Method and apparatus for collapsing an extruded tubular film

Abstract: A method and apparatus is disclosed for lacing an extruded tube 14 of a non-derivatized cellulose through an S-wrap unit 28 to collapse the tube to a flat width. The lacing to form an S-wrap is accomplished without slowing the extrusion speed. At the start of the extrusion operation, the extrusion path leads between a pair of horizontally-oriented lacing members 30 and 32. After the leading edge 52 of the extruded tube has passed downwardly through the space 50 between the lacing members, the members are rotated as a unit to bring them into contact with opposite sides of the extruded tube. This collapses the tube and creates the S-wrap.

Description: The present invention relates to the extrusion of a tubular film and more particularly to the extrusion of a tubular film composed of non-derivatized cellulose wherein the film, while in a gel state, must be flattened by lacing around cylindrical lacing members without interruption of the high speed extrusion process. A solvent system for making cellulosic food casings is known in the art. Briefly, a natural cellulose such as a wood pulp or cotton linters is mixed with an aqueous tertiary amine oxide cellulose solvent such as N-methylmorpholine-N-oxide (NMMO) to prepare a premix. The premix is heated with stirring to evaporate a portion of the water and dissolve the cellulose. The result is a thermoplastic cellulose solution, called "dope", which can be extruded or molded to a desired shape. The extruded or formed article composed of the dope then is contacted with a cellulose non-solvent such as water or a non-solvent mixture of water and NMMO. The contact with the non-solvent extracts the solvent from the dope causing the precipitation or regeneration of the cellulose from the solution. The solvent system, as set out above, is distinguished in that the natural cellulose is dissolved directly as opposed to chemically treating the cellulose to form a soluble cellulose derivative as in the well known viscose process. Accordingly, for purposes of the present invention, the term "non-derivatized cellulose" means a cellulose which has not been subject to covalent bonding with a solvent or reagent but which has been dissolved by association with a solvent or reagent through Van der Waals forces or hydrogen bonding. The dissolution process as described above is more particularly set out in US-A-2,179,181; US-A-3,447,939; US-A-4,145,532; US-A-4,426,228 and US-A-5,094,690. Methods and apparatus for forming a food casing from the thermoplastic cellulose solution are more particularly described in US-A-5,277,857; US-A-5,451,364; US-A-5,759,478 and US-A-5,766,540. In brief, forming a tubular food casing is accomplished by extruding the dope as a thin walled tube about a mandrel and into a bath of non-solvent liquid or "outer bath" which contacts the outer surface of the extruded tube. As noted above, the extraction of solvent and regeneration of the cellulose in the bath forms a hydrated, or "gel", tube of cellulose. After regeneration, the gel tube is washed to remove traces of the solvent. Then it is dipped into a glycerine solution and dried under inflation to about 7 to 10 percent moisture based on the weight of cellulose to form a tubular cellulose film for use as a sausage casing. After drying, the inflated tube (hereafter referred to as casing) is collapsed to its flat width and reeled with up to 11,000 feet (3353 metres) or more of casing on each reel. The casing on the reel is referred to as "semi-finished casing". The semi-finished casing then is subjected to further treatment in order to prepare it for use by the sausage maker. During the course of the downward extrusion, a non-solvent liquid is introduced into the interior of the extruded tube. This introduced liquid forms an internal bath for initiating the extraction of the solvent at the inner surface of the extruded tube. The introduced liquid also cools the interior surface of the extruded tube and provides lubrication between the extruded tube and the mandrel. At some point during its decent into the outer bath, the extruded tube must be collapsed to a flat width so it forms a web for further transport through the process. Collapsing the tube to a flat width holds back the inner bath and prevents most of the inner bath from being carried forward through subsequent steps in the process. A conventional flattening ladder used, for example, to flatten a blown film, is not effective to flatten the extruded tube because it is not able to hold back the liquid of the inner bath. A pair of nip rolls to collapse the extruded tube also can not be used. This is because the extruded tube at this point in the manufacturing process is still relatively fragile and the pressure applied to create the nip unacceptably damages the extruded tube by creasing or folding it. Simply passing the extruded tube around a turn roll or draw roll that directs the extruded tube upward and out of the outer bath will collapse the tube but is unacceptable because the tube tends to slip with respect to the roll and this alters aspects of the casing geometry. Another aspect to consider is that the means to collapse the tube to a flat width should not interfere with the speed of the extrusion at start-up. In this regard, the extrusion speed may be 60 metres per minute or more. Thus, the means used to flatten the tubular extrusion must be applied in a manner which does not slow the extrusion rate. Means found to be effective both to collapse the tube to a flat width and hold back the liquid of the internal bath comprise a plurality of rods around which the tube is laced. Lacing the tube around the rods directs the tube through a sinuous path or "S-wrap" which collapses the tube to a flat width. Moreover, it was found that if the rods are of sufficient diameter, the flattening can be accomplished without creasing the tube. However, while the S-wrap is effective to flatten the tubing and to hold back the internal bath liquid without creasing the casing, lacing the extruded tube around the rods to create the S-wrap is difficult to accomplish at extrusion speeds. Such lacing is particularly difficult because it must be done at some depth below the level of the outer bath. Accordingly, the present invention seeks to provide a method and apparatus for collapsing an extruded tube of non-derivatized cellulose to a flat width without applying a nip to the tube. The present invention also seeks to provide a method and apparatus for collapsing an extruded tube of non-derivatized cellulose to a flat width for holding back an internal bath liquid without creasing the extruded tube. Further, the present invention seeks to provide a method and apparatus for collapsing an extruded tube of non-derivatized cellulose to a flat width by lacing a leading edge of the tube around a lacing means to create an S-wrap. In addition, the present invention seeks to provide a method and apparatus for flattening an extruded tube of a non-derivatized cellulose to a flat width by creating an S-wrap lacing of the tube during the extrusion of the tube without decreasing the speed of the extrusion or distorting the fragile extruded tube. According to the present invention there is provided a method for collapsing an extruded tubular film of non-derivatized cellulose to a flat width during the course of continuous extrusion of the tube comprising the steps of: (a) downwardly extruding a tube composed of a non-derivatized cellulose solution along a substantially vertical extrusion axis and into a bath of non-solvent liquid; (b) arranging a pair of substantially cylindrical lacing members side-by-side in a generally horizontal orientation below the surface of the bath of non-solvent liquid, the lacing members being at least 25.4mm in diameter and a first of the members being arranged with its surface generally tangent to the vertical extrusion axis, the lacing members defining a space therebetween for accommodating the passage of an extruded tube passing substantially vertically through the space and the lacing members being rotatable as a unit about a common, substantially horizontal axis that is laterally spaced from the vertical extrusion axis; (c) passing a leading end of the tube through the space between the lacing members; and thereafter (d) rotating the lacing members approximately 180° about the common horizontal axis that is laterally spaced from the vertical extrusion axis thereby reversing the relative positions of the lacing members; and (e) in the course of said rotating, contacting the lacing members against opposite sides of the tube thereby deflecting the contacted portion of the tube from the vertical extrusion axis and directing the contacted portion of the tube through a sinuous path of travel to form an S-wrap while collapsing the tube to a flat width. In the present invention, collapsing an extruded tube of non-derivatized cellulose to a flat width without creasing the tube is accomplished by lacing the tube around a pair of generally parallel, substantially cylindrical rods to create an S-wrap. The pressure applied by passing the tube around the S-wrap provides for the hold back of the liquid within the tube so that only a minor portion of the liquid passes through the S-wrap. The rods creating the S-wrap are mounted on a rotatable plate. On start up of the extrusion, the plate is positioned so the rods are spaced substantially horizontally. This spacing allows the extruded tube to pass downwardly in a substantially vertical path through the space between the rods. After the leading edge of the extruded tube has passed between the spaced rods, the plate is rotated about approximately 180° so the positions of the two rods are reversed. Rotation of the plate brings the rods to bear against opposite sides of the tube thereby flattening the tube. In another aspect, the present invention provides an apparatus for collapsing an extruded tube of a non-derivatized cellulose to a flat width during the extrusion thereof comprising: (a) extrusion means for downwardly extruding a tube composed of a non-derivatized cellulose solution along a generally vertical path of travel defined by a substantially vertical extrusion axis into a tank containing a bath of a non-solvent liquid; (b) a pair of spaced lacing members disposed in said bath, said lacing members being substantially cylindrical and arranged side-by-side in a generally horizontal orientation below the surface of said bath, said members being at least 25.4mm in diameter and a first of said members being arranged with its cylindrical surface located generally tangent to said vertical extrusion axis, said members defining a space therebetween for the passage of a tube being extruded from said extrusion means, and said lacing members being rotatable as a unit approximately 180° about a substantially horizontal axis spaced laterally from said vertical extrusion axis from a first position wherein said first member has its cylindrical surface located generally tangent to said vertical extrusion axis to a second position wherein the other of said lacing members has its cylindrical axis located generally tangent to said vertical extrusion axis; and (c) means operable for rotating the lacing members as a unit from said first position to said second position after a leading end of a tube being extruded has passed substantially vertically between said lacing members, whereby in the course of said rotation said lacing members contact against the opposite sides of the tube to deflect said tube from its generally vertical path of travel to a sinuous path passing under one of the lacing members and over another while collapsing said tube to a flat width. An embodiment of the present invention will now be described, by way of example only, with reference to the accompanying diagrammatic drawings, in which: Figure 1 is front elevation view of the extrusion apparatus and a portion of the non-solvent bath showing the position of the S-wrap rods during continuous extrusion; Figure 2 is a front elevation view on a larger scale of a portion of the non-solvent bath showing the position of the S-wrap rods during the start-up of extrusion; and Figure 3 is a side elevation view, partly broken away and in section of the S-wrap rods as seen in Figure 2. Referring to Figure 1, a portion of apparatus, generally indicated at 10, for use in the manufacture of a non-derivatized cellulose food casing, includes a die 12 arranged for downwardly extruding a tube 14 of a non-derivatized cellulose solution. The extrusion is about a mandrel 16 which depends from the die. The mandrel forms no part of the present invention and reference is made to US-A-5,766,540; US-A-5,759,478; and US-A-5,277,857 for more details on the mandrel structure and the method for extruding a non-derivatized cellulose casing. It is sufficient to say for purposes of the present invention that the mandrel structure holds the extruded tube open and diametrically stretches the extruded tube. Extrusion is downwardly through a vertical path of travel along an extrusion axis 17 which coincides with the axis of the mandrel and into a regenerating bath of a non-solvent liquid 18. The bath is contained in a tank defined by a bottom 20 and side and end walls 22 and 24 respectively (only one of each being shown). The level of the non-solvent liquid is shown at 26. Since the extruded tube is held open by the mandrel 16, the portion of the tube indicated at 19 below the mandrel fills with the liquid of the regenerating bath. This portion 19, sometimes called "the bag" remains filled and is replenished with regenerating liquid during operation. This is accomplished by continuously adding and removing regenerating liquid through a pair of mandrel conduits (not shown) . In the bath, the extruded tube passes first around an S-wrap unit 28 defined by a pair of lacing members comprising cylindrical rods 30, 32 and then around a pair of driven draw rolls 34, 36 which stretch it in the machine direction. The extruded tube then passes over a stationary glass rod 38 which directs it upwardly and out of the bath. It then passes over a third driven draw roll 40 and back into the bath and then around another glass rod 42. The extruded tube may be festooned over a series of driven rolls 40 and glass rods 42 in order to increase the residence time of the tube in the bath liquid 18 to insure the extraction of sufficient solvent to form a tube of a hydrated non-derivatized cellulose gel. The S-wrap unit 28 performs several functions. It collapses the extruded tube and flattens it so it can be laced through the subsequent system of draw rolls and glass rods. Flattening the extruded tube also serves to hold back the liquid in bag 19 while allowing a minimum quantity of the liquid to bleed through the S-wrap. The liquid which bleeds through prevents the internal surfaces of the collapsed tube from adhering together. It also is important to accomplish the flattening of the extruded tube without forming wrinkles in the flattened tube such that the tube is collapsed to as near a flat width as possible. Also, the tube which passes around the S-wrap is relatively fragile because it is in a gel state and still contains a high percentage of solvent. In this gel state the tube is susceptible to creasing along the edges of the flattened tube during passage through the S-wrap. Creases along the edges of the flattened tube are to be avoided because the crease will be a casing weak point and the casing is likely to fail along the crease during a stuffing operation. It has been found that the configuration and location of the S-wrap components are important to accomplishing the purpose of the S-wrap without damage to the casing. In particular, it has been found that folds are avoided by locating the rod 30 which is first contacted by the extruded tube, so its outer surface is tangent to the centerline 17 of the extruded tube. This allows the diametrically opposite sides of the extruded tube to collapse towards the flat width equally so that one side is not drawn or stretched farther in the machine direction than the diametrically opposite side. There is a preferred amount of surface contact between the extruded tube and rod 30. In this respect it is preferred that the two rods 30, 32 forming the S-wrap are generally in the same horizontal plane as shown. An alternative of locating rotating rod 32 downward from (i.e., below) the plane decreases the surface area of contact between the extruded tube and rod 30 which tends to allow excessive carry-over of the liquid from bag 19. Conversely, locating rotating rod 32 upward from (i.e., above) the plane increases the surface area of contact so that friction may cause the tube to chatter as it passes around the rod. Accordingly, the preferred horizontal arrangement provides the minimum surface area of contact in the S-wrap needed to hold back liquid in the bag 19. To further decrease friction, the rods preferably are made of a relatively friction-free material such as tetrafluoroethylene or glass. Another important factor is the diameter of the rods relative to the diameter of the extruded tube. In this respect, it has been found that a rod diameter considerably smaller than the diameter of the extruded tube will increase the likelihood of creasing the extruded tube as it passes through the S-wrap. For this reason it is preferred that the rods 30, 32 have a diameter that is close to the diameter of the extruded tube and that they be at least 25.4mm in diameter. With a rod diameter of this size there is less of a crimping or creasing force put on the extruded tubing as it travels around the S-wrap. In operation, the cellulose solution can be extruded at the rate of 38 to 60 metres per minute or more. On start up and with the extrusion at these speeds, it should be appreciated that there is little time to direct the leading edge of the extrusion through the tight confines of the S-wrap. The present invention permits the lace-up through the S-wrap at the start-up of extrusion at the full extrusion speed. Reference is made to Figures 2 and 3 which show the orientation of the S-wrap unit at the start of the extrusion operation. Figures 2 and 3 show that the S-wrap unit 28 includes a vertically oriented mounting plate 44. The plate has an axle 46 that is journaled to a fixed bracket 21 extending into the bath so the plate can be rotated about a generally horizontal axis 48 by means (not shown). The bars 30, 32 extend horizontally from the mounting plate, one on either side of the mounting plate rotational axis 48. Figures 2 and 3 show the S-wrap unit at the start of the extrusion operation. At start-up, the position of the S-wrap unit is rotated about 180° degrees from the position shown in Figure 1. As best seen in Figure 2, the horizontal rotational axis 48 of the S-wrap unit is located to one side of the mandrel axis 17. In particular, the surface of rod 32 is substantially tangent to mandrel axis 17 so that the rod is in the path of travel of the tube being extruded from the die 12. In this start-up position, the rods 30, 32 provide an open space 50 which is wide enough so that the leading edge 52 of the tube is led easily between the rods. After the leading edge 52 of the extruded tube has been led through the space 50 and around the draw rolls 34, 36 and 40 (Fig 1), the S-wrap unit 28 is rotated about 180° in the direction shown by arrow 54. In the course of the rotation in the direction of arrow 54, bars 30, 32 contact opposite sides of the extruded tube and exchange positions. This deflects the extruded tube from its vertical path to form the S-wrap as shown in Figure 1 wherein the extruded tube passes under rod 30 and over rod 32. In this manner the start-up of the extrusion is facilitated in that forming the S-wrap of the extruded tube is accomplished quickly and with a minimum of effort. Having the rotational axis 48 of the S-wrap unit 28 located to one side of the extrusion axis 17 as shown positions the bar 30 in the path of travel of the extruded tube so the outer surface of the rod is substantially tangent to the extrusion axis when the S-wrap is formed. This arrangement is believed to be optimal as it allows the bag portion 19 to remain vertical as the extruded tubing below the bag is collapsed by drawing through the S-wrap.

Claims: A method for collapsing an extruded tubular film of non-derivatized cellulose to a flat width during the course of continuous extrusion of the tube comprising the steps of: (a) downwardly extruding a tube composed of a non-derivatized cellulose solution along a substantially vertical extrusion axis (17) and into a bath of non-solvent liquid (18); (b) arranging a pair of substantially cylindrical lacing members (30, 32) side-by-side in a generally horizontal orientation below the surface of the bath of non-solvent liquid, the lacing members being at least 25.4mm in diameter and a first of the members being arranged with its surface generally tangent to the vertical extrusion axis, the lacing members defining a space (50) there between for accommodating the passage of an extruded tube (14) passing substantially vertically through the space and the lacing members being rotatable as a unit about a common, substantially horizontal axis (48) that is laterally spaced from the vertical extrusion axis; (c) passing a leading end (52) of the tube through the space between the lacing members; and thereafter (d) rotating the lacing members approximately 180° about the common horizontal axis that is laterally spaced from the vertical extrusion axis thereby reversing the relative positions of the lacing members; and (e) in the course of said rotating, contacting the lacing members against opposite sides of the tube thereby deflecting the contacted portion of the tube from the vertical extrusion axis and directing the contacted portion of the tube through a sinuous path of travel to form an S-wrap while collapsing the tube to a flat width. A method as claimed in claim 1 comprising rotating the lacing members in a direction so as to form an S-wrap by passing the extruded casing first under one of the lacing members and then over the other. A method as claimed in claim 1 or claim 2 comprising passing the leading end of the extruded tube around at least one draw roll prior to rotating the lacing members. A method as claimed in any preceding claim wherein said extruding is at a speed of at least 38 metres per minute and wherein the lacing members are rotated to form the S-wrap without abating the extruding speed. Apparatus for collapsing an extruded tube of a non-derivatized cellulose to a flat width during the extrusion thereof comprising: (a) extrusion means for downwardly extruding a tube composed of a non-derivatized cellulose solution along a generally vertical path of travel defined by a substantially vertical extrusion axis (17) and into a tank containing a bath of a non-solvent liquid (18); (b) a pair of spaced lacing members (30, 32) disposed in said bath, said lacing members being substantially cylindrical and arranged side-by-side in a generally horizontal orientation below the surface of said bath, said members being at least 25.4mm in diameter and a first of said members being arranged with its cylindrical surface located generally tangent to said vertical extrusion axis, said members defining a space (50) therebetween for the passage of a tube being extruded from said extrusion mean, and said lacing members being rotatable as a unit approximately 180° about a substantially horizontal axis spaced laterally from said vertical extrusion axis from a first position wherein said first member has its cylindrical surface located generally tangent to said vertical extrusion axis to a second position wherein the other of said lacing members has its cylindrical axis located generally tangent to said vertical extrusion axis; and (c) means operable for rotating said lacing members as a unit from said first position to said second position after a leading end of a tube being extruded has passed substantially vertically between said lacing members, whereby in the course of said rotation said lacing members contact against opposite sides of said tube to deflect said tube from its generally vertical path of travel to a sinuous path passing under one of said lacing members and over another while collapsing said tube to a flat width. Apparatus as claimed in claim 5 wherein the substantially horizontal axis of rotation of said lacing members is substantially midway between said lacing members and to one side of said vertical path of travel. Apparatus as claimed in claim 5 or claim 6 wherein said lacing members are substantially cylindrical rods of tetrafluoroethylene. Apparatus as claimed in any one of claims 5 to 7, wherein said lacing members are fixed to a plate and said plate is journaled to said tank.

Inventors: DUCHARME PAUL EDMUND JR, MCGAREL OWEN JOSEPH, DUCHARME, PAUL EDMUND, JR., MCGAREL, OWEN JOSEPH
Applicants: VISKASE CORP, VISKASE CORPORATION
Application year: 2000
Main classification: B29C47
IPC codes: B29C47, A22C13