Abstract:
The present invention is directed to a method and apparatus for precisely controlled and operator safe removal of a desired width of layered paper from the end of a roll of paper web, as for example a paper roll having one or both ends damaged, employing a compound mount for a knife-blade type cutter which is selectively adjustable along multiple axes relative to the rotational axis and width of the paper roll as the roll is rotated independently of the cutter and without unwinding the paper web from the roll. In accordance with one aspect of the present invention, only that quantity of paper web, which is damaged, is removed while maximizing the depth of cut radially into the roll by the cutter.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     Not Applicable  
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
       [0002]     Not Applicable  
       FIELD OF INVENTION  
       [0003]     This invention relates to trimming the ends of rolls of paper or the like, such as for purposes of sizing the width of the roll or removal of damaged paper from the end of the roll.  
       BACKGROUND OF INVENTION  
       [0004]     Formed paper webs are commonly collected in rolls for storage, transport and otherwise handling in the course of conversion of the web into some desired form. In storage, during handling, etc., the ends of these rolls of paper are subjected to becoming damaged, contaminated, wetted or subjected to other destructive treatment which results in the paper adjacent an end of the roll being rendered unusable or undesirable for the intended use of the paper web of the roll. Rolls of paper web may be relatively small, but commonly the web is collected in a jumbo roll which weighs many hundreds of pounds.  
         [0005]     In the process of converting the paper web from a roll into a desired product, the web must be unrolled from the basic roll and fed into a converting machine, of which there are many types. In any event, where one or both of the ends of the roll have experienced moisture, the layers of paper web, at the ends of the roll tend to bond together for a relatively short distance inwardly of the roll from the end thereof. This distance may be as short as about ¼ inch or can be more pervasive inwardly of the width of the roll. Such bonded layers of the paper web tend to cause the paper web to resist unwinding such that the web breaks as it is unwound from the roll. Each such break requires a “shut-down” of the conversion machine to re-thread the web into the machine, costing time and money to process the roll of paper web.  
         [0006]     The prior art includes devices for cutting the ends of a roll of paper such as by sawing, grinding or similar removal of the damaged portion of the end of the roll. Such devices create potentially hazardous amounts of paper dust, and in some instances are inherently hazardous to operate or expensive to protect against operator injury. Other prior art devices are deficient with respect to control over the cutting operation, resulting in loss of valuable paper or inadequate removal of paper from the end of the roll. Moreover, known prior art devices tend to create a less than square end of the cut roll, often leaving ridges and valleys defined in the cut end of the roll.  
       SUMMARY OF INVENTION  
       [0007]     In the present invention there is provided a method and apparatus for precisely controlled and operator safe removal of a desired width of layered paper from the end of a roll of paper web employing a compound mount for a knife-blade type cutter which is selectively adjustable along multiple axes relative to the rotational axis and width of the paper roll as the roll is rotated independently of the cutter and without unwinding the paper web from the roll. In accordance with one aspect of the present invention, only that quantity of paper web which is damaged is removed while maximizing the depth of cut radially into the roll by the cutter.  
         [0008]     In the method of the invention, a paper roll having one or both ends damaged, is mounted for rotation about a central axis thereof. A cutter is mounted for selective movement along multiple axes relative to the rotational axis and width of the roll, and as the roll is rotated, the position of the cutter relative to the roll is adjusted initially a selected distance inwardly of the width of the roll and adjusted periodically as a function of the maximum permissible radial depth of cut made by the cutter. 
     
    
     BRIEF DESCRIPTION OF FIGURES  
       [0009]      FIG. 1  is a schematic representation of a typical roll of paper web mounted for rotation about a radially central axis and depicting various features of the present invention;  
         [0010]      FIG. 2  is an exploded view of one embodiment of a cutter mounted for multi-directional movement when mounted on a carrier associated with the mounting rails for the roll of paper depicted in  FIG. 1 ;  
         [0011]      FIG. 3  is a top elevational representation of a knife-blade type cutter mounted in cutting position to the end of a paper roll;  
         [0012]      FIG. 4  if a schematic representation of a knife-blade cutter of the present invention mounted in a blade mount;, and  
         [0013]      FIG. 5  is a top view of a portion of the apparatus depicted in  FIG. 1  and without any cut having been made on the end of the roll. 
     
    
     DETAILED DESCRIPTION OF INVENTION  
       [0014]     With reference to  FIGS. 1 and 2 , in one embodiment of the present invention, there is provided apparatus for severing or cutting away a selected portion of an end  10  of a roll  12  of paper web  14 . The depicted roll includes a spool  16  upon which the paper web is wound to generate the roll. The depicted spool is fitted with a shaft  18  which extends through the central axis of the spool and beyond the opposite ends  10  and  22  of the depicted roll to define a rotational axis  20  for the roll.  
         [0015]     As depicted in  FIG. 1 , each end of the shaft which projects beyond the respective ends of the roll is provided with a disc  26 , 28  oriented substantially perpendicular to the rotational axis of the shaft/roll and fixed to the shaft for rotation of the shaft upon rotation of the disc. As also depicted in  FIG. 1 , the disc  26  includes an outer circumferential surface  30 . For rotation of the roll about its rotational axis, the outer circumferential surface of the disc is engaged by the outer circumferential surface  32  of a tire  34  fabricated of a frictional material or having a frictional material coating its outer circumferential surface  36 , whereby rotation of the tire effects rotation of the disc, hence rotation of the roll of paper web.  
         [0016]     Rotation of the tire is effected by means of a conventional motor  38 , preferably including a conventional speed control means (not shown), and including a drive shaft  40  upon which the tire is mounted. As desired, the motor may be mounted upon a conventional air support  43  to provide for adjustment of the frictional engagement between the outer circumferential surface of the tire and the outer circumferential surface of the disc.  
         [0017]     As seen in  FIG. 1 , those portions  44 ,  46  of the shaft which project beyond the opposite ends of the roll reside on respective rails  50 , 52  and are supported for rotation of the shaft thereon. Positioning of the shaft relative to the rails may be by any of several suitable means (not shown) such as “V” notches cut into the top surface of each rail, a pair of stops provided on each rail and spaced apart by a distance sufficient to receive the shaft therebetween, or other known means.  
         [0018]     In accordance with the present invention, there is provided on at least one of the rails, a carrier  54  which in the depicted embodiment takes the form of a metal plate  56  which in bent into an “L” shape cross section. The body  58  of the “L” overlies the upper surface  60  of the rail with the longer leg  59  of the “L” lying along an inner surface  62  of the rail and the shorter leg  64  of the “L” lying along the outboard surface  66  of the rail. This carrier is slidably moveable along the length of the rail as indicated by the arrow “C” of  FIG. 2 , and may be selectively and temporarily fixed at any desired location along the length of the rail as by a “C” clamp  61  or other releasable fastening means, such as a stud threaded through the shorter leg  64  of the “L” and frictionally engaging the outboard surface  66  of the rail. Whereas there is depicted a carrier only on one rail, it is to be understood that a mirror image carrier may be provided on the opposite rail.  
         [0019]     Such additional carrier functioning in like manner as the carrier  54  for purposes of the present invention.  
         [0020]     Referring to  FIG. 2  specifically, the present invention further includes first and second elements  80  and  82 , respectively, of a compound  84 .  
         [0021]     The first element  82  of the compound includes a planar rigid plate  86  adapted to be affixed to the carrier  54  for movement with the carrier along the length of the rail. The plate  86  is fitted with a crank  88  having a shaft  90  which is rotatably supported at its opposite ends  92 , 94  by upstanding journal bearings  96  and  98 . The central portion  100  of the crank shaft is provided with external threads and is threadably received within first and second blocks  104 , 106 , each of which is provided with an internally threaded throughbore for receipt of the threaded portion of the crank shaft. Each block, block  104  being typical, includes a flat bottom surface  108  which is disposed in sliding relationship to the top surface  109  of the plate and which is not-rotatable with respect to the crank shaft. Consequently, upon rotation of the crank shaft as by rotation of the crank handle  110 , the blocks  104 , 106  simultaneously slide over the top surface of the plate in the direction of the arrow “A”, the direction of movement being determined by the direction of rotation of the shaft and the extent of their movement being determined by the rotational turns of the shaft.  
         [0022]     The second element  84  of the compound includes a planar rigid plate  112  adapted to be affixed to, and carried with, the blocks  104 ,  106  of the first element  80  of the compound. The fixation of the plate  112  to the blocks may be by means of screws or bolts passing through the thickness of the plate  112  and being threadably received within internally threaded blind bores  114 , 116  provided in the top surfaces  118 , 120  of the blocks. Thus movement of the plate  112  in the direction depicted by the arrow “A” is effected upon movement of the blocks associated with the first element of the compound.  
         [0023]     The plate  112  of the second element is fitted with a crank  122  having a shaft  124  which is rotatably supported at its opposite ends  126 , 128  by upstanding journal bearings  130  and  132 . The central portion  134  of the shaft  124  is provided with external threads and is threadably received within a cutter mount block  140  which is provided with an internally threaded throughbore  144  for receipt of the threaded portion of the shaft  124 . The block  140  includes a flat bottom surface  146  which is disposed in sliding relationship to the top surface  148  of the plate  112  and which is non-rotatable with respect to the shaft  124 . Consequently, upon rotation of the shaft  124  as by rotation of the crank handle  150 , the block  140  slides over the top surface of the plate in the direction of the arrow “B”, the direction of movement being determined by the direction of rotation of the shaft and the extent of the block&#39;s movement being determined by the rotational turns of the shaft.  
         [0024]     Further referring to  FIGS. 2-4 , the second component of the compound is provided with a cutting blade  154  which is removable mounted on a blade carrier  156 , which, in turn, is fixedly mounted to the top surface  158  of the block  140 . The depicted carrier  156  is a hollow metal tube having a rectangular cross-section. The depicted blade is an elongated flat blade and, in the depicted embodiment, is releasably secured within the outboard end  159  of the blade carrier between facing first and second mounting blocks  160 ,  162 , respectively which are mounted within the end  159  of the carrier. These blocks are spaced apart by a distance sufficient for the blade to be slidably positioned between the blocks. The space defined between the blocks is planar and occupies a plane which is non-parallel to the plane of the end  10  of the roll  12 . The magnitude of the angle “D” may vary substantially upwardly from about three degrees. Seven degrees has been found useful for cutting paper web rolls. As seen in  FIG. 3 , the plane of the blade disposed in the space between the blocks is oriented at an angle “D” with respect to the plane occupied by the end of the roll which is to be cut. Once the blade in disposed in a desired position between the blocks, the blade is anchored between the blocks as by a set screw  164  or like anchoring means.  
         [0025]     The cutting blade includes a very sharp cutting end  170  which projects laterally and outboard of the blade carrier  156  and outboard of the side edge  172  of the plate  112  in cantilevered fashion to be in position for presentation to and engagement of the cutting end  170  of the blade with the end  10  of the roll  12  for severing away a portion of the end of the roll as the roll is rotated past the cutting end of the blade. As noted, in the depicted embodiment, the plane of the blade preferably is oriented at an angle with respect to the plane of the end of the roll thereby defining a relief  174  between the blade and the roll to ensure efficient and clean cutting of the paper on the roll. Further, when the blade is disposed properly for cutting the end of the roll, the relief permits the outboard end  159  of the carrier  156  to be disposed distant from the end of the roll, hence the carrier does not engage the end of the roll as cutting progresses. Still, further, in a preferred embodiment, the blade is substantially rigid and is mounted rigidly within the carrier  156  and relative to the compound element  84  to which the carrier  156  is secured to ensure controlled positioning of the cutting end of the blade relative to the end  10  of the roll  12  upon actuation of one or both of the compound elements  80  and  82 .  
         [0026]     In accordance with the method of the present invention, the compound  82  is mounted on the carrier  54  which, in turn, is mounted on the rail  50  for slidable positioning of the carrier  54  along the length of the rail. Initially, the carrier is releasably fixed at a location along the rail which positions the cutting end of the cutter blade contiguous to the outer rim  180  ( FIG. 1 ) of the roll of paper web. Thereupon, the operator turns the crank handle  110  to position the cutting edge of the blade inwardly of the width of the roll by that distance which will permit the blade to cut away from the end of the roll the desired portion of the width of the roll. This distance may range from a fraction of an inch, e.g., one-fourth inch, to multiple inches, in part by reason of the relief defined between the blade and the end of the roll. As desired, the degree of relief defined by the orientation of the planar space between the blocks  104 ,  106  may be selected by changing the angular orientation of the space between the blocks, hence the angular orientation of the blade relative to the end of the roll. Among other things, this feature of the present invention permits the selection of relative large cut widths. Should the width of the cut be greater than the adjustment capacity of the apparatus, multiple cuts may be made, each being a portion of the total desired width of removed paper web from the end of the roll.  
         [0027]     With the roll rotating about its axis, and with the cutting end of the blade disposed contiguous the outer circumference of the end of the roll, the operator turns the crank handle  150  which moves the cutting end of the blade  154  radially relative to the rotational axis of the roll to select the desired depth of the cut into the end of the roll. As the roll is rotating, the operator turns the crank  150  to move the cutting end of the blade in a direction radially inwardly or outwardly of the roll until the desired radial depth of the cut is achieved. This radially inwardly movement of the cutting edge of cutting end of the blade is controlled by the operator as the cut progresses to maintain a maximum depth of cut, thereby minimizing the time required to sever the entire end of the roll.  
         [0028]     Notably, the present invention provides for the cutting edge of the blade to be maintained in its cutting position until the cutting edge has reached the spool of the roll, thereby ensuring a full cutting away of the end of the roll. Moreover, the degree of adjustment of the cutting end of the blade relative to the end of the roll provides the operator the means whereby there may be performed a clean and even cut over the entire end of the roll. A partially cut end of the roll is depicted in  FIG. 1  and shows a smooth cut portion  190  of the end of the roll and an uncut portion  192  of the end of the roll adjacent the spool  16 .  
         [0029]     Importantly, the present invention provides for the clean, even cutting away of the paper web from the roll without unwinding of the paper web from the roll. As desired, however, the cutting away of the end of the roll also may be performed as the paper web is being unwound from the roll. In this latter instance, the depth of cut is adjusted to ensure that at all times the paper web has been cut before it leaves the roll. This latter arrangement is-possible by positioning the location of the cutting operation at a location along the outer circumference of the roll that is located ahead of the location where the paper web leaves the roll (such as depicted in  FIG. 1 ). Further, the present invention permits the operator to manually select the depth of cutting of the blade to accommodate areas of the end of the roll which are more dense due to their being subjected to more severe damage than other areas of the end of the roll, thereby again enhancing the minimization of the time required to fully sever the desired paper web from the end of the roll. Still further, as noted, a device of the present invention may be provided at each of the opposite ends of the roll for simultaneously severing paper web from each end of the roll.  
         [0030]     Paper severed from the roll employing the present invention is in the form of small pieces or continuous strips, both of which are recoverable for recycling. No material dust from the paper on the roll is generated by the present invention. Thus, the present invention provides for material savings over the prior art devices which grind or saw away paper from a roll with the generation of large quantities of dust which is lost to recycling and which is recognized health hazard to operators, etc.  
         [0031]     In the embodiment depicted herein, the paper roll is mounted for rotation on rails and the carrier  54  is slidably mounted on a rail. It will be recognized that the carrier  54  may be supported on a mount which is separate from the support for the paper roll.  
         [0032]     Whereas the present invention has been described herein at times using specific examples, one skilled in the art will recognize that various modifications and/or substitutions may be made without departing from the essentials of the present invention. It is therefore intended that the invention be limited only as set forth in the claims appended hereto.