Apparatus and method for making convolutely wound logs

Abstract: A surface winder for developing a convolutely wound log in which a core introduced into a winding nip is first rotated before engaging a web to effect cutoff and transfer.

Description: This invention relates to apparatus and method for making convolutely wound logs and, more particularly to logs such as toilet tissue and toweling. Up to about 1950, stop-start winders (sometimes referred to as "rewinders") were used to convert jumbo-sized rolls of paper from the paper machine to retail-sized rolls. The critical feature in winding is cutoff and transfer. When the small roll or log is wound to its predetermined "count", it was necessary to sever the web transversely and transfer the web leading edge to a glue-equipped core. After about 1950, this was done automatically so that the winders could operate at continuous speed. Two types of winders have been used. The most widely-employed for years has been the "center" wound type. These used a mandrel on which the core was ensleeved -- with the mandrel being turned with a decreasing speed as the log increased in diameter. The cutoff and transfer problem was handled advantageously first by co-owned Patent US-A-2,769,600 and thereafter, when higher speeds were required, by co-owned Patent US-A-3,179,348. More recently, surface winders have become popular because of being able to avoid the mechanisms used for the decreasing speed characteristic -- thus being less complex and cheaper. These have employed a three-roll cradle, a stationary winding roll, a second winding roll which could be movable, and a movable rider roll. The cutoff and transfer problem was addressed advantageously first by co-owned Patent US-A-4,723,724 and, more recently, by co-owned Patent US-A-4,828,195. In the '195 patent, the web was severed, i.e., "cutoff" by being tensioned between a downstream point provided by the contact of the almost-finished log with the stationary winding roll and an upstream point where the core pinched the web against a breaker bar. Thereafter, the core had to rotate to bring glue-stripe into engagement with the web. The rotation was necessary because the glue stripe on the core had to be between the winding roll and the web on the pinch plate. This resulted in excess material, i.e., slack, in the web leading edge and it also meant that the reversed leading edge was not under control. Closest prior art reference US-A-4,327,877 also discloses a continuous winding device for webs of paper, wherein the core is brought in position between two drums by means of a pusher rig which comprises a plurality of belts. The core initiates rotation as soon as it makes contact between the two drums and the belts continue the rotation of this core at the speed of the paper. A mechanism for temporalily varying the speed of the first drum during a phase of core replacement and for tearing the material is provided as is a mechanism for inserting a core between the two drums. In most cases tearing of the web occurs during this phase in such a way that a certain amount of paper is wasted. According to the present invention, the core is introduced into the nip between the stationary winding roll and the pinch bar without any contact with the web. The coaction of the stationary winding roll and the pinch bar causes the core to rotate to bring the glue stripe into confronting relation with the web when the core first contacts the web to provide the upstream pinch point. This results in severance and transfer substantially simultaneously so as to reduce both undesirable slack generation and an uncontrolled leading edge. BRIEF DESCRIPTION OF THE DRAWING : The invention is described in conjunction with an illustrative embodiment in the accompanying drawing, in which -- FIG. 1 is a fragmentary side elevational view of a surface winder constructed according to prior art patent 4,828,195; FIG. 2 is a view similar to FIG. 1 but showing the surface winder of the instant invention; FIG. 3 is a fragmentary top plan view of a section of the winder such as would be seen along the sight-line 3-3 applied to FIG. 2; FIG. 4 is a schematic side elevational view of the cradle rolls of the prior art '195 patent in "cutoff" position; and FIGS. 5-9 are views similar to FIG. 4 but showing the operation of the instant invention. DETAILED DESCRIPTION : Inasmuch as this invention is an improvement on Hertel and Buxton Patent US-A-4,828,195, reference to that patent may be made for details of construction and operation not set down herein. It will be appreciated that the basic arrangements are the same and therefore FIG. 1 shows basic details of the '195 patent. There, the symbol W designates a web arranged for advance through a first path within the frame 20 of the winder. Shown schematically in the upper left portion of FIG. 1 is a hypocycloidal core-inserting mechanism 21, the details of which can be seen in co-owned patent US-A-4,723,724. FIG. 1 illustrates the orientation of the web at the end of one winding cycle and the beginning of the next. The web passes over stationary turning bar 22 and into contact with a core C just prior to cutoff transfer. The web continues toward the stationary winding roll 23 which is mounted on the frame 20 at 24. The web W is finally seen to be in the process of being wound into a log L. The log L is contacted by a rider roll 25 carried by a pair of pivotally mounted arms 26 which are pivotally mounted on the frame as at 27. The log L is also contacted by the lower, movable winding roll 28 which together with rolls 23 and 25 form a three-roll cradle. The lower winding roll 28 is carried by pivot arms 29 which pivot around axis 30. The function of the winding roll 28 in this invention is the same as that described in the '195 patent -- this invention being concerned with what happens upstream of the winding roll 28, so the invention has broader application than just to the '195 construction. The important difference between this invention and that of the '195 patent is the relocation of the path of web W. This can be appreciated from FIG. 2 to which reference is now made. In FIG. 2 , there is again the three-roll cradle consisting of stationary winding roll 124, the winding roll 128 and the rider roll 125. Contrary to the path of web W in FIG. 1 where it is fed over turning bar 22 into contact with the core C which is pinched between roll 24 and bar 22, the web path in FIG. 2 enters the three-roll cradle downstream of the point where the stationary winding roll 124 pinches the core C against the pinch bar 131 -- see also FIG. 3. In FIG. 3, the frame includes a pair of side frames 120a and 120b. In addition to supporting all the rolls in the fashion described in the '195 patent, the frame supports the pinch bar 131 and the transfer bar 131a. In turn, the transfer bar 131a supports the stationary fingers 132 (compare FIG. 4 with FIGS. 5 and 6). In contrast to the '195 showing, the pinch bar 131 is spaced from the fingers 132 (similar to fingers 32 of the '195 construction) by a throat or gap 133 through which the web W passes in traveling from draw rolls one of which is seen at 135. These perform the same function as the draw rolls 34, 35 of FIG. 1 in feeding the web W from the parent roll (not shown) to the winder. As indicated previously, the core C according to the invention and differing from the '195 patent -- begins to rotate prior to engagement with the web W. As can be appreciated from FIG. 2, the core C after insertion by the mechanism 121 contacts the stationary winding roll 124 at the top (as shown) and the pinch bar 131 at its bottom (also as shown). With the winding roll 124 rotating counterclockwise and with the pinch bar 131 being stationary, the core C rotates clockwise and moves to the right in FIG. 2 -- ultimately contacting the web W which is passing through the throat 133. The operation of the invention -- and the difference from the prior art '195 patent can be appreciated from a consideration of FIGS. 5-9. OPERATION In the prior art showing of FIG. 4, the web W is about to be snapped along a line of perforation 36 located between the downstream pinch point 37 and the upstream pinch point 38. The downstream pinch point 37 is provided by the contact (a line or area of tangency) of the log L with the roll 24. The upstream pinch point is provided by the contact of the core C with the turning bar 22. The snapping occurs because the web is tensioned between the two points -- being advanced at winder speed by the log L downstream but relatively retarded by the core C which is about to begin its rotation. This results in a substantial leading edge portion of the web -- between the point 38 and perforation line 36 and which leading edge portion is uncontrolled. The core C has been introduced into the nip generally designated 40 with its glue stripe 39 approximately midway between the upper and lower contact points 41 and 38, respectively. Introducing the core with the glue stripe near the upper contact point 41 could result in fouling the roll 24 while a lower stripe location could wipe the glue from the core by contact with the web W. So, until the core rotates about 90°, there is no attachment of the web to the core -- but meanwhile the web has been snapped. In contrast, the invention (as seen in FIGS. 5 and 9) provides no contact between the core and web until the core has moved to the position of FIG. 6 where the glue stripe 139 is at its nearest point to the web. It is at this time that severance occurs at 136 (see FIG. 7). Thus, there is substantially simultaneous "cutoff", viz., severance, and transfer. This results in a much shorter length of time during which the web is stopped, providing superior control because the web is now advanced by the core. For example, a 1.7 inch diameter core produces about 5 inches of slack with the '195 configuration but only about 1.75 inches of slack with the instant invention. This happens in the '195 configuration because the web is still advancing after core-web contact until the glue stripe on the core contacts the web. In the invention, the two contacts occur simultaneously -- not being separated in time and space. SUPPORTING STRUCTURE The instant invention differs from the '195 patent prior art in the structures employed for supporting the pinch bar means 131 and the stationary finger means 132. Referring to FIG. 2, the numeral 142 generally designates a tubular supporting member that extends between the side frames 120a and 120b. The member 142 carries a pair of projecting elements 143, 144 (see FIG. 9) which, in turn, carry the pinch bar 131. Also carried by the member 142 is a pipe 145 (still referring to FIG. 9) connected to air source (not shown). The element 144 is equipped with an opening 146 which permits air flowing out of wall apertures 147 in the pipe 145 (see FIG. 8) to impinge against the web W and flow out of the throat 133. The fingers 132 are carried by a transfer bar 131a which in turn is mounted on the side frames 120a and 120b -- see FIG. 3. Also supported from the transfer bar 131a and also connected to the side frames is an angle iron support generally designated 148. Extending between the transfer bar 131a and angle iron support 148 are another pair of projecting elements 149, 150 (see FIG. 7). The elements 144, 149 define a chute or passage 133a through which the web W travels from the draw roll 135 through the throat 133 to the three-roll cradle (124, 128, 125). Here, I again employ a compensator as at 151 (or 51 in FIG. 1) to take up slack upstream of the upstream pinch points 38, 138 (FIGS. 4 and 5, respectively). However, the compensator is unable to respond as fast as the slack is being generated. A second air jet means for the throat 133 is provided in the form of a second pipe 152 (see FIG. 6) -- like that provided at 145. Again, the element 149 adjacent thereto is equipped with an opening 153 to permit air flow from apertures in the pipe 152 against the web W. The fingers 132 function in this invention in the same way as the fingers 32 did in the prior art '195 patent -- providing support for the core when it proceeds in the nip defined by the winding rolls 124, 128. Then, as the winding proceeds, the nip may be opened by moving the roll 126 away from the roll 124 to place the partially wound log L in the three-roll cradle position. SUMMARY OF INVENTION To improve the operation of the '195 patent surface winder by reducing the amount of slack upstream of the attachment point and to better control the web, I have relocated the path of travel of the web W. The web parth includes traveling with the draw roll 135, passing through the throat 133 and traveling with the stationary winding roll 24. More particularly, I have moved the path of travel of the web further into the winder in effect, extending the path of travel of the core. In the '195 patent prior art, the core path terminated when the core was introduced into the nip 40 between the stationary, winding roll 24 and the turning bar 22 where pinching of the web occurred at 38 -- see FIG. 4. Now, the core path is lengthened before it merges into the web path -- see FIGS. 6 and 7 -- where the glue stripe 139 is positioned to engage the web W at the time of severance, severing occurring at 136. Now, the web is being wound on the previous log until contact occurs between the glue stripe and the web. The core path includes being supported by the inserting mechanism 121, passing through the nip 140, contacting the stationary winding roll 124 and the pinch bar 131. In the illustrated embodiment, I provide presser means for the web/glue stripe engagement as at 154 -- see FIGS. 2 and 5. Although excellent results are obtained without the presser means 154, this could be a safeguard to insure transfer in the case of a distorted core. In any event, the core path includes a segment wherein the core enters the nip 140 between the stationary winding roll 124 and pinch bar means 131 -- and upstream of the path of the web -- see FIG. 5. This nip engagement results in rotating and advancing the core by rolling on the pinch bar means to the FIG. 6 position where, for the first time, the core engages the web W, i.e., the web and core paths merge. While in the foregoing specification a detailed description of an embodiment of the invention has been set down for the purpose of illustration, many variations in the details hereingiven may be made by those skilled in the art without departing from the scope of the invention.

Claims: A surface winder for developing a web log comprising a frame (120a, 120b), means (135) operatively associated with said frame for advancing a web (W) along a predetermined path (135, 133, 124) in said frame, a first winding roll (124) rotatably mounted in said frame (120a, 120b) on one side of said path, stationary finger means (132) mounted on said frame (120a, 120b) on the other side of said path (135, 133, 124) adjacent said first winding roll (124) and spaced therefrom a distance sufficient to receive a core (C) to be wound in said path, said first winding roll cooperating with said stationary finger means to rotate said core (C), a second winding roll (128) rotatably mounted in said frame (120a, 120b) on the other side of said path (135, 133, 124) and downstream in the direction of web advance from said stationary finger means and forming a nip (140) with said first winding roll (124), means on said frame for moving a core (C) along a second path (121, 124, 131, 131a), said second path merging (131a) with said first path (135, 133, 124), said first winding roll (124) being on a first side of said second path (121, 124, 131, 131a), characterized in that pinch bar means (131) are provided on the second side of said second path (121, 124, 131, 131a) also adjacent said first winding roll (124) to receive a core (C) and cause the same to rotate by cooperating with said first winding roll (124), said pinch bar means (131) being spaced from said stationary finger means (132) to provide a throat (133) to enable said web (W) to pass between said pinch bar means (131) and said stationary finger means (132), said core (C) comprising at least one axially extending glue stripe (139), and said first winding roll (124), said pinch bar means (131) and said stationary finger means (132) being so arranged that when said glue stripe (139) is in approximate confronting relation with said web (W) the severance of the web (W) and the transfer of the web (W) to the core (C) occur substantially simultaneously. The winder of claim 1 characterized in that two spaced apart support means (142, 148) are provided on said frame (120a, 120b) on opposite sides of said first path (135, 133, 124) upstream of said throat (133), one of said support means (142) being connected to said pinch bar means (131) and the other (148) to said stationary finger means (132), draw roll means (135) rotatably mounted on said frame (120a, 120b) in said first path (135, 133, 124) upstream to said two support means (142, 148), said two support means (142, 148) defining a passage for said web in traveling from said draw roll means (135) to said throat (133). The winder of claim 2 characterized in that said support means are equipped with air jet means (145, 152) for delivering air through said throat (133). The winder of claim 1 characterized in that said finger means is equipped with presser means (154) for urging said web (W) against each glue stripe-equipped core (C). The winder of claim 4 characterized in that said presser means (154) is positioned approximately 90° of the core circumference from the downstream end of said pinch bar means (131). The winder of claim 1 characterized in that said stationary finger means (132) includes a transfer bar (131a) supported on said frame and, in turn, supporting a plurality of stationary fingers (132). The winder of claim 1 characterized in that said second winding roll (128) is movably mounted on said frame (120a, 120b). A method of winding a web (W) on a core (C) to develop a wound log comprising introducing cores (C) sequentially into a nip (140) between a rotating, stationary winding roll (124) and a fixed pinch bar (131), each core having an axially extending glue stripe approximately midway between the lines of contact of said core with said stationary winding roll (124) and said fixed pinch bar (131), rotating each said core (C) to cause the same to roll on said pinch bar (131), first contacting said core (C) with a continuously advancing web (W) when said glue stripe is in approximate confronting relation with said web whereby web severance and transfer to said core (C) occur substantially simultaneously, thereafter continuing to rotate said core (C) to wind the web (W) thereon, wherein said web (W) is advanced along a first path (135, 133, 124) and said core (C) is moved along a second path (121, 124, 131, 131a), wherein said second path is merging (131a) with said first path (135, 133, 124), said first winding roll (124) being on a first side of said second path (121, 124, 131, 131a),a second winding roll (128) being rotatably mounted on the other side of said second path (121, 124, 131, 131a) and downstream in the direction of web advance from said stationary finger means and forming a nip (140) with said first winding roll (124), and wherein said pinch bar means (131) is further spaced from the stationary finger means (132) to provide a throat (133) to enable said web to pass between said pinch bar means (131) and said stationary finger means (132).

Inventors: BUXTON GERRY, BUXTON, GERRY
Applicants: PAPER CONVERTING MACHINE CO, PAPER CONVERTING MACHINE COMPANY
Application year: 1991
Main classification: B65H19
IPC codes: B65H19