Fabric rewind system

The invention is an improved system for rewinding fabric, particularly such fabrics which are more or less impervious and tend to entrap air between successive layers of the fabric being wrapped upon a core means as the rewinding proceeds. The system may be operated in a horizontal rolling mode or in a vertical rolling mode. When operating in the horizontal mode the system utilizes the weight of the supply roll to directly maintain more or less air-free layers, alternatively a minimum mechanical pressure is maintained at the supply roll in the horizontal mode as the weight of the supply roll diminishes near the end of the supply. When operating in the vertical mode, the pressure means is reversed, utilizing a constant mechanical pressure of the roll, or rolls, being wrapped against the supply roll as the rewinding proceeds. This direct pressure system to maintain more or less air-free layers eliminates the tedious and time-consuming threading of the fabric over and under a complicated system of a plurality of idler rolls, drive roll, rider roll, and a core.

BACKGROUND AND SUMMARY OF THE INVENTION 
The invention relates to fabric winding equipment and systems, and 
particularly to fabric rewinding equipment and systems. Specifically, the 
invention relates to fabric rewinding systems that have a tendency to 
entrap air between successive layers of the fabric being wrapped upon a 
core means as the rewinding proceeds. 
The entrapped air enlarges the size of the roll, requiring larger packing 
or packaging means, and ultimately greater bulk in storage. The entrapped 
air makes the roll spongy which hinders some types of applications and 
makes the subsequent use difficult. The entrapped air is particularly 
undesirable in rolls of fabric such a stretch-type film or plastics types 
of film. The present invention eliminates these problems. 
In the prior art, fabric being rewound from a supply roll is tediously 
threaded through and around a maze of a plurality of idler rolls, drive 
roll, rider roll, and a core. This is a time-consuming process of 
threading the fabric over and under the complicated system of the rolls. 
The present invention eliminates these problems. 
In the present invention there are essentially only two rolls, the supply 
roll and the core on which the fabric is being rewound. There isn't any 
complicated and time-consuming threading of the fabric through a maze of 
roll means as in the prior art. The set-up time is rapid and simple. 
The system of the present invention may be operated in a horizontal mode or 
in a vertical mode. In the horizontal mode the horizontal supply roll is 
arranged so as to rise a short distance from the core position while the 
core is set into place, thereafter, as the core begins to rewind fabric 
from the supply roll the supply roll is lowered and rests on the rewinding 
roll as it turns. The system may be arranged for either the supply roll or 
the rewind roll to be powered. 
The system as shown in the drawings provides for the core roll being 
powered and thus pulling, withdrawing, or in effect peeling, the fabric 
from the supply roll. The weight of the supply roll rolling upon the roll 
being wound upon the core, squeezes the air from the continuous 
spiral-like layer being played on to the core. A very tight and compact 
roll results without the mass of air between the spiral like layers. 
One example is to rewind a roll of 6000 feet in length on to four smaller 
rolls of 1500 feet each in length. As a measuring device rolling on the 
surface of the fabric being peeled off stops the machine at each 1500 
feet, the operator removes the rewound core and inserts another blank 
core. It is a very quick operation to draw the fabric around the new core 
means in a first wrap and restart the rewind process. It is to be 
understood that any length of a supply of fabric can be rerolled upon a 
rewind roll. 
It is to be noted that the process is also applicable to supply rolls that 
are being slit and the slit units wrapped upon separate core means. 
One problem arises as the horizontal supply roll diminishes, the weight of 
the supply roll reduces as the roll diminishes so that as the last portion 
is peeled off for the last rewinding roll, the weight is such that the 
rewound roll may not be as tight, with some chance of some air entrapment 
between some of the spiral-like layers. To overcome this, a pre-load 
pressure means is added to the shaft means of the supply roll to maintain 
a minimum load upon the rewinding roll, even though the static load of the 
supply roll is steadily diminishing. 
In the vertical mode the vertical supply roll exerts no pressure upon the 
roll or rolls being rewound from the supply. It is to be noted when a 
large supply roll is to be slit into several shorter rolls, the vertical 
mode has advantages, in that the plurality of shorter rolls can be spaced 
around the periphery of the suppy roll. This peripheral spacing makes it 
convenient for servicing each roll being rewound from the supply roll. 
In the vertical mode, as noted hereinbefore, the supply roll exerts no 
pressure upon the roll or rolls to be rewound to keep the air squeezed out 
from between the spiral-like layers. Instead, in the vertical mode, each 
of the rewind rolls is pre-loaded to maintain a constant contact pressure 
with the supply roll so that the air is constantly squeezed out from under 
the layer of fabric being wound at the moment upon each of the rewind 
rolls. 
The fabric rewind system of the present invention is applicable to a wide 
range of fabrics, including those of cloth, paper products, plastics 
materials, and particularly those such as plastics stretch film. The 
system is particularly useful for rewinding impervious type fabrics under 
which air may be trapped. It is to be noted that the terms "fabric" and 
"web" may be used interchangibly. 
It is, therefore, an object of the invention to provide a fabric rewind 
system capable of rewinding all types of fabric. 
It is also an object of the invention to provide a fabric rewind system 
that will rewind plastics and other types of impervious fabrics, including 
such fabrics as plastics stretch film. 
It is a further object of the invention to provide a fabric rewind system 
that will operate in a horizontal mode and in a vertical mode. 
It is another object of the invention to provide a fabric rewind system 
that continually squeezes any entrapped air from between succeeding 
spiral-like layers of fabric being rewound. 
It is still another object of the invention to provide a fabric rewind 
system that eliminates the need for one or a plurality of idler rolls 
between the supply roll and the rewind roll. 
It is yet another object of the invention to provide a fabric rewind system 
that rewinds directly from the supply roll to the rewind roll. 
It is yet still another object of the invention to provide a fabric rewind 
system that utilizes the weight of the supply roll to squeeze entrapped 
air continually from between succeeding spiral-like layers of fabric being 
rewound in a horizontal mode. 
It is also another object of the invention to provide a fabric rewind 
system that uses a rewind pressure means to squeeze entrapped air 
continually from between succeeding spiral-like layers of fabric being 
rewound in a vertical mode. 
Further objects and advantages of the invention will become more apparent 
in the light of the following description of the preferred embodiments.

DESCRIPTION OF THE PREFERRED EMBODIMENTS 
Referring to the drawings: a typical fabric rewind system of the prior art 
is shown at 10 in FIG. 1; a first embodiment of the present invention of 
an improved fabric rewind system is shown at 50 in FIGS. 2 and 3; a second 
embodiment of the present invention is shown at 65 in FIG. 4; and a third 
embodiment of the present invention is shown at 70 in FIGS. 5 and 6. 
Referring again to FIG. 1 to discuss the typical fabric rewind system of 
the prior art 10, the complexity of the maze of rolls and the threading of 
the fabric through them is readily apparent. 
The fabric of the supply roll 12 of fabric on core means 14 is threaded 
through the complicated plurality of rolls: first by leading the fabric 16 
under a first idler roll 18; then over a second idler roll 20; then past a 
slitter means 22, if the fabric is to be slit into two or more portions, 
thereafter the fabric 16 would move forward as a plurality of fabric 
sheets 24; next the plurality of fabric sheets 24 pass over a rubberized 
or similar type drive roll 26; then under a third idler roll 28, at which 
point the several sheets 24 (two are illustrated) would be directed to 
separate rewinding rolls as described hereinafter; fabric sheet 24A passes 
over a rider roll 34, the rider roll 34 revolving on a carrier arm means 
36 which pivots about a fixed point 38; the fabric sheet 24A is then 
rewound upon a core means 32 to form the first rewound roll 30; the fabric 
sheet 24B follows a movement similar to fabric sheet 24A, first passing 
over a rider roll 44, the rider roll 44 revolving on a carrier arm means 
46 which pivots about a fixed point 48, the fabric sheet 24B is then 
rewound upon a core means 42 to form a second rewound roll 40. 
The direction of the turning of the various rolls (supply, idler, drive, 
rider, and rewind) in FIG. 1 is indicated by the arrows at each roll. It 
is to be noted that the fabric rewind systems of the prior art are 
essentially of a horizontal mode. 
It is to be noted that if a supply roll 12 were merely being rewound as a 
plurality of smaller capacity rolls, without slitting, the aforementioned 
references to fabric sheet 24B and the associated rolls leading to the 
rewound roll 40 would be eliminated. 
The rider roll 34, and the rider roll 44, serve to squeeze the air out from 
between the successive layers of fabric that are laid in a spiral-like 
fashion to form the rewound rolls of fabric 30 and 40 respectively. 
The complicated maze of rolls and the need for tedious threading of the 
fabric around the plurality of rolls in the prior art is obvious. The 
present invention eliminates these problems. 
Turning now to FIGS. 2 and 3, the first embodiment of an improved fabric 
rewind system 50 is illustrated. In FIG. 2 the supply roll 52 of fabric on 
a core means 54 is at a standstill and is shown raised from contact with 
core means 56, upon which fabric 58 is to be rewound into smaller rolls. 
The direction that the supply roll 52 and the rewind roll or core means 56 
turn may be reversed but only one direction is shown by dashline arrows in 
this illustration. The raised position of the supply roll 52 permits a new 
core means 56 to be inserted in the rewind machine, easily, and provides 
space to start the next wrap of fabric 58 around the core means 56. 
In FIG. 3 the aforementioned supply roll 52 is shown in operation and 
rewinding the fabric upon core means 56 to form the rewind roll 60 of the 
fabric. The direction of turning of the rolls is shown by the arrows. The 
direction of turning is shown in all views for all embodiments by similar 
directional arrows. It is to be noted that these directions of turning 
could be reversed. 
The supply roll 52 rides directly upon the fabric as it peels off of supply 
roll 52 and rewinds directly upon the rewinding roll 60 on core 56. This 
action of the supply roll 52 riding directly upon the fabric at the 
interface, where it is being rewound to form the rewound roll 60, squeezes 
the air out from between the succeeding layers of fabric to form a firm 
and tight roll without entrapped air between the successive layers of the 
spiral-like winding. 
Thus, the first embodiment of the improved fabric rewind system is a 
distinct improvement over the prior art. There isn't any plurality of a 
complicated maze of rolls and no threading of the fabric is necessary. A 
tremendous amount of time is saved in set up and in starting the next 
succeeding roll of fabric. As described, the first embodiment of an 
improved fabric rewind system 50 is in a horizontal mode. 
Depending upon the size of roll being rewound and the dead weight of the 
mandrel or shaft means in the core means 54 and the core means 54 itself, 
the last rewound roll 60 from the supply roll 52 may be somewhat loose in 
comparison to the tight and compact prior rewound rolls 60 that were first 
taken from the supply roll 52. Although this slightly loose last roll is 
still satisfactory for use, the slightly larger diameter may interfere 
with the ease of packing. To cause all rewound rolls 60 to be of the same 
tight and compact consistency and of substantially the same size, a second 
embodiment of the improved fabric rewind means is provided. 
It is to be noted that the core means 56 is carried and supported by a 
combined powered head stock means and a dead tail stock means 57. The core 
means 56 is directly under the core means 54 in a vertical plane, so that 
the supply roll 52 rests directly on the rewind roll 60 during operation. 
It is to be noted that the desirability of tight and compact rolls of 
rewound fabric are desirable to reduce bulk for packing and storage. In 
addition, the tight and compact rolls of rewound fabric without the 
entrapped air between the succeeding spiral-like layers of fabric are most 
desirable to assure an ease of use. The fabric without entrapped air will 
peel off easier, better, and in a more firm and positive manner for the 
succeeding use. It is most desirable to produce these tight and compact 
rolls without the time consuming and tedious task of doing the rewinding 
by the typical prior art method and system of a maze of a plurality of 
rolls. 
It is to be noted and understood that the power may be applied to the 
supply roll 52 core means 54 instead of to the core means 56. Such a 
variation is within the scope and intent of this invention. 
Turning now to FIG. 4 to discuss the second embodiment of an improved 
fabric rewind system 65 of this invention, it is to be noted that the 
arrangement is essentially the same as for the first embodiment of an 
improved fabric rewind system 50. The second embodiment of an improved 
fabric rewind system 65 is also in a horizontal mode like the first 
embodiment. 
The difference between the first and second embodiment of an improved 
fabric rewind system 50 and 65, respectively, is that in the second 
embodiment a minimum downward constant pressure is maintained on the 
journal ends of the mandrel or shaft means 66 through the core means 54 of 
the supply roll 52 of fabric to be rewound. This is achieved by a downward 
pressure structural means 67 bearing upon the journal ends of the mandrel 
or shaft means 66 through the core means 54 of the supply roll 52 of 
fabric that is to be rewound. 
It is to be noted that this downward pressure structural means 67 may be 
achieved by several methods: by a direct pre-loaded means 68 bearing down 
directly upon the journal ends of the said mandrel or shaft means 66; by 
an upward pressure 61 upon a rear cantilever end of the suspension means 
62 for the supply roll, thus forcing the supply roll downward; or by 
downward pull means 63 on a forward cantilever end of the suspension means 
62 for the supply roll. Further, the downward pressure means 68 could be 
solid, granular, liquid, or any such means to provide instant increase as 
the supply roll diminishes. The means 61 and 63 could be air, springs, 
hydraulic, rubber, or any such means to provide instant increase as the 
supply roll diminishes. 
The minimum downward constant pressure that is to be maintained is that 
amount that is required to overcome the diminishing weight of the supply 
roll 52 as it nears the end of the fabric upon it. It is desirable that 
the downward pressure come into action, or be applied as a constant, so 
that the last roll 60 will not be of a loose type of wrap, but will 
maintain the tight and compact wrap of the initial rewound rolls 60. 
The downward pressure structural means 67 may be of an adjustable 
pre-loaded type so that by experiment the amount of downward pressure 
required on the journal ends of the mandrel or shaft means 66 can be 
refined to the amount needed but would not be excessive. The variation of 
the aforementioned downward pressure means should be noted. 
The combination of the suspension means 62, the head and tail stock means 
57, along with a base 64 and support 69 form a frame means for the system. 
Turning now to the third embodiment of a fabric rewind system 70 shown in 
FIGS. 5 and 6, it is to be noted that the third embodiment is operated in 
a vertical mode. Essentially the horizontal and vertical modes are alike 
in operation and structure, and produce substantially the same results. 
The vertical mode provides a simpler means for loading the core means and 
controlling the pressure that expels the entrapped air from between 
succeeding spiral-like layers of fabric. The vertical mode maintains all 
rewinding core means, and the rewinding rolls upon them, in the same 
relative location to the surface of the supply roll of fabric being 
rewound, when a slitting operation is involved, or for a single rewind 
roll when a slitting operation is not involved. 
FIG. 5 is a top view of the vertical mode and FIG. 6 is a side view of FIG. 
5. In the third embodiment of a fabric rewind system 70, a supply roll 72 
of fabric to be rewound, or to be slit and rewound, is on a core means 74 
and it revolves about the center of the core means 74 in the direction of 
the arrow in FIG. 5. 
Three rewinding rolls 78, 86, and 92 are shown equally spaced around the 
supply roll 72. It is to be understood that any plurality of rewinding 
rolls about the vertical supply roll 72 is within the scope and intent of 
this invention. In a simple rewind operation, without slitting, only one 
rewinding roll would be involved. It is also to be noted that the 
direction of rotation could be reversed and still be within the intent and 
scope of this invention. 
The rewinding rolls 78, 86, and 92 are being rewound on core means 80, 88, 
and 94 respectively. In order to maintain an equal and constant pressure 
between the rewinding rolls 78, 86, and 92 and the supply roll 72, so that 
entrapped air is squeezed out from between the succeeding spiral-like 
layers of fabric being rewound, an inward pressure structure means 82, 90, 
and 96 is imposed upon the journal ends of the combined head and tail 
stock means 98, 100, and 102, respectively, that are inserted into the 
core means 80, 88, and 94, respectively. The application of the inward 
pressure through inward pressure structure means 82, 90, and 96 is 
comparable and similar to the downward pressure structural means 67 in 
action and in configuration, including the frame means. 
Thus, the same pressure relationship exists in the third embodiment of an 
improved fabric rewind system 70, as aforementioned for the first and 
second embodiments 50 and 65, in order to squeeze out the entrapped air 
between successive spiral-like layers of fabric being rewound. 
The vertical mode shown for the third embodiment 70 is shown with slitter 
means 76 and 84 suitably mounted near rewind rolls 78 and 86, 
respectively. The slitter means 76 makes the first cut or slit as the 
revolving rewind roll 78 peels off the fabric from the supply roll 72 and 
the slit or cut-off portion is rewound around core means 80 to form rewind 
roll 78. The slitter means 76 and 84 may be rotary or blade type slitters. 
Rotary type slitters are shown in the drawings. 
As the supply roll 72 continues to turn the second slitter means 84 cuts or 
slits the next portion that is rewound around core means 88 to form rewind 
roll 86. 
As the supply roll 72 continues to turn the remaining portion of the fabric 
is rewound around core means 94 to form rewind roll 92. 
It is to be understood that the spaced slitter means 76 and 84 may both be 
located along the same common vertical centerline instead spaced from each 
other as aforementioned. In this latter case, some slit portions would 
travel further before being rewound. 
It is to be noted and understood that the third embodiment 70 can be 
operated to rewind a single rewind roll (without slitters) as shown for 
the first and second embodiments 50 and 65, respectively. It is also to be 
noted and understood that the first and second embodiments 50 and 65, 
respectively, can also be structured with slitter means and corresponding 
rewinding means as shown for the third embodiment 70. The slitter means 76 
and 84 may be adjusted to cut through a single layer or a plurality of 
layers of fabric. 
It is to be noted that in the present invention the rewinding rolls 60, 78, 
86, and 92 are the powered rolls and these rolls peel the fabric off of 
the supply rolls 52 and 72 as the case may be. 
However, as noted hereinbefore, the power may be applied to the supply 
rolls 52 or 72, which in turn, revolve the rewinding rolls 60 or 78, 86, 
and 92 respectively by the interface pressured contact therebetween. 
It is to be noted and understood that the downward pressure structure means 
67 and the inward pressure structural means 82, 90, and 96 may be 
preloaded by mechanical spring means, hydraulic means, air pressure means 
or by other similar means. 
It is to be noted and understood that the mounting centers for the supply 
rolls 52 and 72 and the head and tail stock combinations 57, 98, 100, and 
102 are all adjustable in order to accept and hold a plurality of lengths 
of rewind cores 56, 80, 88, and 94. Thus, the centers of a single head and 
tail stock combination 57, 98, 100, or 102 can be adjusted for a core 
length for a simple rewind requirement from a supply roll 52 or 72 
respectively. Or, the centers can be adjusted as needed for the plurality 
of rewind rolls that will be required from supply rolls 52 and 72 that are 
to be slit and rewound. 
It is to be noted and understood that it is within the scope and intent of 
this invention that the rewind cores 56, 80, 88, and 94 may be of a length 
equal to the width of the fabric being rewound or they may be longer. 
As can be readily understood from the foregoing description of the 
invention, the present structure can be configured in different modes to 
provide the ability to squeeze out entrapped air between succeeding 
spiral-like layers of fabric on a rewound roll and to accomplish the 
rewinding without a plurality of rolls and roll-type means as used in the 
prior art. 
Accordingly, modifications and variations to which the invention is 
susceptible, may be practiced without departing from the scope and intent 
of the appended claims.