Abstract:
The apparatus and method for application of a protective covering to an unprotected paper roll in locations without major paper handling equipment is described to provide an inexpensive and portable system for paper roll refurbishing. Apparatus used in the present invention includes: an apparatus for holding the body wrapper supply roll and measuring the unrolled wrapper to a desired length; an apparatus for rewinding and cutting individual wrappers for transport to the point of use; an apparatus for applying the wrappers to the paper roll; an apparatus for transporting the rolls from the resizing area to the wrapping area; and an apparatus for crimping the body wrap over the end of the roll to retain the header; an apparatus for retention of the headers and caps under pressure during curing of the retaining adhesive.

Description:
APPLICATION FOR UNITED STATES LETTERS PATENT 
     This application claims benefit of co-pending U.S. patent application Ser. No. 60/293,714 filed May 25, 2001, entitled “Paper Roll Refurbishing” which is hereby incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates generally to handling large rolls of paper. More particularly, this invention pertains to the application of a protective covering to an unprotected paper roll in locations without major paper handling equipment. 
     In the printing and paper industry, large rolls of paper are handled and processed. In the course of this processing, rolls are sometimes damaged and must be scrapped or may be salvaged by the process and machine of U.S. Pat. No. 5,964,024, issued to Wallace on Oct. 12, 1999, entitled “Roll-Cutter” which is currently in use in the industry. This patent is hereby incorporated by reference. Often, the paper is simply of the incorrect dimension and may be resized by the roll cutter to a usable size. 
     When the roll cutter is used to resize a roll, at least one of the headers is removed during the cutting operation. This leaves that end exposed to dirt and possible damage. When the roll is used at the same facility, this exposure is not significant because the duration of storage is usually minimal. However, where long term storage is needed, or when the resized paper roll must be transported to other facilities, the possibility for contamination and damage to the roll is increased. This mandates that a new wrapper, headers, and caps be applied to refurbish the roll. 
     Paper mills and large paper processing plants are equipped with machinery to apply wrappers and headers to the finished rolls. This machinery is large, complex, very expensive, and is certainly not portable. Large production machinery does not lend itself to small orders such as for samples or incidental damage. During an equipment breakdown at these large facilities, production will cease. In critical situations, this shutdown may have a significant economic impact. In addition, during application of the roll cutter where relatively few rolls of paper are involved, difficulty arises in re-wrapping and applying new headers. Transporting the rolls to a wrapping facility is cost prohibitive and would defeat the purpose of the roll cutter. The present invention provides a method to overcome the limitations on the prior art large production rate equipment. 
     The prior art roll covering application sequence is shown in FIG. 1, beginning at the left and progressing to the right, where a paper roll  10  is protected by wrapping the paper roll  10  in a with a heavy gauge of paper wrapper  12 , also call a body wrap  12 , which extends over the ends  18  of the paper roll  10 . The edges  14  of the body wrap  12  are then folded over the ends  18  of the paper roll  10 . The edges  14  are then unfolded and a disc  16  is inserted between the folded edges  14  and the end  18  of the paper roll  10 . The header disc  16  is a circular disc of heavy fibrous (cardboard) material approximating but smaller than the diameter of the roll  10  being refurbished and having a center hole corresponding to the diameter of the core tube. The protective disks  16  or headers  16  are applied to protect the ends  18  of the roll  10  from physical damage. The edges  14  of the wrapper  12  are then crimped back over the header  16  and a seal cap  20  is then applied and retained with adhesive to retain the body wrap  12  and eliminate contamination from dust and dirt. The end seal cap  20  is a circular disc of paper that is bonded to the crimped wrapper  12  to retain the crimp and exclude dirt from the paper roll. The cap  20  does not have a center hole to keep its sealing effect. 
     Current practices for wrapping small quantities of rolls is to lay the wrapper on the floor and manually roll the paper over the wrapper until it is wound around the roll. An alternative practice is to place the paper roll onto rollers to facilitate turning of the roll during re-wrapping. These rollers press into the wrapper and make it difficult to obtain a tight wrap. 
     The reconditioning of some rolls requires that the outer layers of paper be removed. Perhaps several inches of paper may need to be removed. The current practice is to slit the roll along its axis with a portable circular saw to the depth that needs to be removed. This creates a problem because rolls may be upwards of seven feet in diameter which will result in a slab of paper over twenty-one feet in length. 
     Additionally, the body wrap material is supplied on large rolls similar to the paper itself, only in wider dimensions. This presents the added difficulty of cutting the wrapper material to the size needed to handle an individual roll. 
     What is needed, then, is an apparatus and method to provide an inexpensive and portable system for paper roll refurbishing. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to apparatus and methods to provide an inexpensive and portable system for paper roll refurbishing. Apparatus used in the present invention includes: an apparatus for holding the body wrapper supply roll and measuring the unrolled wrapper to a desired length; an apparatus for rewinding and cutting individual wrappers for transport to the point of use; an apparatus for applying the wrappers to the paper roll; an apparatus for crimping the body wrap over the end of the roll to retain the header; an apparatus for transporting the rolls from the resizing area to the wrapping area; and an apparatus for retention of the headers and caps under pressure during curing of the retaining adhesive. 
     These apparatus provide a system of machines and equipment that provide a comprehensive, low cost, portable system for refurbishing paper rolls. 
     This present invention provides a support for the body wrap and provides a way to unwind a predetermined length of body wrap material. This material is then rewound in small, easy to handle individual rolls. These pre-cut rolls may be cut to a shorter size and thus eliminate the need to obtain and store wrapper stock of various widths. In this manner, a single roll of wrapper can supply all of the sizes as required. 
     The present invention overcomes the problems with obtaining a tight wrap by supporting the roll from its center core and providing a powered rotation to overcome the limitations of the prior art. 
     The present invention provides for support of the roll from its center to elevate the roll to facilitate in removal of the excess or damaged paper, and the application, wrapping, and crimping of the body wrap material. 
     The present invention provides for an easily transportable roll for portable movement for refurbishing. 
     The present invention also provides for the retention of the body wrap during a bonding process to obtain a tightly wrapped roll. 
     A method for using the equipment and apparatus is also provided. 
     In this manner, the objective of providing improved process flow for each of the actions for refurbishing a paper roll are provided by the present invention. 
     Other objects and further scope of the applicability of the present invention will become apparent from the detailed description to follow, taken in conjunction with the accompanying drawing wherein like parts are designated by like reference numerals. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a sequential view of the prior art method for wrapping a paper roll. 
     FIG. 2 is an end view of the wrapper supply roll holding, measuring, re-rolling, and cutting station. 
     FIG. 2A is an end view at the web clamp, cutter guide, and roll up shaft. 
     FIG. 3 is a cut away left side view of the wrapper supply roll holding, measuring, re-rolling, and cutting station. 
     FIG. 4 is a cut away left side view of the wrapper supply roll holding, measuring, re-rolling, and cutting station with the roll lifted into position. 
     FIG. 5 is a right side view of the wrapper supply roll holding, measuring, re-rolling, and cutting station. 
     FIG. 6 is a front perspective view of one end the paper roll wrap station. 
     FIG. 6A is a top front perspective view of the expander spindle. 
     FIG. 7 is a top front perspective view of one end of the paper roll wrap station. 
     FIG. 8 is a side view of two paper roll wrap stations supporting a paper roll and folding the wrap edges. 
     FIG. 9 is a side view of the roll transporter supporting a roll. 
     FIG. 10 is a side view of the header and cap clamping station. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     As shown in FIGS. 2 through 10, the present invention provides a system of machines or equipment to provide a portable refurbishing system for a paper roll. The equipment includes a wrapper supply roll holding, measuring, re-rolling, and cutting station  200 ; a paper roll wrap station  800 ; a roll transporter  900 , and header and cap damping station  1000 . 
     FIGS. 2 through 5 show the wrapper supply roll holding, measuring, re-rolling, and cutting station  200 , also known as the wrapper supply roll station  200 . The wrapper supply roll station includes a main frame  202 , a loading carriage  204 , wrapper roll lifts  214  including a fixed roll lift assembly  206  and a moveable roll lift assembly  208 , and a measuring, re-roll and cut station  210 . 
     The main frame  202  is a stationary frame of suitable size for holding the rolls of body wrap material shown as the supply roll  203 . Typical supply rolls  203  of body wrapper material are up to seven feet in diameter and 152 inches long. The main frame  202  forms the base of the wrapper supply roll station  200 . Within the main frame  202 , four longitudinal beams  212  act as structural members to attach and support the wrapper roll lifts  214 . Two of these beams  202  act as tracks  216  for a movable loading carriage  204 . 
     The loading carriage  204  receives the roll of supply material  203 . The supply roll  203  is placed upon the carriage  204  that has two uprights  218 , one on each side, that retain the roll  203  on the carriage frame  220 . Rollers  222  mounted to the carriage frame  220  allow the carriage  204  to be moved back and forth along the tracks to the desired position. The loading carriage  204  may be moved along the tracks  216  and positioned for different lengths of supply rolls  203 . Once the supply roll  203  is placed on the loading carriage  204 , the spindles  226  are vertically adjusted to be placed at the height of the roll core  228  and the roll  203  and carriage  204  are moved to position the wrapper roll  203  such that the roll  203  may be lifted by the roll lifts  214 . 
     Each end of the main frame  202  is equipped with roll lifts  214  for lifting the supply roll  203  off of the carriage  204 . The fixed roll lift  206  is fixed in position on the frame  202  while the adjustable roll lift  208  is mounted on wheels  224  that allow the wrapper supply roll station  200  to accommodate various length supply rolls  203 . The adjustable lift  208  rides upon the same tracks  216  as the carriage  204 . 
     Each roll lift  214  is equipped with a spindle  226  that inserts into the core  228  of the supply roll  203 . The spindle  226  of each lift  214  is attached to a vertically mounted guide plate  234  moving between guide tracks  238 . The vertically mounted guide plate  234  is connected to a hydraulic cylinder  236  to provide the controlled vertical movement of the plate  234  within the tracks  238 . The cylinders  236  are actuated to raise and lower the supply roll  203 . Each lift  214  is equipped with an independent hydraulic power unit that powers the cylinders  236  and in the instance of the fixed lift  206 , powers a hydraulic wrapper supply roll rotation motor  230 . The spindle  226  of the fixed lift is powered by a hydraulic motor  230  attached to the spindle through a drive  232  so that it can rotate the supply roll  203  for unwinding the wrapper. The spindle  226  of the movable lift  208  acts as an idler and is used to support and lift the supply roll  203 . 
     FIG. 2 is an end view of the wrapper supply roll station  200  showing a supply roll  203  loaded onto the carriage  204 . FIG. 2A is a more detailed end view showing a web path through the guide  246 , clamp  248 , measuring wheel  250 , and rollup shaft  254 . The path of the supply material web  244  is shown going under a horizontal guide member  246 , over a horizontal web clamp bar  247 , under a pivoted web clamp  248 , under a measuring wheel  250 , over a cutting guide member  252 , and finally onto roll-up shaft  254 . 
     FIG. 5 shows a second hydraulic wrapper rotation motor  256  that pulls the wrapper web  244  from the supply roll  203  and turns the roll-up shaft  254 . The roll rotation and wrapper motors  230 ,  256  are coordinated such that the supply roll  203  is rotated in harmony with the roll-up shaft  254  so as to maintain tension on the web  244  for a wrinkle free product during the transfer. 
     As shown in FIGS. 2,  2 A, and  5 , the measure wheel  250  is a commercially available instrument. The measure wheel  250  allows a preset length to be programmed into its controls to stops rotation of the supply roll  203  and roll up shaft  254  when the correct length of wrapper web  244  has been moved onto the roll up shaft  254 . 
     A pivoted clamp  248  that is self actuated by gravity holds the supply wrapper web  244  in place against the horizontal web clamp bar  247 . The guide-cutting member  252  includes an upper support area  256  with a slot  258  so that a knife may be used to sever the wrapper web  244  along the guide cutting member  252 . The knife blade is pulled along the slot  258  such that the wrapper web  244  is supported on both sides of the slot  258 . Pivoted clamp  248  prevents web  244  from being pulled from the guides when the web  244  is cut. 
     The roll-up shaft  254  has opposed longitudinal bars  260  that are cammed into an extended position by a cam activation device  253  when the shaft  254  is rotated. This effectively increases the diameter of the shaft  254 . After the correct amount of wrapper  244  has been measured and cut from the supply roll  203 , these bars  260  are retracted an end support  262  is disconnected to allow for an axial removal of the pre-cut wrapper  12 . This results in a roll of approximately six to eight inches in diameter that maybe easily transported. Adhesive backed tape, not shown, is applied to the trailing edge of the pre-cut wrapper  12  to prevent unrolling. These pre-cut wrappers  12  may then be further packaged if they are to be shipped to a remote location. The pre-cut wrapper  12  may be cut to a new desired axial width by well known methods, such as the use of a circular saw. 
     FIGS. 6 and 7 show the wrapping carts  600  used in the paper roll wrap station  800  shown in FIG.  8 . Two of these carts  600  are required to lift and rotate the paper roll  10  that is to be refurbished. Each cart  600  is identical consisting of a framework  602  mounted on rollers  604  for mobility. A vertical portion  606  of the frame  602  forms tracks  608  as a guide for a plate  609  supporting a powered spindle  610  that is attached to a vertically mounted hydraulic cylinder  612 . Hydraulic motors  614  power the spindles  610  through drives  616 , shown as a chain drives, which rotate the roll  10  during the wrapping procedure. Hydraulic motors  614  are powered by a hydraulic power unit consisting of an electric motor of approximately 1½ hp., a commercially available hydraulic pump, valves, and other standard components found in a hydraulic power system. Hydraulic motors  614  are connected to a gear reducer and a one way clutch which drives spindle  610 . The clutch allows the motor to drive spindle  610  but prevents the pump from being turned backward by the spindle. The gear reducer output speed is about 54 rpm. 
     The carts  600  are positioned at each end of the paper roll. A header is placed onto the spindle  610  for use at a later time. The spindle  610  is then inserted into the ends of the rolls  10  and the roll  10  is then lifted using the spindle  610  and the grippers  618 . As shown in FIG. 6A, a segmented gripper  618  of the correct size for the core tube of the paper roll  10  is placed on each spindle  610 . The segmented gripper  618  is shown in FIG.  6 A and includes a set of eight segments  620  held on by a ring  622  such that the segments  620  may expand the diameter of the spindle  610  to fit the inside diameter of the roll  10  core. Segments  620  fit on the small diameter adjustment shaft  624  of the spindle  610 . Retracting this adjustment shaft  624  into the spindle  610  causes the segments  620  of the gripper  618  to expand to grip the interior  13  of the core tube  11  to prevent slippage. The most prevalent core sizes are 3″ and 6″ but other sizes may be accommodated. 
     To lift the roll  10 , the spindles are positioned so as to enter the hollow core tube  11  in the center of each roll  10 . The spindles  610  are then elevated which lifts the paper roll  10  off of the floor. The front edge of a precut body wrapper  12  is attached to the paper roll  10  using tape (not shown). The spindle motors  614  then rotate the roll  10  causing the wrapper  12  to wind about the roll  10 . The trailing edge of the wrapper  12  is then secured using an adhesive tape  265  as shown in FIG.  9 . Note: a one-way clutch is utilized in the gearbox of each cart. This prevents the hydraulic motor  614  from being driven backwards and becoming a pump when it is driven in the opposite direction by the opposing drive motor as previously described. 
     As noted in the process of FIG. 1, the next step is to crimp the edges  14  of the resulting body wrapper  12  that overhangs the paper roll  10  by about six inches on each end  18 . As shown in FIGS. 6 and 8, each cart  600  is equipped with a circular rotating element crimper  622 , also known as a crimp disc  622 , consisting of five blades  624 , which is used to perform a crimp to the overhung body wrap material  14 . A hydraulic disc motor  626  mounted to a frame  628  powers the crimper  622 . This frame  628  is pivoted at pivots  630 ,  632  operating in two directions at the bottom of the frame  628 . The rotational speed of the crimper is approximately 54 rpm. 
     As shown in FIG. 8, one pivot  630  allows the crimper  622  to rotate in toward the end  18  of the roll  10 . This positions the plane of the crimping disc  622  in the same plane as the end  18  of the roll  10 . The other pivot  632  allows the disc  622  to move parallel with the end  18  of the roll  10 . In use, the crimper disc  622  is first rotated away from the outer diameter surface of the paper roll  10 . When placed into motion, the roll  10  and the crimper  622  are both rotating. The crimper  622  is slowly pivoted into the roll  10  until the crimper  622  begins to bend the wrapper overhang  14  ninety (90) degrees to be parallel with the end  18  of the roll  10 . A fold  15  or crimp is formed as the crimper  622  is pivoted toward the axis of the roll  10 . The resulting folded over crimp retains the protective header  16  that will be inserted. A wireless foot switch  634  is used to control the rotation of the crimper  622 . This eliminates the electrical cable and the associated hazards and inconveniences that would otherwise exist. 
     In order to allow use of the mobile roll wrapper from readily available electrical power, namely 120 volts 60 Hz operation in the United States, the size of the electric motors (1½ hp) for the hydraulic pumps are limited in size to prevent overloading of the circuits. Each cart may be connected to a separate electrical power supply circuit in order to prevent overloading of the circuits. This motor size limitation allows operation of either the roll motor  614  or the crimper motor  626 , but would not allow the operation of both motors simultaneously off of the same low power circuit. To explain: When cart # 1  rotates the roll, the opposite cart # 2  powers the Crimper  622  on cart # 2 . The roles of the carts are then changed so that cart # 2  turns the roll and cart # 1  powers the Crimper  622  on cart # 1 . Thus only one motor per cart is connected to the electrical power source. This allows the use of both motors off of standard circuits for portable operation that does not require a fixed high power supply. 
     FIG. 9 shows the roll transporter  900 . When the crimping operation is complete the roll  10  is lowered onto a modified version of a commercially available pallet jack  902  for transport to the header and cap clamping station  1000 . This jack  902  is modified to retain the roll  10  with two uprights  904 , one on each side of the jack  902 , that retain the roll  10  on the pallet jack  902 . Rollers  906  mounted to the jack  902  allow the jack  902  to be moved to the desired position for installing the header  16  and cap  20  end protection. 
     FIG. 10 shows the header and cap clamping station  1000 . The clamping station  1000  equipment consists of vertical end frames  1002  of structural steel that support an overhead steel beam  1004 . Two commercially available lifting hoist trolleys  1006  ride on the lower flange  1007  of this beam  1004 . This assembly is approximately 14-ft long×5-ft wide×8-ft high. Attached to each trolley  1006  is a spreader bar  1008  of structural steel about 4-ft long. A holding chain  1010  is affixed to each end  1012  of this spreader bar  1008 . These holding chains  1010  support a steel clamp plate  1014  that may assume various dimensions depending upon the size of the paper roll  10  being refurbished. A typical dimension may be 4-ft×5-ft. These plates  1014  are reinforced with structural steel shapes  1016  to reduce bending. A clevis  1018  is affixed at the mid-point  1020  and near the side edge  1022  of each of these two plates  1014 . 
     Additional components include two hydraulic cylinders  1024  attached to a length of clamping chain  1026  on each side of the clamping station  1000 . These cylinders  1024  have a stroke length of say 10-inches and are capable of exerting a force of up to 10,000 lbs. This force level is not required and is limited by controlling the hydraulic pressure. 
     The trolleys  1006  and attached clamp plates  1014  are moved toward the ends  1028  of the trolley beam  1004 . A paper roll  10  previously rewrapped and crimped is moved under the clamping equipment  1000 . Adhesive is applied to an end cap  20  and to the crimped body wrap  14 . The end cap  20  is placed against the crimped wrap  14 . 
     The trolleys  1006  are rolled toward the paper roll  10  until each clamp plate  1014  is against the end cap  20 . One end  1030  of the pull-back cylinder  1024  is connected to a clevis  1018  on one clamp plate  1014 . The other end  1032  of the cylinder  1024  connects to the chain  1026  that is affixed to a clevis  1018  on the opposite plate  1014 . This connection is made with the cylinder  1024  extended. 
     Hydraulic pressure is applied to the cylinders  1024  on each side of the plates  1014  that retract, drawing the clamp plates  1014  against the paper roll  10 . The control system uses a preset hydraulic pressure to stop the cylinders  1024 , thus maintaining force against the roll end caps  20 . This force is maintained for a recommended time period adequate to allow the adhesive to cure. 
     The clamp plates  1014  are released and the roll is removed from the clamping station  1000 . Product identification labels (not shown) are applied thus completing the refurbishing process. The refurbished roll is then transported to an appropriate location. 
     A commercially available self-contained hydraulic power unit (#4ZC75 for ref only) is utilized to operate the clamp cylinders  1024 . This is a ½ horsepower 120-volt unit capable of pressures adjustable to 10,000 psi. It is typically set at 3000 psi. for operating the clamp cylinders. The power unit is controlled by a pendant type control shown in FIG. 10 that allows the cylinders to be retracted and held in the clamped position and then extended to release the clamp plates. 
     Thus, although there have been described particular embodiments of the present invention of a new and useful Apparatus and Method for Paper roll Refurbishing, it is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims.