Abstract:
A track and flap assembly employs an elongate compressible foam member completely covering an elongate channel that carries a paper cutting tape. Between the bottom of the foam member and the top of the channel are one or two pivotally mounted resilient flap members that cooperate with the foam member to provide a desired frictional drag and exiting resistance to control the cutting tape movement during turn up. A compressed air passage is provided to allow for forced air removal of debris and other contaminants from the tape channel. The assembly is constructed in two configurations to accommodate different papermaking apparatus.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     Not Applicable. 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable. 
     REFERENCE TO A “MICROFICHE APPENDIX” 
     Not Applicable. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to track assemblies for cutting tape used in turn up operations in the papermaking industry and particularly to an enclosed track assembly used to minimize contamination of the cutting tape. 
     2. Related Art 
     A wide variety of protected track assemblies are known to the art. For example, applicant&#39;s U.S. Pat. No. 5,467,937 discloses a movable flap for covering the cutting tape and the guideway that it rests within. Improvements are necessary, however, to provide for greater protection of the tape. In addition, improvements are needed in cutting tape tension control. The devices known to the art are deficient in that they do not provide both features with the same assembly. 
     BRIEF SUMMARY OF THE INVENTION 
     In one aspect of the present invention there is provided a track assembly for guiding a cutting tape transversely across a moving web of paper being wound on a roll and transferring the cut web to an empty roll. The assembly includes a track and a track support, the track being an elongated member having an upper portion and a lower portion and a first mounting means for supporting the track on the track support and a longitudinal channel formed in the upper portion for containing a length of a cutting tape therein. The channel is covered by a compressible means along the channel adapted to be compressed to uncover the channel when a cutting tape is exiting the channel. A second mounting means is rigidly affixed to the track for securing the compressible means to the track, the compressible means providing a controlled resistance against a cutting tape exiting to assist in control of a tape spooling on an empty roll. compressible means is formed of a foam material and includes an upper surface and a lower surface, the lower surface extending transversely across the channel. 
     In other aspects of the invention there is provided a first elongate flap member mounted between the lower surface of the compressible means and the upper portion of the member and extending transversely across the channel and being substantially the length of the track. The first flap member is movable upwardly when a cutting tape is withdrawn from the channel to compress said compressible means, the first flap member has an upper surface and a lower surface, the lower surface of the first flap member frictionally engaging a cutting tape when the tape is being withdrawn from the channel. Securing means for securing the first flap member to the track. A second elongate flap member has an upper surface and a lower surface mounted between the lower surface of the first flap member and the upper surface of the member, the lower surface of the second flap member upwardly movable and frictionally engaging a cutting tape when the tape is exiting the channel. 
     The track has a proximal end near an operator and a distal end across the width of the web of paper, the compressible means including a first portion adjacent said distal end of the track and a second portion extending from the first portion to the proximal end, the first portion of the compressible means having a relative compressibility different from the relative compressibility of the second portion of said compressible means to provide for two different controlled resistances for controlling the exiting of the cutting tape from the channel. There is also compressed air means for blowing air into the channel when a cutting tape is exiting the channel to keep the channel free of contaminants from the surrounding environment. The track is an elongated member having an upper portion and a lower portion and a first longitudinal channel formed in the lower portion for supporting the track on the track support and a second longitudinal channel formed in the upper portion for containing a length of a cutting tape therein. The second channel being covered by an elongated compressible means adapted to be compressed to uncover the second channel when a cutting tape is exiting the second channel. A thin elongated film member having an upper surface and a lower surface is mounted to the lower surface of the first flap member, the lower surface of the film member upwardly movable and frictionally engaging a cutting tape when the tape is exiting the second channel. The flap members include an inner edge portion and an outer edge portion adjacent the roll and securing means are provided for pivotally mounting a flap member at the inner edge portion to said track. The compressible means and flap member are removably mounted to the track. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
     The novel features which are believed to be characteristic of this invention are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and method of operation, together with further objects and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings, in which: 
     FIG. 1 is an end elevation of the improved track and flap assembly in accord with the present invention; 
     FIG. 2 is an end elevation of an alternate embodiment of the present invention; 
     FIG. 3 is a perspective view of a portion of a track assembly according to the present invention; 
     FIG. 4 is a perspective view of the assembly of FIG. 1 showing its relationship to papermaking machinery; 
     FIG. 5 is a pictorial cross-sectional view of an alternative track and flap assembly adjacent one end thereof; and 
     FIG. 6 is a schematic pictorial diagram of the tube of FIG.  5  and associated air supply and securing apparatus. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     INTRODUCTION 
     As understood in the art, a length of paper tape is used in the paper industry to cut a moving web of paper being wound up on a roll and to transfer the cut edge of the paper to an empty wind up roll without having to stop the paper movement. The web of paper moves under a lead-in roller and over a drive roller to a wind up roll. A drive roll is driven by an outside source, and it drives a wind up roll by frictional contact. When the wind up roll becomes large enough it is necessary to cut the paper web and start it winding on a new roll. In this case, an empty wind up roll is lowered vertically until it contacts the drive roll. 
     In order to cut the moving paper web and start it winding onto the empty roll a cutting tape is moved forward and is caught in the nip of the rolls. The tape is wrapped helically around the roll and in so doing it cuts through the paper web and leads the cut edge onto the empty roll which continues to wind up the web until it is full and the entire operation is repeated to cut and transfer the web to a new, empty wind up roll. Soon after the web is transferred to the roll, the full roll is moved away from the drive roll and an empty roll is moved down to the previous position of the full roll. 
     The tape that is introduced into a track may be directed to a dispensing section where it is treated to apply a coating of pressure-sensitive adhesive to the forward section of the tape. The tape is then cut to a finite length and pushed along until the tip is at the terminal of a end guideway. The tape is then stopped and held in position until an operator decides it is time to cut and transfer the web to a new roll. Neither a dispensing station nor the adhesive-applying station is a necessary part of the present invention. 
     The track assembly used abuts the end of the track from a dispensing section and continues across the web from a proximal end to a distal end. The track continues from the distal end through an upward curing and twisting section to a terminal end. The adhesive coating, if applied in the dispensing section, is preferably on the bottom of tape as it crosses through the track assembly and must be twisted to be on top when it is fed to roll so as to stick to the roll and carry along with it the cut edge of the paper web. 
     The present invention relates to the track and carrier from the proximal end to the terminal end. 
     The systems used often include a brake in the form of a clamping device to apply a variable resistance to the tape for preventing or inhibiting its movement through the track assembly. Movement is stopped when the tape is first moved into position with its forward tip at the terminal end. When the time for cutting the web of paper occurs, the tip of the tape is fed into the nip and the tape is suddenly accelerated to a high speed by its contact with the roll which causes the tape to be jerked out of the track assembly. At this time the brake is applied to provide resistance but not prevent movement of the tape. As soon as the tip starts to wind around the roll, the brake resistance causes the tape to become taut and cut the web as it is moved across the web because of being wound helically on the roll. The tape will be pulled rapidly and upwardly out of track and brake must be applied properly for this to happen with control and without breakage of the tape. A sensor may also be employed to be sure there is no tape in the track after the cutting operation is finished. If the tape breaks, there may be some pieces of tape in the track that will impede the next setup. 
     The system described herein is applicable in other industries besides papermaking that use the turn up methodology disclosed. 
     CONSTRUCTION 
     With regard now to FIG. 1, the improved track and flap assembly is illustrated at numeral  10 . The assembly  10  includes a frame  11  for mounting to the papermaking machinery. A housing portion  12  includes a top wall  13  and a side wall  14  and is rigidly connected to frame member  11  by adhesive or other appropriate means as understood in the art. 
     An elongate foam block member  17  is mounted between walls  13  and  14  via fasteners  15  and  16 . Foam member  17  is compressible. A flap member  18  is secured via fasteners  15  and  16  and is mounted under foam member  17 . Flap member  18  is used to provide a smooth low friction surface for contact with tape band  21  when the tape is withdrawn from the elongate channel  20 . Depending upon the variables in a particular application such as paper type and machine speed it may be possible to provide a foam member  17  that has a lower surface with the desired friction coefficient and accordingly flap  18  could be eliminated. 
     A second flap  19  is illustrated to be either a distinct member located between flap  18  and channel  20 . In most cases flap  19  would actually be a thin film of low friction material attached by adhesive to the lower surface of flap  18 . 
     Channel  20  is a tape band guideway and is formed in frame member  11  to accommodate the tape band  21  that is to be used in a given application. It is to be understood that tape band  21  may include a strip of adhesive  21 ′ and the V-notched base of channel  20  provides space below adhesive strip  21 ′ to prevent it from sticking to the channel  20 . T-shaped channel  24  is used to mount the assembly  10  to the frame of the associated papermaking apparatus. 
     Air hose  22  directs air via passageway  23  into guideway channel  20  to prevent contamination from entering the channel  20  during tape withdrawal. Such contamination could adversely affect the withdrawal of a tape band  21  during the turn up cycle. 
     During the withdrawal of tape  21  foam block  17  is compressed as flaps  18  and  19  are forced against it due to the tension on the tape  21 . The amount of movement will depend on the specific application including factors such as the speed and angle of tape  21  exit as well as the type of material used for block  17  and the flaps  18  and  19  (if used in the circumstances). 
     In FIG. 2 an alternative embodiment of the improved track and flap assembly is illustrated at numeral  25 . Housing  26  includes side wall  27  and bottom wall  28  rigidly connected to frame  34 . Foam block  29 , first flap  30  and second flap  31  may be identical to their counterparts in FIG. 1 or may be of different materials as desired in the circumstances. Fasteners  32  and  33  provide attachment means for elements  29 ,  30  and  31 . 
     Channel or passageway  36  is formed in frame  34  and supports tape band  35  including adhesive layer  35 ′. Air hose connection  38  provides a means for directing pressurized air into passageway  37  and to passageway  36  to prevent contamination from entering the passageway during the withdrawal of tape band  35 . T-shaped space  39  provides for the mounting of frame  34  to a frame support  40 . 
     Assembly  25  employs a different layout than that of assembly  10 . The choice of assembly  10  or  25  is controlled largely be the available space to mount the apparatus to a specific papermaking apparatus and maintain adequate clearance to minimize interference with the machines. 
     In both assemblies  10  and  25  the housings  12  and  26  are rigidly mounted to respective frames  11  and  34  to prevent any movement between them. This feature allows for control of the tension of the corresponding tape band  21  and  35  to be controlled during withdrawal by way of the selection of the materials for the foam blocks  17  and  29  and the use of additional flaps  18 ,  19  and  30 ,  31  if desired. Movement of either frame  11  or  34  combined with compression of block  17  or  29  would greatly complicate the control of the withdrawal of a respective tape band  21  or  34  during turn up. 
     ASSEMBLY OPERATION 
     Flaps  18  and  19  (FIG. 1) and  30  and  31  (FIG. 2) are pivotally mounted via respective fasteners  15 ,  16  and  32 ,  33 . Flaps  18  and  30  are preferably made of urethane or ultrahigh molecular weight (UHMW) polyethylene material to provide the desired stiffness and coefficient of friction to control tape withdrawal. If needed, an additional flap element  19  and  31  may be added or bonded to respective flaps  18  and  30  if the flaps  18  and  30  have the desired stiffness but not the desired friction surface. 
     Frames  11  and  26  are also preferably made of UHMW polyethylene to minimize friction against tape band  21  or  35  yet to also have sufficient rigidity for proper tape withdrawal. Foam blocks  17  and  29  are made of a material chosen for the specific application and function as springs to provide a braking action on respective tape band  21  or  35  during tape withdrawal. The braking action assists in maintaining proper tension of a tape band to provide for fast turn up. In addition, proper tension of a tape band assists in straightening curved band material if it is supplied to a user in a wound spool as is often the case. 
     Two perspective views of the assembly  10  are provided in FIGS. 3 and 4. FIG. 3 illustrates the leading end  45  of tape band  21  extending slightly beyond the distal end  47  of the track assembly in FIG. 3 an alternative embodiment of foam block  17  is shown illustrating two types of foam  17 ,  17 ′ that have different densities and therefore different compressibility against tape band  21  during withdrawal. This feature provides for less braking of the tape band  21  against low density block  17  as tape withdrawal begins and more braking of the tape  21  as it is withdrawn against block  17 ′ which extends all the way to the entry or proximal end  41  of the track assembly  10 . Foam material having lengthwise variable density can also be used if desired in the circumstances. 
     In FIG. 4 an overall view of an assembly  10  is shown in relation to the web moving in direction  48 . Tape loading apparatus  42  (shown only generally) feeds a length of tape band into a first substantially straight track section  43  and from there into a vertical and curved track section  44 . Distal end  47  of the track assembly  10  is supported by frame  46 . Empty roll  49 , roller  50 , and full roll  51  are all standard. Frame support  40  fits into space  24  (FIG. 1) or  39  (FIG. 2) and is shown only generally. Sections  43  and  44  are preferably fabricated separately for ease in manufacturing. 
     With reference now to FIG. 5, an alternative embodiment of a track and flap assembly is shown at numeral  52 . Top wall  53  and side wall  54  form housing  55  which is mounted to the frame  56  of the papermaking apparatus and is shown only generally. 
     Flap  57  is hinge mounted by fitting flap base portion  58  between inside portion  59  of housing  61  and track body  60  carried therein. Track body  60  includes a lower channel  62  and an upper channel  63  shown carrying tape  64 . Channel  62  is identical to channel  63  and can be used when channel  63  wears our or becomes damaged by inverting body  60 . Housing  61 , track body  60  and flap base  58  can be held in place by any appropriate means such as adhesive. 
     An air-filled longitudinal tube  65  shown expanded is used to apply downward force on flap  57 . Tube  65  is flexible to allow for compression when tape  64  is withdrawn from channel  63  during a turn up operation. The means to secure tube  65  against lateral movement is shown generally at  66 . A plastic loop clamp  70  is secured around tube  65  loosely as indicated by space  71 . The two ends  72  of clamp  70  are pulled through space  74  in top wall  53  are secured via securing tie  73 . Clamp  70  is narrow enough longitudinally speaking to not interfere with the downward force tube  65  maintains on flap  57 . The number of means  66  used depends on the specific application and variables such as the length of tube  65 . 
     Assembly  52  will generally extend the entire width of the web of paper and into the upwardly curved portion of the track (as shown in FIG.  4 ). 
     With regard to FIG. 6, a pictorial view of a length of tube  65  is shown as it may be mounted adjacent. Tube  65  is generally flat when not inflated and is cut to the desired length for a particular application. One end  76  of tube  65  is closed by inserting plug  80  into opening  77 . Adhesive, such as silicone, is placed on the exterior of plug  80  before it is inserted into opening  77 . Two standard hose clamps  81  are used to secure plug  80  in place. 
     The other end  75  of tube  65  is attached to the system air apparatus as illustrated in FIG.  5 . Once the tube  65  is pressurized to the desired pressure the end  75  is closed by squeezing it between two clamp members  78  that are pulled together via screws and washers  79  after end  75  is pulled upwardly through opening  82 . 
     Air supply fitting  67 , air hose  68  and control valve  69  are the means by which the tube  65  is inflated are standard items as understood in the art and are shown only generally. The air pressure apparatus is preferably removable from the tube after the desired pressure in tube  65  is attained. Air is the preferred way of pressurizing tube  65  but water might also be used in appropriate circumstances. 
     While the invention has been described with respect to certain specific embodiments, it will be appreciated that many modifications and changes may be made by those skilled in the art. It is intended, therefore, by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the invention.