Patent Publication Number: US-10781046-B2

Title: Vacuum nose roll

Description:
TECHNICAL FIELD 
     The present disclosure is directed to apparatuses for conveying material. 
     BACKGROUND OF THE DISCLOSURE 
     One important process step in the manufacture of many items is the transporting of material along a manufacturing pathway. In the specific case of manufacturing absorbent articles in a continuous process, materials and article components that form part of the produced absorbent articles move along different conveyer systems in the manufacturing process. Processing steps such as bonding steps or application of absorbent material or the like may happen along the manufacturing process to produce the absorbent articles. In some instances, the materials and article components may be transferred between adjacent conveyer systems within the manufacturing process. The hand-off from one conveyer system to the next can be a source of production errors or malfunctions. For instance, the materials and article components may become wrinkled, an edge of the materials or article components may be become folded over, or, particularly in high speed manufacturing processes, air may get under a leading edge of an article component, causing the component to flip, become skewed, or even fly off of the conveyer system. Accordingly, improved conveyer systems for safely and consistently transferring materials and article components between conveyer systems within a manufacturing process are desired. 
     SUMMARY OF THE DISCLOSURE 
     The disclosure is directed to several alternative designs and methods of for conveying material. 
     In a first illustrative example a vacuum conveyer system may comprise a vacuum box extending between a first box end and a second box end and comprising a first discrete vacuum chamber, a nose roll disposed adjacent to the first box end and comprising a second discrete vacuum chamber, and a foraminous member disposed about both of the nose roll and the vacuum box. 
     In a second illustrative example, the first illustrative example mayer further comprise a single vacuum source which supplies a vacuum to both the first discrete vacuum chamber and the second discrete vacuum chamber. 
     In a third illustrative example, any of the first or second illustrative examples may further comprise a first vacuum source which supplies a vacuum to the first discrete vacuum chamber and a second vacuum source which supplies a vacuum to the second discrete vacuum chamber. 
     In a fourth illustrative example, the second discrete vacuum chamber of any of the first through third illustrative examples may be external to the first discrete vacuum chamber. 
     In a fifth illustrative example, the first box end of any of the first through fourth illustrative examples may comprise an inlet end of the vacuum conveyer system. 
     In a sixth illustrative example, the second discrete vacuum chamber of any of the first through fifth illustrative examples may be substantially free of obstructions. 
     In a seventh illustrative example, the nose roll of any of the first through sixth illustrative examples may comprise a dead shaft and a live roll, and a recess within the dead shaft may form the second discrete vacuum chamber. 
     In an eighth illustrative example, a cross-sectional area of a region bounded by the recess of the seventh illustrative example may comprise between about 25% and about 50% of a cross-sectional area of a portion of the dead shaft not comprising the recess. 
     In a ninth illustrative example, the live roll of any of the seventh or eighth illustrative examples may comprise a plurality of apertures to allow airflow into the second discrete vacuum chamber, and the apertures may be chamfered. 
     In a tenth illustrative example, any of the seventh through ninth illustrative examples may further comprise an airflow conduit disposed adjacent to the live roll and a labyrinth seal connecting the live roll to the airflow conduit. 
     In an eleventh illustrative example, a vacuum conveyer system may comprise a vacuum box extending between a first box end and a second box end, the vacuum box comprising a vacuum box vacuum chamber, a nose roll disposed adjacent to the first box end, the nose roll comprising a nose roll vacuum chamber, a foraminous member disposed about both of the nose roll and the vacuum box, a first discrete airflow conduit connecting the vacuum box vacuum chamber to a vacuum source, a second discrete airflow conduit connecting the nose roll vacuum chamber to the vacuum source. 
     In a twelfth illustrative example, the second discrete airflow conduit of the eleventh illustrative example may extend at least partially through the vacuum box vacuum chamber. 
     In a thirteenth illustrative example, the first discrete airflow conduit of the eleventh or the twelfth illustrative example may connect the vacuum box vacuum chamber to a first vacuum source, and the second discrete airflow conduit may connect the nose roll vacuum chamber to a second vacuum source that is separate from the first vacuum source. 
     In a fourteenth illustrative example, any of the eleventh through thirteenth illustrative examples may further comprise a labyrinth seal between the second discrete airflow conduit and the nose roll. 
     In a fifteenth illustrative example, the labyrinth seal of the fourteenth illustrative example may comprise a sealing member, and the sealing member may extend around the nose roll for a length equal to between 5% and 25% of the circumference of the nose roll. 
     In a sixteenth illustrative example, the second discrete airflow conduit of any of the eleventh through fifteenth illustrative examples may comprise an adjustable inlet plate. 
     In a seventeenth illustrative example, a vacuum conveyer system may comprise a vacuum box extending between a first box end and a second box end, the vacuum box comprising a vacuum box vacuum chamber, a nose roll disposed adjacent to the first box end, the nose roll comprising a nose roll vacuum chamber, and a foraminous member disposed about both of the nose roll and the vacuum box, and wherein the nose roll vacuum chamber is substantially free of obstructions. 
     In an eighteenth illustrative example, the system of the seventeenth illustrative example may further comprise a first airflow conduit connecting the vacuum box vacuum chamber to a first vacuum source, and a second airflow conduit connecting the nose roll vacuum chamber to either the first vacuum source or a second vacuum source. 
     In a nineteenth illustrative example, the nose roll of the seventeenth or eighteenth illustrative examples may comprise a dead shaft and a live roll, and a recess within the dead shaft may form the nose roll vacuum chamber. 
     In a twentieth illustrative example, a cross-sectional area of a region bounded by the recess of the nineteenth illustrative example may comprise between about 25% and about 50% of a cross-sectional area of a portion of the dead shaft not comprising the recess 
     The above summary of some example embodiments is not intended to describe each disclosed embodiment or every implementation of aspects of the disclosure. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       The aspects of the disclosure may be further understood in consideration of the following detailed description of various embodiments in connection with the accompanying drawings, in which: 
         FIG. 1  is a perspective view of a vacuum conveyer system, according to aspects of the present disclosure; 
         FIG. 2  is a perspective partial view of the vacuum conveyer system of  FIG. 1  depicting internal components of the system; 
         FIG. 3  is a perspective view of a nose roll assembly of the vacuum conveyer system of  FIG. 1 , according to aspects of the present disclosure; 
         FIG. 4  is a cross-section view of the nose roll assembly of  FIG. 3  taken along line  4 - 4 ; and 
         FIG. 5  is a cross-section view of a nose roll shaft of the nose roll assembly of  FIG. 3  taken along line  4 - 4 . 
     
    
    
     Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the disclosure. Additionally, while the aspects of the disclosure are amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit aspects of the disclosure to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure. 
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     The present disclosure is generally directed towards several alternative designs and methods of for conveying material. In some high speed manufacturing processes, moving materials and article components from one conveyer system to another conveyer system can introduce undesired movement of the materials and article components, from slight skewing of the materials and components with respect to desired positions all the way to complete dislodgment of the materials and components from the conveyer system. Generally, conveyer systems employ vacuum pressure to help keep materials and article components in position on the conveyer as the materials and components move within the system. However, this vacuum pressure can be difficult to localize at front and/or rear ends of conveying systems, thereby making the transition from one conveying system to another conveying system a source of manufacturing problems. The present disclosure relates to vacuum conveying systems with improved abilities for retaining materials and article components on the conveying systems and along the desired conveying paths as the materials and components transition from one conveying system to another conveying system. 
     The following detailed description should be read with reference to the drawings in which similar elements in different drawings are numbered the same. The detailed description and the drawings, which are not necessarily to scale, depict illustrative embodiments and are not intended to limit the scope of the disclosure. The illustrative embodiments depicted are intended only as exemplary. Selected features of any illustrative embodiment may be incorporated into an additional embodiment unless clearly stated to the contrary. 
     When introducing elements of the present disclosure or the preferred embodiment(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Many modifications and variations of the present disclosure can be made without departing from the spirit and scope thereof. Therefore, the exemplary embodiments described above should not be used to limit the scope of the invention. 
     Definitions: 
     The term “nonwoven” refers herein to materials and webs of material which are formed without the aid of a textile weaving or knitting process. The materials and webs of materials can have a structure of individual fibers, filaments, or threads (collectively referred to as “fibers”) which can be interlaid, but not in an identifiable manner as in a knitted fabric. Nonwoven materials or webs can be formed from many processes such as, but not limited to, meltblowing processes, spunbonding processes, carded web processes, etc. 
     The term “spunbond” refers herein to small diameter fibers which are formed by extruding molten thermoplastic material as filaments from a plurality of fine capillaries of a spinnerette having a circular or other configuration, with the diameter of the extruded filaments then being rapidly reduced by a conventional process such as, for example, eductive drawing, and processes that are described in U.S. Pat. No. 4,340,563 to Appel et al., U.S. Pat. No. 3,692,618 to Dorschner et al., U.S. Pat. No. 3,802,817 to Matsuki et al., U.S. Pat. Nos. 3,338,992 and 3,341,394 to Kinney, U.S. Pat. No. 3,502,763 to Hartmann, U.S. Pat. No. 3,502,538 to Peterson, and U.S. Pat. No. 3,542,615 to Dobo et al., each of which is incorporated herein in its entirety by reference. Spunbond fibers are generally continuous and often have average deniers larger than about 0.3, and in an embodiment, between about 0.6, 5 and 10 and about 15, 20 and 40. Spunbond fibers are generally not tacky when they are deposited on a collecting surface. 
     The term “superabsorbent” refers herein to a water-swellable, water-insoluble organic or inorganic material capable, under the most favorable conditions, of absorbing at least about 15 times its weight and, in an embodiment, at least about 30 times its weight, in an aqueous solution containing 0.9 weight percent sodium chloride. The superabsorbent materials (SAM) can be natural, synthetic and modified natural polymers and materials. In addition, the SAM can be inorganic materials, such as silica gels, or organic compounds, such as cross-linked polymers. 
       FIG. 1  is a perspective view of vacuum conveyer system  100 . Vacuum conveyer system  100  may generally comprise vacuum box  102 , vacuum nose roll assembly  104 , and moveable belt member  106 . Moveable belt member  106  may be driven by belt motor assembly  103 , which can drive belt member  106  to move about vacuum box  102  and vacuum nose roll assembly  104  in machine direction  120 . 
     Vacuum box  102  may generally include a hollow interior forming a discrete vacuum box vacuum chamber  130  (as depicted in  FIG. 2 ), and the hollow interior may be connected to airflow conduit  110 . Airflow conduit  110 , in turn, may be connected to vacuum source  114 . In this way, vacuum source  114  can create a pressure differential within vacuum box  102  relative to the space outside of vacuum box  102 . In some embodiments, vacuum box  102  may include a porous top surface, which, in combination with vacuum source  114 , creates a suction force at the porous top surface of vacuum box  102  as air is pulled into vacuum box  102  due to the pressure differential between the inside of vacuum box  102  and the outside of vacuum box  102 . In other embodiments, vacuum box  102  may be enclosed only on three sides while the top is left open. In such embodiments, belt member  106  may act as the top surface of vacuum box  102 . 
     Belt member  106  may generally be comprised of any number of suitable flexible materials, and in some embodiments may comprise a screen. For example, belt member  106  may be comprised of any rubber material having suitable flexible properties enabling belt member  106  to bend around vacuum nose roll assembly  104 . Alternatively, belt member  106  may be comprised of any suitable metal material that has the suitable flexibility. In general, these types of belt or screen members are well-known in the art. One important aspect of belt member  106  is that belt member  106  includes porous region  108 . As mentioned previously, vacuum box  102  may be configured with vacuum source  114  to create a pressure differential within vacuum box  102  relative to the space outside of vacuum box  102 . Porous region  108  of belt member  106  allows air to flow through belt member  106  and into vacuum box  102  due to the pressure differential, thereby creating a suction force at belt member  106 . This suction force helps to maintain the positioning of materials and article components being transported on belt member  106 . 
     Although only depicted in  FIG. 1  in a small region relative to the size of belt member  106 , in other contemplated embodiments porous region  108  may take on any shape or size. For instance, porous region  108  could extend along belt member  106  all the way up to the entire length of belt member  106 . Additionally, in  FIG. 1 , porous region  108  extends approximately along the entire cross-machine direction  122  length of belt member  106 . However, in other embodiments, porous region  108  may only extend along a portion of the cross-machine direction  122  length of belt member  106 , such as along a cross-machine direction  122  length approximately equal to a cross-machine direction  122  length of materials or article components to be transported on vacuum conveyer system  100 . 
     Vacuum nose roll assembly  104  may be generally disposed adjacent one end of vacuum conveyer system  100 . In some embodiments, vacuum nose roll assembly  104  may be disposed adjacent an inlet end of system  100  where material is brought onto system  100 . However, in other embodiments, vacuum nose roll assembly  104  may be disposed adjacent an outlet end of system  100  where material exits system  100 . As will be described in more detail below, vacuum nose roll assembly  104  may comprise a discrete nose roll vacuum chamber  132  (as seen in  FIG. 4 ) which is separate and distinct from vacuum box vacuum chamber  130  and not fluidly connected to vacuum box vacuum chamber  130 . Vacuum conveyer system  100  may further comprise an airflow conduit that is separate from airflow conduit  110  and which connects vacuum nose roll assembly  104  to a vacuum source. In some contemplated embodiments, system  100  may include airflow conduit  112   a  which connects vacuum nose roll assembly  104  to vacuum source  114 , the same vacuum source that is connected to airflow conduit  110  and vacuum box  102 . In other contemplated embodiments, however, system  100  may include airflow conduit  112   b  which connects vacuum nose roll assembly  104  to vacuum source  116  which is separate from vacuum source  114 . In general, vacuum sources  114  and/or  116  may be vacuum pumps, fans, or any other suitable energy source configured to provide airflow out of vacuum box vacuum chamber  130  and nose vacuum chamber  132 . Vacuum sources  114  and/or  116  may be configurable to provide adjustable pressure differentials within vacuum box vacuum chamber  130  and/or nose roll vacuum chamber  132 . In other embodiments, airflow conduits  110  and/or  112   a ,  112   b  may include one or more dampers which can be adjusted to provide different pressure differentials within vacuum box vacuum chamber  130  and/or nose roll vacuum chamber  132 . 
     The presence of distinct vacuum box vacuum chamber  130  and nose roll vacuum chamber  132  allows for greater control of the pressure differentials within each chamber  130 ,  132 . This greater control may help to ensure that transported materials and article components maintain their position as they travel a path through a manufacturing process, both along a vacuum conveyer system such as system  100  and during transitions between adjacent conveyer systems. 
       FIG. 2  is a perspective view of the vacuum conveyer system of  FIG. 1  with belt member  106  removed. As can be seen in  FIG. 2 , airflow conduit  112   a  (or  112   b ) connecting vacuum nose roll assembly  104  to one of vacuum sources  114 ,  116  may further connect to airflow conduit  113  which extends at least partially through vacuum box vacuum chamber  130 . Although shown vacuum box vacuum chamber  130  is depicted as a single chamber, in other embodiments vacuum box vacuum chamber  130  may comprise two or more vacuum chambers with additional airflow conduits connecting each vacuum chamber to a vacuum source (or the same vacuum source in some embodiments). In still other contemplated embodiments, vacuum chamber  130  may comprise any suitable number of chambers, such as between 1 chamber and 5 chambers. 
     As described previously, vacuum conveyer system  100  may be suitable for transporting materials and article components used in the manufacture of absorbent articles. Example materials that vacuum conveyer system  100  may transport include webs constructed of any of a variety of materials, such as synthetic fibers (for example, polyester or polypropylene fibers), natural fibers (for example, wood or cotton fibers), a combination of natural and synthetic fibers, porous foams, reticulated foams, apertured plastic films, or the like. Such materials may be in the form of various woven and non-woven fabrics which can include spunbond fabric, meltblown fabric, coform fabric, carded web, bonded-carded web, bicomponent spunbond fabric, spunlace, or the like, as well as combinations thereof. 
     Vacuum conveyer system  100  may also be suitable for transporting absorbent article components such as absorbent cores. Exemplary absorbent cores may be comprised generally of pulp fluff, SAM, or pulp fluff combined with SAM. Vacuum conveyer system  100  may be particularly useful in transporting materials and article components that are thin and flexible, for example absorbent cores that are equal to or greater than 75% of SAM by weight. 
     It should be understood that although the examples used herein describing materials that may be transported by vacuum conveyer system  100  include materials and articles used in the production of absorbent articles, these specific uses do not limit vacuum conveyer system  100  in anyway. Rather, vacuum conveyer system  100  may be suitable for transporting any suitable material, component, or product. 
     In order to successfully transport such materials and article components, for instance ensuring the materials and article components maintain their positions as they travel throughout the manufacturing process, vacuum source  114  (and possibly  116 ) may be configured to provide specific pressure differentials within vacuum box vacuum chamber  130  and nose roll vacuum chamber  132  (as seen in  FIG. 4 ). In some embodiments, vacuum source  114  (and possibly  116 ) may be fans rated at between about 1,000 cubic feet per minute (CFM) and about 10,000 CFM. Such vacuum source(s) may be able to create pressures of between about 0.5 inch of water (0.125 kPa) and about 100 inches water (25 kPa) within vacuum box vacuum chamber  130  and within nose roll vacuum chamber  132 . In other embodiments, vacuum source  114  (and/or  116 ) may be able to create pressure of between about 1 inch of water (0.25 kPa) and about 10 inches of water (25 kPa) within vacuum box vacuum chamber  130  and within nose roll vacuum chamber  132 . 
       FIG. 3  is a perspective view of nose roll assembly  104  of vacuum conveyer system  100 . Nose roll assembly  104  generally comprises nose roll  150  and nose roll shaft  152 . Nose roll  150  and nose roll shaft  152  are configured in a live-roll-dead-shaft configuration where nose roll shaft  152  maintains its rotational position throughout operation of vacuum conveyer system  100 , and nose roll  150  rotates about nose roll shaft  152  during operation of vacuum conveyer system  100 . 
     Nose roll  150  generally comprises apertures  154 , ridges  156 , and smooth areas  158 . Apertures  154  may allow air to flow through nose roll  150  and into nose roll vacuum chamber  132  (as seen in  FIG. 4 ), as evidenced by airflow paths  162 . Ridges  156  may cooperate with sealing member  161  (as can be further seen in  FIG. 4 ) to provide a seal between airflow conduit  113  and nose roll  150 . Similarly, smooth areas  158  may cooperate with sealing members  160  in order to provide a seal between airflow conduit  113  and nose roll  150 . 
     In at least some embodiments, nose roll assembly  104  may further include adjustable inlet plate  164 . In these embodiments, adjustable inlet plate  164  may cover a portion of airflow conduit  113  and may further comprise apertures  166 . For example, adjustable inlet plate  164  may be a top portion of airflow conduit  113 , and apertures  166  may allow air to enter airflow conduit  113 , as depicted by air flow paths  162 , thereby providing a suction force along adjustable inlet plate  164 . In this way, vacuum conveyer systems  100  that include adjustable inlet plate  164  may provide a suction force on materials and article components as they pass over nose roll assembly  104  and transition past nose roll assembly  104  but before they pass over vacuum box vacuum chamber  130 . In at least some embodiments where vacuum conveyer system  100  includes adjustable inlet plate  164 , adjustable inlet plate  164  may be moveable in the direction of arrows  165 . Moving adjustable inlet plate  164  along a path aligned with arrows  165  may adjust both a positioning of the suction force due to the changing of location of apertures  166  (and/or opening a gap between nose roll  150  and adjustable inlet plate  164 ) and the level of suction force within airflow conduit  113  at adjustable inlet plate  164 . In other embodiments, plate  164  may be adjustable in a direction different than depicted by arrows  165 , for example aa direction having any angle with respect to arrows  165 . In some of these embodiments, plate  164  may comprise a pair of plates with aligned apertures. Moving the top plate of the pair in any direction may un-align the apertures of each of the pair of plates, thereby adjusting the suction strength along plate  164 . 
       FIG. 4  is a cross-section view of nose roll assembly  104  taken as viewed along line  4 - 4 . As can further be seen in the profile view of  FIG. 4 , vacuum nose roll  150  comprises apertures  154  and ridges  156 . Apertures  154  of vacuum nose roll  150  may fluidly connect the exterior of vacuum nose roll  150  with the interior of vacuum nose roll  150  and with airflow conduit  113 . As described above, vacuum source  114  (and/or  116 ) may be connected to airflow conduit  112 , which connects to air flow conduit  113 . Accordingly, when vacuum source  114  (and/or  116 ) is in operation, air may move from the exterior of vacuum nose roll  150  to the interior of vacuum nose roll  150  through one or more apertures  154  and into nose roll vacuum chamber  132 , as depicted by arrow  170 . Nose roll vacuum chamber  132  may be formed by a recess of nose roll shaft  152 . The air that entered nose roll vacuum chamber  132  may additionally move out of nose roll vacuum chamber  132  through one or more additional apertures  154  and into airflow conduit  113  due to the action of vacuum source  114  (and/or  116 ), as shown by arrow  171 . In this manner, vacuum source  114  (and/or  116 ), airflow conduits  113 ,  112 , and nose roll assembly  104  may be configured to achieve a suction force at the outer surface of vacuum nose roll  150 . In at least some embodiments, apertures  154  may have chamfered inner edges  153  in order to help create smooth airflow into nose roll vacuum chamber  132 . In other embodiments, instead of chamfered inner edges  153 , apertures  154  may comprise angled walls such that apertures  154  widen from as they extend toward nose roll vacuum chamber  132 . 
     Vacuum nose roll  150  may comprise both ridges  156  and recesses  157  and may further be described as having both a minor diameter and a major diameter due to ridges  156  and recesses  157 . In this manner, vacuum nose roll  150  may comprise both surfaces  155 , which may be the surface of the minor diameter of vacuum nose roll  150 , and surfaces  159  which may be the surface of the major diameter of vacuum nose roll  150 . 
     Surfaces  159  may be the outer most portion of ridges  156 , and ridges  156  may interact with sealing member  161  in order to form a seal between vacuum nose roll  150  and airflow conduit  112 . For example, ridges  156  and sealing member  161  may be configured such that there is a very small-to-no gap between surfaces  159  and sealing member  161  as ridges  156  pass adjacent to sealing member  161 . This close fit forms a seal between vacuum nose roll  150  and airflow conduit  113  to help prevent air entering airflow conduit  113  from locations other than through vacuum nose roll  150  and nose roll vacuum chamber  132 . Locations where air enters airflow conduit  113  from locations other than through vacuum nose roll  150  and nose roll vacuum chamber  132  may be thought of as “leaks”. For instance, air entering airflow conduit  113  from locations other than through vacuum nose roll  150  and nose roll vacuum chamber  132  reduces the amount of pressure differential vacuum source  114  (and/or  116 ) may create between nose roll vacuum chamber  132  and the exterior of vacuum nose roll  150 . This reduced pressure differential equates to a reduced suction force at the surface of vacuum nose roll  150 . Additionally, the specific configuration of sealing member  161  and of recesses  157  and surfaces  159  on vacuum nose roll  150  as shown in  FIG. 4  may be termed a labyrinth seal. In this configuration, as vacuum nose roll  150  spins about nose roll shaft  152 , air becomes trapped within recesses  157  as they pass by sealing member  161 . These trapped pockets of air further help to impede any airflow from outside of vacuum nose roll  150  into airflow conduit  113  from between vacuum nose roll  150  and sealing member  161  due to the relatively lower pressure within airflow conduit  113 . 
     In order to form an effective labyrinth seal, the specific dimensions of recesses  157  and sealing member  161  may need to fall within particular boundaries. For instance, sealing member  161  has a surface  163  which may curve to follow the contour of vacuum nose roll  150 . In some embodiments, surface  163  of sealing member  161  may have a contour length equal to between about 5% and about 25% of the circumference of vacuum nose roll  150 . The contour length of surface  163  may be the length of surface  163  from the top of sealing member  167  to the bottom of sealing member  169 , as seen in  FIG. 4 , found by following the curvature of the surface  163 . Additionally, recesses  157  may have a maximum width of between about 0.5 mm and about 10 mm. In other embodiments, recesses  157  may have a width that is equal to portion of a circumferential length of vacuum nose roll  150 . In some embodiments, recesses  157  may have a maximum width equal to between about 0.5% and about 5% of the circumference of vacuum nose roll  150 . Ridges  156  may have a radial height of between about 2 mm and about 20 mm. 
     In some embodiments, the maximum width of ridges  156  may be the same as the maximum width of the recesses  157 . However, this is not necessary in all embodiments. For instance, the maximum width of ridges  156  may range between about 50% and about 200% of the maximum width of the recesses  157  in different embodiments. 
     In some further embodiments, nose roll assembly  104  may further comprise recesses  168  disposed on nose roll shaft  152 . Similar to recesses  157  and sealing member  161 , recesses  168  and interior surface  151  of vacuum nose roll  150  may form a labyrinth seal to prevent air from entering nose roll vacuum chamber  132  and/or airflow conduit  113  from between vacuum nose roll  150  and nose roll shaft  152 . In different embodiments, recesses  168  may vary in depth between about 2 mm and about 20 mm. Additionally, recesses  168  may have a maximum width that ranges from about 0.5 mm to about 10 mm in different contemplated embodiments. 
     Nose roll vacuum chamber  132  may be formed of a recess within nose roll shaft  152 . For example, a portion of nose roll shaft  152  not comprising the recess forming nose roll vacuum chamber  132  may have a first cross-sectional surface area, which comprises the area bounded by surfaces  159  of nose roll shaft  152  as shown in  FIG. 5 . Further, nose roll shaft  152  may have a second cross-sectional surface area at a portion of nose roll shaft  152  comprising the recess forming nose roll vacuum chamber  132 . In the example of  FIG. 5 , this second cross-sectional surface area would be the first cross-sectional surface area less the region bounded by dotted line  176  defining the recess forming nose roll vacuum chamber  132 . In at least some embodiments, the second cross-sectional surface area may be between about 50% and about 75% of the first cross-sectional surface area. As some illustrative examples, the first cross-sectional surface area may be between about 10 in 2  (64.5 cm 2 ) and about 150 in 2  (968 cm 2 ). Accordingly, the second cross-sectional surface area may then be between about 5 in 2  (32.2 cm 2 ) and about 112.5 in 2  (726 cm 2 ). This would put the cross-sectional area of the region forming nose roll vacuum chamber  132 , e.g. the region bounded by dotted line  176 , between about 25% percent and about 50% of the first cross-sectional area. Using the exemplary area values above, this means the cross-sectional area of the region forming nose roll vacuum chamber  132  may be between about 0.5 in 2  (3.2 cm 2 ) and about 52.5 in 2  (339 cm 2 ). However, it should be understood that these are only exemplary values. In other contemplated embodiments, nose roll  150  and nose roll shaft  152  may be as large or small as necessary for whatever particular desired application of vacuum conveyer system  100 . 
     In at least some embodiments, nose roll shaft  152  may have a further feature where nose roll vacuum chamber  132  is substantially free of obstructions. The more open and smooth nose roll vacuum chamber  132  is, the less turbulence will be introduced to air entering nose roll vacuum chamber  132 . Lower turbulence of air present in nose roll vacuum chamber  132  equates to lower levels of pressure able to be achieved by vacuum source  114  (and/or  116 ) given a static amount of vacuum energy supplied by vacuum source  114  (and/or  116 ). Accordingly, if nose roll vacuum chamber  132  is substantially free of obstructions, the greater the suction force may be achieved at nose roll surface  155  than where nose roll vacuum chamber  132  is not substantially free of obstructions. The phrase ‘substantially free of obstructions’ may be construed to mean there are no portions of nose roll shaft  152  or hardware or other members attached to nose roll shaft  152  which extend into nose roll vacuum chamber  132  an amount greater than about 10 mm. 
     Those skilled in the art will recognize that aspects of the present disclosure may be manifested in a variety of forms other than the specific embodiments described and contemplated herein. Accordingly, departure in form and detail may be made without departing from the scope and spirit of the present disclosure as described in the appended claims.