Patent Publication Number: US-10308460-B2

Title: Web transfer device with vacuum hood and methods for web transfer

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Patent Application Ser. No. 62/127,573, entitled “Web Splicing Device with Vacuum Hood,” and filed Mar. 3, 2015, the subject matter of which is incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to a web transfer device for a multiple spindle turret type winder for use in a continuous web process line and more particularly to a web transfer device having a transfer apparatus that employs a vacuum hood assembly for holding, cutting and transferring the web from a full core to a new core. The present invention is also directed to methods for web transfer in a continuous web process line. 
     BACKGROUND OF THE INVENTION 
     Turret winders wind webs of paper, paperboard and non-paper products, such as film and polyethylene, onto cores and into rolls. Products, properties, speeds and widths vary from winder to winder and from plant to plant. The proper procedure of threading and attaching each particular product to the winder, therefore, varies as well from winder to winder. 
     In addition, many turret winders wind rolls of paper or film using a pressure roll, sometimes called a rider roll, pack roll, lay-on roll, or bump roll. Typically, the lay-on roll is a straight beam (e.g., cylindrical shaft, spindle or tube) which applies pressure to the film as it is being wound onto one or more cores into one or more winding rolls positioned on a core shaft of the turret winder. When one of the cores has a full capacity of the web wound thereon (i.e., full core), the web is typically cut thereby creating a trailing edge and a new leading edge of the web. The trailing edge is wound around the full core and the full core is move to an outboard position on the turret. The turret positions a new core into position for receiving the new leading edge. The transfer of the web from the full core to the new core occurs during production in a continuous mode. Prior art cutting devices are known to leave non-uniform leading edges and trailing edges. This can create non-uniform web build up on the new core and can lead to waste associated with removing a portion of the web proximate the tail on the full core. Such waste is of particular concern for self-wound-adhesive webs, expensive web materials and automated packaging applications. 
     There is a need to improve the process for cutting and transferring the web from a full core to a new core. 
     SUMMARY 
     There is disclosed herein a web transfer device for a multiple turret winder on a continuous web process line. The web transfer device includes a web delivery assembly having delivery rolls and a core transfer assembly having one or more core receiving structures. The transfer device includes a web transfer assembly configured to receive a web from the web delivery assembly and configured to communicate with the core transfer assembly. The web transfer assembly includes a frame and lay-on roll moveably positioned relative to the frame. The web transfer assembly includes a vacuum hood moveably positioned relative to the frame. The vacuum hood has a cutting device mounted therein and one or more suction holding surfaces that are configured to releasably hold a portion of the web. The suction holding surfaces are movable relative to the frame and the core receiving structures. The suction holding surfaces communicate with the core receiving structures to transfer the web thereto. 
     There is further disclosed herein a method for transferring a web in a continuous web process line. The method includes providing a web transfer device that includes a web delivery assembly comprising one or more web delivery roll, a core transfer assembly comprising two ore more core receiving structures; and a web transfer assembly configured to receive a web from the web delivery assembly and configured to communicate with the core transfer assembly. The method includes providing the web transfer assembly with a frame and lay-on roll moveably positioned relative to the frame. The web transfer assembly includes a vacuum hood moveably positioned relative to the frame. The vacuum hood has a cutting device mounted therein. The vacuum hood has one or more suction holding surfaces. The method includes the following steps in this order: a) stopping the web on one of the at least two core receiving structures; b) holding the web with the at least one suction holding surface; c) cutting the web with the cutting device to create a leading edge and a trailing edge; d) releasing the trailing edge from the at least one suction holding surface; and e) securing the leading edge, via the at least one suction holding surface, to another of the least two core receiving structures. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is a schematic view of a portion of a continuous web processor line showing a web transfer device of the present invention in an initial thread up configuration; 
         FIG. 1B  is a schematic view of the portion of the continuous web processor line showing the transfer device in a winding configuration on a new core; 
         FIG. 1C  is a schematic view of the portion of the continuous web processor line showing the transfer device in the winding configuration on a full core; 
         FIG. 1D  is a schematic view of the portion of the continuous web processor line showing the transfer device in a configuration ready of turret indexing; 
         FIG. 1E  is a schematic view of the portion of the continuous web processor line showing the turret having indexed to a roll-change position; 
         FIG. 1F  is a schematic view of the portion of the continuous web processor line showing the transfer device in an initial position for web transfer with the turret indexed to the roll-change position; 
         FIG. 1G  is a schematic view of the portion of the continuous web processor line showing the web clamped against a portion of a vacuum hood of the transfer device for severing the web with the turret indexed to the roll-change position; 
         FIG. 1H  is a schematic view of the portion of the continuous web processor line showing the severed web clamped against a portion of a vacuum hood with the transfer device slightly retracted and with the turret indexed to the roll-change position; 
         FIG. 1I  is a schematic view of the portion of the continuous web processor line showing the severed web clamped against a portion of a vacuum hood of with the transfer device slightly retracted and with the turret indexed to engage and attach a leading edge of the severed web to the new core; 
         FIG. 1J  is a schematic view of the portion of the continuous web processor line showing a trailing edge of the severed web being rolled onto the full core and with the vacuum hood retracted; 
         FIG. 2A  is a schematic view of a portion of a continuous web processor line showing another embodiment of a vacuum hood and cutter portion of a web transfer device of the present invention in a configuration wherein the winding has stopped; 
         FIG. 2B  is a schematic view of the portion of the continuous web processor line of  FIG. 2A  wherein the vacuum hood and lay-on roll are in a retracted position; 
         FIG. 2C  is a schematic view of the portion of the continuous web processor line of  FIG. 2A  wherein the vacuum hood grasps the web; 
         FIG. 2D  is a schematic view of the portion of the continuous web processor line of  FIG. 2A  wherein the cutting arm is raised and cuts the web; 
         FIG. 2E  is a schematic view of the portion of the continuous web processor line of  FIG. 2A  wherein the cutting arm retracts and vacuum is released from the upper chamber and maintained in the lower chamber; 
         FIG. 2F  is a schematic view of the portion of the continuous web processor line of  FIG. 2A  wherein the turret indexes a new core into the inboard position; 
         FIG. 2G  is a schematic view of the portion of the continuous web processor line of  FIG. 2A  wherein the vacuum hood and lay-on roll is extended to attach the leading edge of the web to the new core; 
         FIG. 2H  is a schematic view of the portion of the continuous web processor line of  FIG. 2A ; 
         FIG. 3  is a graphical representation of one embodiment of the movement sequence of a web transfer device of the present invention; 
         FIG. 4  is a photograph of a portion of a web transfer device of the present invention in a continuous web processing line showing the vacuum hood retracted; 
         FIG. 5  is a photograph of the web transfer device of the continuous web processing line of  FIG. 4  showing the cutter device in a standby position; 
         FIG. 6  is a photograph of the web transfer device of the continuous web processing line of  FIG. 5  showing the vacuum hood beginning to pivot towards the new core; 
         FIG. 7  is a photograph of the web transfer device of the continuous web processing line of  FIG. 5  showing the vacuum hood further pivoting towards the new core; 
         FIG. 8  is a photograph of the web transfer device of the continuous web processing line of  FIG. 5  showing the vacuum hood grasping and cutting the web; 
         FIG. 9  is a photograph of the web transfer device of the continuous web processing line of  FIG. 5  showing the trailing edge of the web being released from the vacuum head; 
         FIG. 10  is a photograph of the web transfer device of the continuous web processing line of  FIG. 5  showing the trailing edge of the web released from the vacuum head and the vacuum hood pivoting further towards the new core; 
         FIG. 11  is a photograph of the web transfer device of the continuous web processing line of  FIG. 5  showing the vacuum hood pivoting further towards the new core; 
         FIG. 12  is a photograph of the web transfer device of the continuous web processing line of  FIG. 5  showing the vacuum hood securing the leading edge of the web to the new core; 
         FIG. 13  is a photograph of the web transfer device of the continuous web processing line of  FIG. 5  showing the vacuum hood pivoting away from the new core; 
         FIG. 14  is a photograph of the web transfer device of the continuous web processing line of  FIG. 5  showing the vacuum hood pivoting away from the new core and with the new core rotating with the leading edge of the web attached thereto; and 
         FIG. 15  is a photograph of the web transfer device of the continuous web processing line of  FIG. 5  showing the vacuum hood in the standby position pivoted away from the new core and with the new core rotating with the leading edge of the web wound there around. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In reference to  FIGS. 1A and 5 , a web transfer device  10  for multiple turret winder  30  for a continuous web process line  100  includes a web delivery assembly  20  comprising at least one web delivery roll  20 R. For example, the web delivery assembly  20  includes a web forming system that feeds a web  11  into a dryer assembly  12 . The web transfer device  10  is particularly well suited for processing and splicing webs  11  made from Polyethylene and Polyurethane foams, with single sided or double sided pressure sensitive adhesive applied. The web  11  thickness can vary from 0.5 to 0.012 inches. The dryer assembly  12  includes a plurality of rollers  12 R that support the web  11 . The web transfer device  10  includes a core transfer assembly  30  that includes two core receiving structures  30 R, for example a spindle  30 R mounted on opposing ends of an arm  30 A of a core transfer assembly, for example a turret  30 . Each of the spindles  30 R are adapted to receive a core  38 A or  38 B thereon for winding the web  11  there around. The arm  30 A is pivotally mounted about a pivot (e.g., bearings) on a frame  30 F (e.g., a two legged frame) that is fixedly secured to a foundation or base plate  15 . Each of the spindles  30 R are in communication with a drive mechanism  57  (e.g., motor, gear and or belt drive) to rotate the respective core  38 A or  38 B mounted thereon for causing the web  11  to be wound around the respective core  38 A or  38 B. The web  11  is wound around the respective core  38 A or  38 B until it reaches a maximum capacity. The turret  30  is configured to swing the arm  30 A about the pivot point  30 P to position a new core  38 B for winding the web  11  there around while swinging the core  38 A that is wound to full capacity with the web  11  in an unloading position for removal from the spindle  30 R. Since the web  11  is continuously processed in the line  100 , the web  11  is cut and positioned on the new core  38 B as described further herein. 
     While the turret  30  is shown and described as having two core receiving structures  30 R on opposing ends of the turret arm  30 A, the present invention is not limited in this regard as the turret  30  may employ more than two core receiving structures  30 R (e.g., three spindles). 
     The web transfer device  10  includes a web transfer assembly  40  configured to receive a web  11  from the web delivery assembly  20 . The web transfer assembly  40  is configured to communicate with the core transfer assembly (e.g., a turret)  30 . The web transfer assembly  40  includes a frame  41  and lay-on roll  42  moveably positioned relative to the frame  41 . The frame  41  is fixedly secured to the base plate  15 . The web transfer assembly  40  includes a vacuum hood  43  moveably positioned relative to the frame  41 , for example via a pivot  43 P. The vacuum hood  43  has a cutting device  44  moveably (e.g., axially slidably mounted for slitting or radially translationally mounted for chopping) mounted in a slot  44 G in the suction holding surface  45 A as described herein. The vacuum hood assembly  43  has two suction holding surfaces  45 A,  45 B. Vacuum sources  43 X and  43 Y are in communication with the suction holding surfaces  45 A,  45 B, respectively. The suction holding surfaces  45 A,  45 B are configured to releasably hold a portion of the web  11 . The suction holding surfaces  45 A,  45 B are movable relative to the frame  41  and are moveable relative to the core receiving structure  30 R and the cores  38 A or  38 B mounted thereon. For example, suction holding surfaces  45 A,  45 B move with the vacuum hood assembly  43  on a carriage assembly  55  such as a ball screw assembly that enables the vacuum hood assembly  43  to move translationally along the frame  41 . Thus, the vacuum assembly  43  is moveable relative to the frame  41  and is moveable relative to the core receiving structure  30 R and the cores  38 A or  38 B thereon. The lay-on roll  42  is also mounted to the carriage assembly  55  and is moveable relative to the frame  41  and is moveable relative to the core receiving structure  30 R and the cores  38 A or  38 B thereon. The vacuum hood assembly  43  is pivotally mounted to the carriage assembly  55 . 
     As shown in  FIGS. 1A-1J  the web transfer assembly  40  includes a horizontal traveling roller assembly  56  for spindle drive trim. As best shown in  FIG. 1F  the web transfer assembly  40  includes a carry-over idler roller  59  to guide the web  11  during the web transfer process. 
     The suction holding surfaces  45 A,  45 B communicate with the core receiving structure  30 R to transfer the web  11  to a core  38 A or  38 B mounted on the spindle of the core receiving structure  30 R. In the embodiments shown in  FIGS. 1E-1J and 5-15  the web is cut after the full core  38 A is moved to the outboard position (B 2 ) and the new core  38 A is in the inboard (B 1 ) position and after cutting the web  11  the new leading edge  11 L (see  FIG. 14 ) is secured to a new empty core  38 B. As used herein the term inboard position B 1  refers to the spindle or core receiving assembly  30 R being proximate the lay-on roll  42 ; and the outboard position B 2  refers to the position of the core receiving structure  30 R on an opposite end of the arm  30 A of the turret  30 . 
     In the embodiment shown in  FIGS. 2A-2H and 3 , the web  11  is cut while full core  38 B is in the inboard position B 1 . After cutting the web  11 , the full core  38 B is placed in the outboard position B 2  and a new core  38 B is placed in the inboard position B 1 . The new leading edge  11 L is secured to the new empty core  38 B while in the inboard position B 1 . 
     The vacuum hood assembly  43  includes a pivot assembly  43 P for pivotally mounting the vacuum hood assembly  43  to the carriage assembly  55 . The vacuum hood assembly  43  is divided into two internal chambers (e.g., a first chamber and a second chamber). The first chamber has a first inlet defined by suction holding surface  45 A and is in communication with a first vacuum supply  43 X. The suction holding surface  45 A has a plurality of holes  51  extending therethrough (see  FIG. 5 ). The second chamber has a second inlet defined by the suction holding surface  45 B and is in communication with a second vacuum supply  43 Y. The suction holding surface  45 B has a plurality of holes  51  extending therethrough (see  FIG. 5 ). As shown in  FIG. 5 , the first inlet and the second inlet are spaced apart from one another defining a gap G 10  therebetween. A plurality of rollers  49  is positioned in the gap G 10 . The suction holding surfaces  45 A,  45 B are coated with a lubricious material. In one embodiment, the lubricious material is PTFE. 
     As shown in  FIG. 1A , the web transfer assembly  40  includes an accumulator  48  which has a first roller (e.g., an idler roller)  48 A and a second roller (e.g., idler roller)  48 B. The first roller  48 A is rotationally mounted on an axle  47 A that is fixedly secured to the frame  15 . The second roller  48 B is rotationally mounted on an axle  47 B that is fixedly secured to a moveable portion of a carriage  47 . A fixed portion of the carriage  47  is fixedly secured to the frame  15 . The carriage  47  is configured to translate the second roller  48 B away from the first roller  48 A in the direction of the arrow R 2 , as shown for example, in  FIG. 1G-I  wherein the accumulator  48  accumulates the web  11  while winding is stopped at the core  38 A and the continuous web process line  100  continues to feed the web  11  to the web transfer device  40 , during the web transfer process. When the web transfer process is completed, the carriage  47  translates the second roller  48 B towards the first roller  48 A in the direction of the arrow R 1  as shown in  FIG. 1J  to empty the accumulated web  11  from the accumulator  48 . 
     In one embodiment according to the sequence in the order of  FIGS. 1A to 1J , a method for web transfer includes an initial thread-up with the carriage  55  retracted. A rope threading rig is supplied to facilitate web thread-up through a dancer  56  and the accumulator  48  (see  FIG. 1A ). With the web  11  attached to core  38 A the carriage  55  comes forward in the direction of the arrow R 3  to run the lay-on roll  42  in contact surface mode or gap winding mode with the core  38 A. (See  FIG. 1B ). The lay-on roll  42  moves in the direction indicated by the arrow R 4  in the contact or gap mode until turret  30  is ready (i.e., the core  38 A is full) to index for roll-change. (See  FIG. 1C ). The lay-on roll  42  and carriage  55  further retract in the direction of the arrow R 4  away from the full core  38 A to allow the full core  38 A to index on the turret arm  30 A. (See  FIG. 1D ). The turret  30  indexes a new core  38 B into a roll-change position. (See  FIG. 1E ). The lay-on roll  42  and the carriage  55  move towards the new core  38 B in the direction of the arrow R 5  into the web transfer position. (See  FIG. 1F ). The vacuum hood  43  lowers (e.g., pivots about the pivot point  43 P) with a vacuum source  43 X and/or  43 Y applied. (See  FIG. 1G ). The full core  38 A goes to zero speed. (See  FIG. 1G ). The accumulator  48  starts to fill as indicated by the arrow R 2 . (See  FIG. 1G ). The web  11  is vacuum clamped against vacuum hood  43 . (See  FIG. 1G ). The cutter (e.g., an integral zip knife) translates across the vacuum hood  43  cutting a straight cut leading edge  11 L and trailing edge  11 T (See  FIGS. 1G, 5, 10 and 14 ). The carriage  55  retracts slightly (e.g., see gap G 12  in  FIG. 1H ) to paste or attach the web  11  onto the new core  38 A. The web  11  remains vacuum clamped to the vacuum hood, for example to the suction holding surfaces  45 A,  45 B. (See  FIGS. 1H and 5 ). The turret  30  indexes the new core  38 A into suction holding surfaces  45 A,  45 B (e.g., rubber faced surfaces with holes therein) vacuum hood  43  applying leading edge of cut web to core. ( FIGS. 1I and 5 ). The vacuum hood  43  releases the trailing edge of the web  11  and retracts to a stand by position. (See  FIG. 1J ). The full core  38 A is rotated via the drive mechanism  57  which winds the trailing edge  11 T. (See  FIG. 1J ). The new core  38 A is caused to over speed by the drive mechanism  57  to empty the accumulator  48  by translating the second roller  48 B of the accumulator to translate via movement of a portion of the carriage assembly  55  in the direction indicated by the arrow R 1 . (See  FIG. 1J ). As shown in  FIGS. 1A to 1D, 1I and 1J  the turret arm  30 A is horizontal. As shown in  FIGS. 1E to 1H  the turret arm  30 A is in a standby position at an angle γ from horizontal. 
     In one embodiment according to the sequence in the order of  FIGS. 2A to 2H , a method for web transfer includes winding the web  11  on the core  38 A until it is full (e.g., core  38 A is wound to a 40-inch diameter). (See  FIG. 2A ). The vacuum hood  43  is applied to the web  11  when the core  38 A is stopped and the accumulator  48  starts to fill. (See  FIG. 2A ). In the embodiment shown in  FIGS. 2A-2H  the vacuum hood  43  is a clamp configuration having an upper jaw  43 J that houses the vacuum chambers  43 M and  43 N which are in communication with the vacuum sources  43 X and  43 Y which can be controlled (e.g., activated and deactivated) individually, independent of one another or together. The upper jaw  43 J is pivotable about the pivot point  43 P. The vacuum hood  43  of the clamp configuration shown in  FIGS. 2A to 2H  includes a cutting arm  44 A that is pivotable about pivot point  44 P. The cutting arm  44 A includes the cutter  44  therein. As shown in  FIG. 2B , the lay-on roll  42  and carriage assembly  55  retract exposing the web  11  to be grasped and cut. The upper jaw  43 J of the vacuum hood  43  is moved (e.g., pivoted or lowered) to engage the web  11  and vacuum is applied in both vacuum chambers  43 M and  43 N thereby grasping the web against the suction holding surfaces  45 A,  45 B (e.g., perforated rubber web holding plate). (See  FIG. 2C ). The cutting arm  44 A moves (e.g., pivots or is raised) to engage the cutter  44  with the web  11  and then cut the web  11 . (See  FIGS. 2C and 2D ). The cutting arm  44 A retracts and vacuum is turned off to chamber  43 M thereby releasing the trailing edge  11 T of the web  11  from the suction holding surfaces  45 A and the trailing edge  11 T is wound onto the full core  38 A. (See  FIG. 2E ). The new leading edge  11 L of the web  11  is retained against suction holding surface  45 B. (See  FIG. 2E ). The turret  30  indexes the new core  38 B into the web attachment position as shown in  FIG. 2F . As shown in  FIG. 2G , the lay-on roll  42  and the carriage assembly  55  extend inwardly toward the new core  38 B and the holding surface  45 B attaches the leading edge  11 L of the web  11  to the new core  38 B by releasing the vacuum from the second vacuum chamber  43 N. As shown in  FIG. 2H , the carriage assembly  55  extends inwardly to cause the lay-on roll  42  to engage or be in gap proximity to the new core  38 B while the upper jaw  43 J of the vacuum hood  43  retracts. 
     In one embodiment according to the sequence in the order of  FIGS. 4 to 15 , a method for web transfer includes a standby configuration wherein the vacuum hood  43  is retracted as shown in  FIGS. 4 and 5 . As shown in  FIG. 6  the vacuum hood  43  begins to pivot towards the new core  38 B. As shown in  FIG. 7  the vacuum hood further pivots towards the new core  38 B. As shown in  FIG. 8  is the vacuum hood grasps the web  11  and cuts the web  11 . As shown in  FIG. 9  the trailing edge  11 T of the web  11  is released from the suction holding surface  45 A of the vacuum head  43 . As shown in  FIGS. 10 and 11 , after release of the trailing edge  11 T, the vacuum hood  43  pivots further towards the new core  38 B. As shown in  FIG. 12  the leading edge  11 L of the web  11  is secured to the new core  38 B. As shown in  FIG. 13  the vacuum hood  43  pivots away from the new core  38 B. As shown in  FIG. 14  the new core  38 B is rotating with the leading edge  11 L of the web  11  attached thereto. As shown in  FIG. 15 , the vacuum hood  43  in the standby position pivoted away from the new core  38 B and with the new core  38 B rotating with the leading edge  11 L of the web  11  wound there around. 
     In one embodiment, according to the sequence in  FIG. 3 , a method for web transfer includes applying the vacuum hood  43  to the web  11  while the web is stopped at the core  38 A but the line  100  continues to produce the web  11  and during which the web  11  is accumulated in the accumulator  48  (step  3 A). The carriage assembly  55  retracts, exposing the web  11  for transfer (step  3 B). The turret  30  indexes to proper position based upon the diameter of the core  38 A (step  3 C 1 ). The cutter  44  and vacuum hood  43  actuate into position proximate the web  11  (step  3 C 2 ). The vacuum is applied to vacuum hood  43  (step  3 C 3 ). The cutter  44  cuts the web  11  (step  3 D). The cutter  44  retracts (step  3 E). The full core  38 A winds up the trailing edge  11 T (step  3 F). The turret  30  index a new core  38 B into the inboard position B 1  (step  3 G). The vacuum hood  43  applies the leading edge  11 L of the web  11  to new core  38 B (step  38 H). The turret  30  indexes to a horizontal position (step  3 I). 
     In one embodiment, during the transfer operation, the web  11  is stopped at a position just prior to the core  38 A while the process line  100  continues to run while the web  11  is stored in the accumulator  48  as shown in  FIG. 1A . While the web  11  is stopped at the core  38 A and prior to the indexing of the turret  30 , the vacuum hood  43  is positioned over the finished roll  38 A of web material while in the inboard position. A cutter  44  (e.g., chopper type or traversing razor type knife) severs the web  11  at the outer most wrap of the finished roll without disturbing the outer most wrap of the finishing wound roll of web material. The vacuum hood  43  holds the leading edge  11 L of web material just prior to, during and after the web  11  is severed. The turret  30  then rotates to position a new core  38 B under the vacuum hood in the inboard position B 1 . The vacuum hood  43  with the leading edge  11 L of web  11  adhered to it lowers to the new core  38 B. Either by tape or adhesive on the new core  38 B, or self-adhesive on the web  11 , the web  11  is attached to the new core  38 B. The vacuum source  43 X and  43 Y are turned off, the vacuum hood  43  retracts and winding begins. The accumulator  48  is unloaded by running the new core  38 B faster than the process web leading into the accumulator  48 . The above described sequence is repeated. 
     While the present disclosure has been described with reference to various exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.