as the belt traverses over the pulleys used to drive the belt.  
           [0003]    The steel corded or stranded belts may extend several miles and cost millions of dollars to fabricate and install. The fabrication of such belts occurs initially at a factory wherein steel strands or cords are arranged in a coplanar relationship parallel to the surface of the belt so that the belt will exhibit uniform expansion and minimize weaving that can otherwise damage the belt as it traverses its designated route.  
           [0004]    The prior art method of fabricating belts requires the steps of vulcanizing the rubber belt and winding it onto large spools for shipping to the site. Once the spools of the belt are received at the site, the ends must be prepared for splicing by removing the vulcanized rubber from the strands over a distance determined to be sufficient to provide enough joint length to make a secure splice.  
           [0005]    Removal of the rubber can be a very time consuming and tedious task. Often time&#39;s piano wire is used to peel the vulcanized rubber from the strands. In large belts of several feet in width over a hundred strands must be exposed at each joint end. Once exposed, the strands had to be cleaned of as much of the vulcanized rubber as possible. Various alternative methods of splicing a conveyor belt have been proposed in order to expedite and simplify the process. U.S. Pat. No. 3,487,871 teaches a joining member having a plurality of strand receiving grooves. Such a method for effecting a splice, however, proved less than optimal because the number of grooves must equate with the number of strands in the belt. Since conveyor belts are of not standardized in width, a custom connector member must be used for each size belt.  
           [0006]    An improved method of effecting a splice between ends of a conveyor belt has been proposed comprising the steps: (a) removing a portion of the rubber from the belt ends to be joined exposing a plurality of strands; (b) providing at least two unvulcanized strips of rubber at least one strip being a bottom strip having a plurality of substantially parallel strand receiving grooves on an upper surface and the other strip being a top strip; (c) placing exposed strands of the belt ends being joined in the grooves of the bottom strip; (d) placing the top strip overlying the bottom strip and vulcanizing the strips together thereby forming the spliced joint. The strands may be at least partially sheathed in the vulcanized rubber.  
           [0007]    To utilize the foregoing method, a preform splice is used, consisting of a multiple (e.g. 21 inch) uncured insulation gum slabs each having longitudinal grooves formed on one side into which the splice cords are laid. The groove spacing and diameter are carefully controlled. The preform slab is fabricated into rolls that are shipped to an end user that removes the roll from shipping container. Once removed, the user unrolls a desired length of material and scores the material. The free end portion of material is then manipulated until breakage along the score line occurs. The remaining roll of the material is then stored until needed for the next splice.  
           [0008]    The quality of the resultant splice is influenced by a number of factors. First, the dimensional accuracy of the length of cut must be controlled for a high quality splice. Secondly, the dimensional and structural integrity of the roll must be protected and maintained. Damage to the roll can occur from handling during shipment, removal from its shipping container, during the cutting operation, or subsequent storage of the roll between repair occasions. Such damage to the roll can affect the structural integrity and performance the splice material removed therefrom and of the splice made therewith. A need, therefore, exists for an improved method for protecting the integrity of a roll of splice material from structural damage during its shipment to a field site, its use at the site, and in subsequent storage. The method should further accommodate convenient and accurate removal of desired lengths of splice material while protecting the material from damage. In addition, the method should facilitate easy and ergonomic transportation and dispensing of splice material from a roll source at a minimum cost.  
         SUMMARY OF THE INVENTION  
         [0009]    The present invention provides shipping and dispensing container for a roll of sheet material such as, but not limited to, a roll of material used in field splicing conveyor belt ends together. The container comprises a body reconfigurable between a shipping configuration in which the roll of material is enclosed and a dispensing configuration in which an access passageway is exposed. A free edge portion of the roll may be withdrawn through the passageway in the dispensing configuration. A container sidewall portion is pivotally attached to the container body and pivots to an open position to expose the passageway in the dispensing configuration and to a closed position in the shipping configuration to close off the passageway. Pursuant a further one aspect of the invention, the side wall portion enclosing the passageway is substantially horizontal in the open position and may be supported by at least one leg, whereby forming a worktable. The free end of the roll may be drawn across the worktable and scored at an appropriate location. The side wall portion and the support leg may be pivoted against the container in storage positions when the container is transported between fieldwork sites.  
           [0010]    According to another aspect of the invention, the roll of material may optionally be dispensed from the top within the container or inverted and dispensed from the bottom. Appropriate guide rollers are provided to direct the free edge portion of the roll to the passageway in either roll orientation.  
           [0011]    Yet another aspect of the invention is to provide means for regulating the speed at which the roll material is withdrawn from its roll. The roll is provided with a pivot shaft having protruding opposite ends resident within a respective slot channel in opposite side panels. The speed regulation means in one embodiment represents a cable disposed to exert controlled pressure upon the roll of material to reduce the rate at which the material is withdrawn.  
           [0012]    Pursuant to yet a further aspect of the invention, a method of shipping and dispensing a roll of sheet material is provided, comprising the steps: rotatably seating the roll of sheet material within a container body, the body including a plurality of side panels defining therebetween an internal chamber dimensioned to receive the roll of sheet material; configuring the container body to substantially enclose the roll of sheet material in a shipping orientation; providing an access passageway through the container body through which a free edge portion of the roll of material may be withdrawn, the access passageway being enclosed by a side panel portion pivotal between a closed position substantially covering the passageway and an open position substantially exposing the passageway. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]    The invention will be described by way of example and with reference to the accompanying drawings in which:  
         [0014]    [0014]FIG. 1 is an exploded perspective view of the subject container shown with the access door in the closed position;  
         [0015]    [0015]FIG. 2 is an exploded perspective view of a material roll and the subject container shown with the access door in the open, worktable orientation.  
         [0016]    [0016]FIG. 3 is a partially assembled perspective view thereof shown with the lid removed and in a dispensing configuration;  
         [0017]    [0017]FIG. 4 is a transverse section view through the center of the subject container;  
         [0018]    [0018]FIG. 5 is a longitudinal section view through the center of the container;  
         [0019]    [0019]FIG. 6 is a transverse section view of the container with the access door in a partially distended position.  
         [0020]    [0020]FIG. 7 is a longitudinal section view of the container with the free edge portion of the roll extended across the work surface provided by the access door. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0021]    Referring initially to FIGS. 1 and 2, the subject container for transporting and dispensing roll material is shown at  10 . The container  10  comprises an elongate quadrilateral body having end panels  12 ,  14  and side panels  16 ,  18  terminating at peripheral edges of a bottom floor panel  20 . A lid  22  is provided to enclose an internal compartment  23  of the container  10  defined by sides  12 ,  14 ,  16 ,  18 , and floor panel  20 .  
         [0022]    A reinforcement edge flange  24  is provided to extend upward from the floor panel  20  along each corner of the container  10 . Three elongate support flanges  26 ,  28 ,  30  are affixed to a lower surface of the floor panel  20  and extend across the container  10 . Reinforcement panels  31  are affixed to the container against outward surfaces of side panels  16 ,  18  and function to provide structural support to the box in carrying the intended load. Further adding reinforcement for lateral stiffness are edge reinforcement strips  32  along top edges of the side panel  16 ,  18 .  
         [0023]    Extending downward into the midsection of each side panel  16 ,  18  are elongate and relatively narrow guide slots  34 ,  36 , respectively. The slots  34 ,  36  each terminate at a lower slot end  38 . Mounted to the interior wall of each panel  16 ,  18  in a spaced apart semi-circular pattern are support rollers  40 ,  42 ,  44 ,  46 , and  48 . The rollers may be fixedly attached or, as preferable, rotatable. The rollers support the roll of splice material as will be explained below.  
         [0024]    A door panel  50  is pivotally coupled to the forward end panel  12  at hinge  52  and covers a generally rectangular through- passageway  54  that communicates with the interior compartment  23 . Mounted along opposite sides of the door panel  50  are support legs  56 . While preferably two support legs  56  are utilized, more or fewer legs may be employed if desired. The support legs  56  are elongate and hinge to upper corners of the door panel  50 . In the storage, or shipping configuration, represented in FIG. 1, the legs  56  collapse along the panel  50  and align with the vertical reinforcement edges strips  24  extending along opposite sides of the panel  12 . The door panel  50  pivots outward into generally a horizontal disposition as shown in FIGS.  2 - 7 , representing a dispensing configuration. Each leg  56  has an abutment shoulder flange  60  at a top end. In the dispensing configuration the legs  56  are pivoted downward, the abutment flange  60  of each leg abuts an underside of the support panel  50 . The legs  56  are thereby positioned to support the panel  50  on a work surface in a horizontal attitude. The panel  50  thus becomes a work table positioned adjacent to passageway  54  and passageway  54  provides an unobstructed access into the compartment  23   
         [0025]    The lid component  22 , as best seen from FIG. 1, is generally rectangular comprising a central panel  62  having peripheral reinforcement edge flanges  64  affixed to an upper surface. Extending transversely across an underside of the lid panel  62  are end reinforcement flanges  66 .  
         [0026]    As seen from FIGS.  2 - 7 , a material roll  68  is intended for residence within the internal compartment  23  of container  10 . While various types of rolled materials may be utilized in accordance with the invention, the invention has particular utility in the shipping and dispensing splice material for field splicing a conveyor belt. Such material  70  is wound around an, axial spool  72  through which an axial pivot shaft  74  extends. End portions of the spool  72  project outward a distance from edges of the material roll  70  and end portions  76 ,  78  of the pivot shaft  74  project outward a distance from the ends of the spool  72  as shown. The pivot shaft  74  may be eliminated by using another method of winding such as surface winding. The material  70  is formed of a non-vulcanized rubber compound and may have a liner formed from suitable material such as polycarbonate laminated to one or more surfaces. The material  70  is intended to splice together ends of a belt such as a conveyor belt having longitudinal cords disposed therein. Lengths of material are removed from the roll  70  as needed in the creation of a splice preform consisting of a wide (e.g. 21 inch) uncured insulation gum slab having longitudinal grooves formed on one side into which the splice cords are laid. In order to function as intended, it is important to maintain the structural and geometric integrity of the material roll  70  during shipment to and from a field work site, while dispensing material, and during subsequent storage between splice jobs. Fully wound, the spool and material roll weigh a substantial amount. Should such weight be brought to bear upon the material surrounding the spool in a misdirected manner, a tearing, folding, or collapse of the material sheet could result. Making a high quality splice from material so damaged would, accordingly, be rendered more difficult or impossible altogether.  
         [0027]    Referring to FIGS. 3, 4, and  5 , the material roll  68  is inserted into the internal compartment  23  of the container  10  with the lid  22  removed therefrom. The end portions  76 ,  78  are aligned with and enter into slots  34 ,  36  and proceed downward therein until the end portions of the spool  72  supportively engage the rollers  40 ,  42 ,  44 ,  46 , and  48 . The rollers cradle and support the spool  72  in a centered location within the compartment  23 . Screws  80  are provided extending through apertures  82  of the side panels  16 ,  18  and are used for shipping purposes for securing the roll of material during transit and are removed for dispensing.  
         [0028]    As will be noted, the roll  68  may be positioned within the compartment  23  upon rollers  40 ,  42 ,  44 ,  46 , and  48  in the upright position so that a free edge portion  84  of the roll can be withdrawn from the top and unrolled in a forward direction. Preferably, however, the roll  68  is positioned as shown in the inverted position such that the edge portion  84  is withdrawn from the bottom. A bottom feed reduces the extraction force required to rotate the roll when the roll is full because the weight of the spool and the full roll is not bearing upon the edge portion  84 . The free edge portion  84  may be drawn upward and fed through the passageway  54  whereby exiting the internal compartment  23 . With the door panel  50  in the upright, or closed position, the container assumes a transportation configuration in which the roll  68  is centered, supported, and enclosed within the compartment  23 . The material  70  is thereby protected from contact with surrounding structure and damage that may result therefrom during transit and storage. Bending, damage, or tearing of the material  70  that might otherwise occur is avoided and the quality of subsequent splices made from the material is not compromised.  
         [0029]    The door  50  is positioned in the table configuration shown in FIGS.  3 - 7  prior to withdrawal of the roll edge portion  84 . So positioned, the container assumes a dispensing configuration in which the edge portion  84  may be withdrawn threw the passageway  54  in a flat, undamaged condition and across the door panel  50  that is adjacent thereto. The door panel  50  protects and supports the free edge portion during the withdrawal procedure. As the edge portion is drawn over the door panel  50 , a straight edge  86  may be positioned transversely across the edge portion  84 , a cut is made through the material. A score line is made thereafter along the straight edge through the liner material. The edge portion  84  may thereafter be manually manipulated along the score line until a clean break results.  
         [0030]    As more splices are made and the roll  68  is diametrically reduced, the speed at which the material  70  is withdrawn may increase to an undesirable level. In order to place drag on the rotation of the roll  68 , speed regulation means in the preferred form of an elastomeric cable or band  88  may be utilized. The band  88  may be formed specifically for the application out of elastomeric material such as rubber or a commercially available band such as a “bunge” cord may be employed. The band  88  is attached as shown in FIG. 7 at end tie downs  90 ,  92  to the end panels  12 ,  14  a midsection  94  is drawn across the spool  72 . The force applied against the spool and the frictional drag resulting therefrom may be adjusted by an appropriate selection of band length. As the spool  72  rotates, the band  88  frictionally impedes rotation and slows the spool rotation to a desired level.  
         [0031]    After a field splice has been completed, the free edge portion  84  is placed inside the compartment  23  and the door panel  50  is pivoted from the horizontal, dispensing orientation into the closed position shown in FIG. 1. A latch (not shown) may be employed in conventional manner to releasable lock the door in the closed position. The roll of material may thereafter be safely transported to another work site or stored within the container fully protected from damaging contact with surrounding objects.  
         [0032]    From the foregoing, it will be appreciated that the subject container is economical to manufacture. The container may be formed from conventional materials such as wood, plastic, or metal by conventional means. The container further does not require a center shaft to support the roll of material therein, thereby reducing its weight and resultant cost of manufacture and shipping. Also, the container serves as both a shipping container and a dispensing container, fully protecting the roll during transit yet allowing for a protected withdrawal of material in the dispensing mode of operation. The door converts into a table surface as needed to support the material during the scoring and cutting operation. Maintaining the splice material in a flat, non-deformed condition assures that the grooves extending along the splice are maintained in a linear and uniform condition. The grooves thus are in condition to readily receive the belt cords therein and a high quality spice may be achieved. Finally, as discussed, the container functionally accommodates either an upright orientation of the roll therein for top withdrawal of material or an inverted orientation of the roll for a bottom feed of material.  
         [0033]    Variations in the present invention are possible in light of the description of it provided herein. While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the subject invention. It is; therefore, to be understood that changes can be made in the particular embodiments described which will be within the full intended scope of the invention as defined by the following appended claims.  
       TECHNICAL FIELD  
       [0034]    Variations in the present invention are possible in light of the description of it provided herein. While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the scope of the subject invention. It is, therefore, to be understood that changes can be made in the particular embodiments described which will be within the full intended scope of the invention as defined by the following appended claims.