CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] None

BACKGROUND

[0002] The disclosure herein relates to turret unwind and splicing units and a method using same. Turret unwind units, which automatically splice an expiring roll of material with a waiting roll of material are disclosed, the turret unwind units provided with a recovery system for recovering end portions of the material carried by the expiring roll, and automatically separating an expiring roll core from the expiring material. Two waste streams are created — each of a single material, making recycling and downstream handling of the expiring roll cores and expiring material simpler and more efficient.

[0003] A turret unwind and splicing unit is described in U.S. Pat. No. 11 ,325,801 which is commonly owned by the Assignee of this application and which is incorporated herein by reference. U.S. Pat. No. 11 ,325,801 discloses a turret unwind unit that includes a vacuum structure which recovers a free end of a severed web after a splice has been initiated. The vacuum structure disclosed in U.S. Pat. No. 11 ,325,801 may not be optimal for recovery of the free end. An improved design for recovery of the free end is desirable.

BRIEF STATEMENT OF THE DISCLOSURE

[0004] Provided are methods and apparatus for minimizing waste and improving quality and production in web processing operations in a high speed, small footprint environment.

[0005] T urret unwind units, which automatically splice an expiring roll of material with a waiting roll of material are disclosed, the turret unwind units provided with a recovery system for recovering end portions of the material carried by the expiring roll. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The drawings illustrate embodiments presently contemplated for carrying out the disclosure.

[0007] In the drawings:

[0008] FIGS. 1 -7 depict front elevation views of a turret unwind and splicing unit according to a first embodiment for carrying an expiring roll of material and a waiting roll of material.

[0009] FIGS. 8 and 9 depict front elevation views of a turret unwind and splicing unit according to a second embodiment for carrying an expiring roll of material and a waiting roll of material.

[0010] FIGS. 10 and 11 depict front elevation views of a turret unwind and splicing unit according to a third embodiment for carrying an expiring roll of material and a waiting roll of material.

[0011] FIGS. 12 and 13 depict front elevation views of a turret unwind and splicing unit according to a fourth embodiment for carrying an expiring roll of material and a waiting roll of material.

[0012] FIGS. 14-17 depict front elevation views of alternate embodiments of a roller for use with the turret unwind and splicing unit.

DETAILED DESCRIPTION

[0013] While the present disclosure may be susceptible to embodiment in different forms, there is shown in the Figures, and will be described herein in detail, specific embodiments, with the understanding that the present disclosure is to be considered an exemplification of the principles of the present disclosure, and is not intended to limit the present disclosure to that as illustrated.

[0014] As such, references to a feature or aspect are intended to describe a feature or aspect of an example of the present disclosure, not to imply that every embodiment thereof must have the described feature or aspect. Furthermore, it should be noted that the description illustrates a number of features. While certain features have been combined together to illustrate potential system designs, those features may also be used in other combinations not expressly disclosed. Thus, the depicted combinations are not intended to be limiting, unless otherwise noted.

[0015] A turret unwind and splicing unit 10 is disclosed that can be used in formation of products such as diapers, but can be applied to a wide variety of web-based converting processes. The turret unwind and splicing unit 10 is used to splice an expiring roll 12 to a waiting roll 14. Each roll 12, 14 has a roll core 16, around which is wrapped material 18. In one embodiment, the waiting roll 14 has a splice material 20, such as adhesive or tape, provided thereon as is known in the art. In alternative embodiments, a bonding unit (not shown) may be provided to mechanically bond the material 18 of the expiring roll 12 to the material 18 of the waiting roll 14.

[0016] The turret unwind and splicing unit 10 includes a unit base 22 upon which a web winding unit mount 24 is rotationally mounted at a center pivot shaft 26 which rotates around an axis 28 of rotation. The web winding unit mount 24 includes first and second turret arms 30, 32 which extend from the pivot shaft 26 and each of which has a rotatable shaft 34, 36 mounted thereon, and third and fourth turret arms 38, 40 which extend from the pivot shaft 26 and which has cylindrical rollers 42, 44 mounted thereon. Each shaft 34, 36 has an axis of rotation 46, 48 and is independently driven by a motor (not shown), and each roller 42, 44 has an axis of rotation 50, 52 and is freely rotatable on the turret arms 38, 40. The shafts 34, 36 are equidistantly spaced from the axis 28 of the center pivot shaft 26, the axes of rotation 46, 48 are parallel to each other and are parallel to the axis 28 of the center pivot shaft 26, and may be aligned along a first imaginary line passing through the axis 28. The rotatable shafts 34, 36 support the rolls 12, 14 in use. The rollers 42, 44 are spaced at a distance from the axis 28 of the center pivot shaft 26, the axes of rotation 50, 52 are parallel to each other and are parallel to the axis 28 of the center pivot shaft 26, and may be aligned along a second imaginary line passing through the center pivot axis 28 which is transverse to the first imaginary line. The rollers 42, 44 may be spaced further from the center pivot shaft 26 than the shafts 34, 36. In the exemplary arrangement shown in the drawings, the web winding unit mount 24 is in a first position in which the shaft 34 is at the twelve o’clock position, the roller 44 is at the three o’clock position, the shaft 36 is at the six o’clock position, and the roller 42 is at the nine o’clock position. As described herein, the web winding unit mount 24 is rotated around so that in a second position, the shaft 36 is at the twelve o’clock position, the roller 42 is at the three o’clock position, the shaft 34 is at the six o’clock position, and the roller 44 is at the nine o’clock position. In alternative embodiments, the rollers 42, 44 may be spaced at any number of different relative positions while operating in a similar manner as described herein and thus the clockface positions referenced herein are to be understood as non-limiting and provided for explanatory purposes only. Furthermore, the web winding unit mount 24 may be configured to rotate in the clockwise manner illustrated herein or in a counterclockwise manner for alternate handed configurations.

[0017] The turret unwind and splicing unit 10 further includes a splicer unit device 110 which is positioned below the center pivot shaft 26 and offset to one side thereof to be proximate to the waiting roll 14 when in a first, use position.

[0018] The splicer unit device 110 includes a non-movable base structure 112 having a fixed rail 114 at its top end. A unit housing 116 is mounted on the rail 114 and can be moved along the rail 114. The unit housing 116 houses a roller 118, a cutting device 120 such as a cutting wire or knife unit, and a web deflection device 122 such as a bump arm. The cutting device 120 and the web deflection device 122 can be fired by an air cylinder(s) or motor driven.

[0019] The unit housing 116 is slid along the rail 114 to be in the path of rotation of the web winding unit mount 24 in a first position, and the unit housing 116 is slid along the rail 114 to not be in the path of rotation of the web winding unit mount 24 in a second position. In the exemplary arrangement shown in the drawings, the unit housing 116 is positioned between the six o’clock position and the nine o’clock position in the first position. It is be understood that a mirror image of the turret unwind and splicing unit 10 can be provided wherein the unit housing 116 is positioned between the three o’clock position and the six o’clock position in the first position.

[0020] In an embodiment as shown in FIGS. 1-7, a vacuum structure 124 which is coupled to a source of negative pressure (not shown) is fixedly mounted on the unit housing 116, such that the vacuum structure 124 moves with the unit housing 116 along the rail 114. The vacuum structure 124 includes a plate 126 having an opening therethrough, and a pipe 128 connected to the plate 126 which draws a vacuum through the opening in the plate 126. The plate 126 is positioned proximate the roller 42 or 44 during use. The plate 126 preferably has a planar portion 130 which is mounted on the end of the pipe 128 and through which the opening is provided, and a curved portion 132 which extends outwardly therefrom. The curve of the curved portion 132 generally mirrors the curvature of the cylindrical rollers 42, 44 and causes the air being pulled to smoothly flow into the pipe 128. The pipe 128 may include a Venturi to speed the flow of the fluid being drawn therethrough.

[0021] In an embodiment as shown in FIGS. 8 and 9, the vacuum structure 224 is decoupled from the unit housing 116 and instead is pivotally mounted on a stationary structure 2434, such as the floor, separate from the splicer unit device 110. The vacuum structure 224 is coupled to a source of negative pressure (not shown) and includes a base structure 236 pivotally mounted to the stationary structure 234, a pipe 228 coupled to the base structure 236, and a plate 226 having an opening therethrough. The pipe 228 draws a vacuum through an opening in the plate 226. The plate 226 preferably has a planar portion 230 which is mounted on the end of the pipe 228 and through which the opening is provided, and a curved portion 232 which extends outwardly therefrom. The curve of the curved portion 232 generally mirrors the curvature of the cylindrical rollers 42, 44 and causes the air being pulled to smoothly flow into the pipe 228. The pipe 228 may include a Venturi to speed the flow of the fluid being drawn therethrough. The base structure 236 can be pivoted relative to the unit base 22 and the splicer unit device 110 so as to move the plate 226 from a first position which is in the path of rotation of the web winding unit mount 24 to a second position which is out of the path of rotation of the web winding unit mount 24. As shown in FIG. 8, the plate 226 is positioned proximate the roller 42 or 44 in the first position.

[0022] In an embodiment as shown in FIGS. 10 and 11 , the vacuum structure 324 is pivotally mounted to the unit base 22. The vacuum structure 324 is coupled to a source of negative pressure (not shown) and includes a base structure 336 pivotally mounted to the unit base 22, a pipe 328 coupled to the base structure 336, and a plate 326 having an opening therethrough. The pipe 328 draws a vacuum through an opening in the plate 326. The plate 326 preferably has a planar portion 330 which is mounted on the end of the pipe 328 and through which the opening is provided, and a curved portion 332 which extends outwardly therefrom. The curve of the curved portion 332 generally mirrors the curvature of the cylindrical rollers 42, 44 and causes the air being pulled to smoothly flow into the pipe 328. The pipe 328 may include a Venturi to speed the flow of the fluid being drawn therethrough. The base structure 336 can be pivoted relative to the unit base 22 and the splicer unit device 110 so as to move the plate 326 from a first position which is in the path of rotation of the web winding unit mount 24 to a second position which is out of the path of rotation of the web winding unit mount 24. As shown in FIG. 10, the plate 326 is positioned proximate the roller 42 or 44 in the first position.

[0023] Operation of the turret unwind and splicing unit 10 is described with regard to the embodiment shown in FIGS. 1-7, with the understanding that operation of the embodiments of FIGS. 8-11 is the same. In use to perform a splice sequence, the web winding unit mount 24 is in its first position and the splicer unit device 110/vacuum structure 124 is positioned in its/their first position. The running web of material 18 on the expiring roll is paid off the roll 12, around roller 42, between the roller 42 and the plate 126, over and around the roller 118, between the web deflection device 122 and the new material 18 of the waiting roll 14, and then to the further line processing station (not shown). The web deflection device 122 is proximate to, but spaced from the waiting roll 14. [0024] Referring now to FIG. 3, the waiting roll 14 of material 18 is driven by its controlled motor so that at the moment of splice, the material 18 of the expiring roll 12 is bumped towards splice material 20 by the web deflection device 122 and bonds the material 18 of the expiring roll 12 to the splice material 20 of the waiting roll 14. At the same time as the bump, the cutting device 120 severs the material 18 of the expiring roll 12 and creates a leading portion of the material 18 of the expiring roll 12 and a trailing portion of the material 18 of the expiring roll 12. In this manner, the leading portion of the expiring roll 12 is instantly joined to the material 18 of the waiting roll 14. In some embodiments splicing is timed based on a calculated roll diameter. In alternate embodiments an optional vision system or a photo eye (not shown) is provided for detecting when the roll 12 mounted on the shaft 34 is coming close to expiration (compare the size of expiring roll 12 from FIG. 1 to FIG. 2) and an optional vision system or a photo eye (not shown) is provided for detecting the position of the splice material 20 of the roll 14.

[0025] Referring now to FIG. 4, at the moment that the material 18 is severed, a free end 54 of material 18 of the expiring roll 12 is created. Just prior to or when material 18 is severed, a vacuum is initiated and drawn by the vacuum structure 124. The free end 54 may snap back and contact the plate 126. The curve of the curved portion 132 of the plate 126 causes the air being pulled into the pipe 128, and thus the free end 54, to follow along and dive into the pipe 128. The material 18 is sucked into the pipe 128 as shown in FIG. 5. The provision of the unit housing 116/vacuum structure 124 in the position shown in FIGS. 4 and 5 (and FIGS. 8 and 10) optimizes the movement of the free end 54 into the pipe 128. In an embodiment, the material 18 is paid out by rotation of shaft 34 and sucked into the pipe 128 until the entirety of the material 18 becomes separated from roll core 16. At this point, shaft 34 is no longer required to rotate until called upon to begin rotation of the next expiring roll. In this embodiment, the material 18 is thus automatically separated from the expiring roll core 16. In this embodiment, two single material waste streams are created, one of the roll core 16 of the expiring roll 12, and the other of the expiring material 18, which makes recycling and downstream handling of the expiring roll cores 16 and expiring material 18 simpler and more efficient because the waste streams are not required to be handled manually.

[0026] Next referring to FIG. 6 (and FIGS. 9 and 11 ), the web deflection device 122 and the cutting device 120 are retracted, and the unit housing 116/vacuum structure 126 is moved to its/their second position.

[0027] The web winding unit mount 24 is rotated into its second position which rotates the roll 14 clockwise to place the roll 14 into the expiring roll position (because the roll 14 will now be an expiring roll 12), preferably at the top vertical position of the web winding unit mount 24. Clockwise rotation of the web winding unit mount 24 also places the shaft 34 (still carrying roll core 16 of the expired roll 12) into the waiting roll position in order to receive a waiting roll 14. During rotation of the web winding unit mount 24, it is desirable to vary V2 during rotation of the waiting roll 14 from the waiting position to the expiring roll position, in order to maintain constant tension and supply rate of material 18 to the downstream processing operations.

[0028] Referring now to FIG. 7, rotating web winding unit mount 24 causes the expiring roll 14 to reach the expiring roll position, and the unit housing 116/vacuum structure 126 is moved back to its first position as shown in FIG. 1 (or FIGS. 8 and 10) for the next splice sequence. The roll core 16 is taken off of shaft 34 for discard, and the waiting roll 14 is thereafter loaded onto the shaft 34.

[0029] In an embodiment, after severing the material 18 to form the free end 54, and prior to the complete expiration of the material 18 from the roll 14, the vacuum structure 124 is stopped and the rotation of the shaft 34 is reversed in order to rewind the material 18 onto the roll core 16 of the roll 12 for disposal before the web winding unit mount 24 is moved to its second position as shown in FIG. 7.

[0030] In another embodiment as shown in FIGS. 12 and 13, the splicer unit device 410 and vacuum structure 424 are mounted between two unit bases 22a, 22b, both of which are continuously operating. Like elements in this embodiment are denoted with like reference numerals with the like elements being labeled in the four hundreds.

[0031] The splicer unit device 410 includes a non-movable base structure 412 having a fixed rail 414 at its top end. A unit housing 416 is mounted on the rail 414 and can be moved along the rail 414 to be proximate to each unit base 22a, 22b to perform a splice sequence as needed. The unit housing 416 has a roller 418, a cutting device 420 such as a cutting wire or knife unit, and a pair of web deflection devices 422a, 422b, such as bump arms. The cutting device 420 and the web deflection devices 422a, 422b can be fired by an air cylinder(s) or motor driven. In the exemplary arrangement shown in the drawings, when positioned proximate to the right-most unit base 22a as shown in FIG. 12, the unit housing 416 is positioned between the six o’clock position and the nine o’clock position in the use position. In alternate configurations, the unit housing 416 when positioned proximate to the right-most unit base 22a may be positioned to contact the roll 14 anywhere between the six o’clock and eleven o’clock positions. When positioned proximate to the left-most unit base 22b as shown in FIG. 13, the unit housing 416 is positioned between the three o’clock position and the six o’clock position in the use position. In alternate configurations, the unit housing 416 when positioned proximate to the left-most unit base 22b may be positioned to contact the roll 14 anywhere between the one o’clock and three o’clock positions.

[0032] The unit housing 416 is slidably mounted on the rail 414, so as to be able to move into a first position which is in the path of rotation of the right-most web winding unit mount 24, and into a second position which is in the path of rotation of the left-most web winding unit mount 24. In some embodiments, the unit housing 416 is slidably mounted on the rail 414 so as be positioned in a third position which is out of the path of rotation of both web winding unit mounts 24.

[0033] In the illustrated embodiment, the vacuum structure 424 which is coupled to a source of negative pressure (not shown) is mounted on the unit housing 416, such that the vacuum structure 424 moves with the unit housing 416. The vacuum structure 424 is pivotally mounted on the unit housing 416, and includes a plate 426 having an opening therethrough, and a pipe 428 connected to the plate 426 which draws a vacuum through the opening in the plate 426. The plate 426 is positioned proximate the roller 42 or 44 of the respective unit drive 22a, 22b during use. The plate 426 preferably has a pair of curved portions 432a, 432b. The curves of the curved portions 432a, 432b generally mirror the curvature of the cylindrical rollers 42, 44 and causes the air being pulled to smoothly flow into the pipe 428. The pipe 428 may include a Venturi to speed the flow of the fluid being drawn therethrough.

[0034] In use to perform a splice sequence, the web winding unit mount 24 of the right-most unit base 22a in its first position and the unit housing 416/vacuum structure 424 is positioned in its first position. The vacuum structure 424 is pivoted relative to the unit housing 416 to move into the first position. The running web of material 18 on the expiring roll is paid off the roll 12, around roller 42, between the roller 42 and the plate 426, over and around the roller 418, between the web deflection device 422 and the waiting roll 14, and then to the further line processing station (not shown). The web deflection device 422 is proximate to, but spaced from the waiting roll 14.

[0035] The waiting roll 14 is driven by its controlled motor so that at the moment of splice, the material 18 of the expiring roll 12 is bumped towards splice material 20 by the web deflection device 422 and bonds the material 18 of the expiring roll 12 to the splice material 20 of the waiting roll 14. At the same time as the bump, the cutting device 420 severs the material 18 of the expiring roll 12 and creates a leading portion of the material 18 of the expiring roll 12 and a trailing portion of the material 18 of the expiring roll 12. In this manner, the leading portion of the expiring roll 12 is instantly joined to the material 18 of the waiting roll 14. In some embodiments splicing is timed based on a calculated roll diameter. In alternate embodiments an optional vision system or a photo eye (not shown) is provided for detecting when the roll 12 mounted on the shaft 34 is coming close to expiration and an optional vision system or a photo eye (not shown) is provided for detecting the position of the splice material 20 of the roll 14. [0036] At the moment that the material 18 is severed, a free end of material 18 of the expiring roll 12 is created. Just prior to or when material 18 is severed, a vacuum is initiated and drawn by the vacuum structure 424. The free end may snap back and contact the plate 426. The curve of the curved portion 432a of the plate 426 causes the air being pulled into the pipe 428, and thus the free end, to follow along and dive into the pipe 428 (the curve of the curved portion 432b of the plate 426 causes the air being pulled into the pipe 428, and thus the free end, to follow along and dive into the pipe 428 when being used with the left-most unit base 22b). The material 18 is sucked into the pipe 428. The provision of the unit housing 416/vacuum structure 424 in the position shown in FIGS. 12 and 13 optimizes the movement of the free end into the pipe 428. In an embodiment, the material 18 is paid out by rotation of shaft 34 and sucked into the pipe 428 until the entirety of the material 18 becomes separated from roll core 16. At this point, shaft 34 is no longer required to rotate until called upon to begin rotation of the next expiring roll. In this embodiment, the material 18 is thus automatically separated from the expiring roll core 16. In this embodiment, two single material waste streams are created, one of the roll core 16 of the expiring roll 12, and the other of the expiring material 18, which makes recycling and downstream handling of the expiring roll cores 16 and expiring material 18 simpler and more efficient because the waste streams are not required to be handled manually.

[0037] The web deflection device 422 and the cutting device 420 are retracted, and the unit housing 416/vacuum structure 424 are moved its second position to be proximate to the left-most unit base 22b to perform a like splice operation for the left-most unit base 22b. The vacuum structure 424 is pivoted relative to the unit housing 416 to move into the first position relative to the left-most unit base 22b.

[0038] The web winding unit mount 24 of the right-most unit base 22a is rotated into its second position which rotates the roll 14 clockwise to place the roll 14 into the expiring roll position (because the roll 14 will now be an expiring roll 12), preferably at the top vertical position of the web winding unit mount 24. Clockwise rotation of the web winding unit mount 24 also places the shaft 34 (still carrying roll core 16 of the expired roll 12) into the waiting roll position in order to receive a waiting roll 14. During rotation of the web winding unit mount 24 of the rightmost unit base 22a, it is desirable to vary V2 during rotation of the waiting roll 14 from the waiting position to the expiring roll position, in order to maintain constant tension and supply rate of material 18 to the downstream processing operations.

[0039] Rotating web winding unit mount 24 of the right-most unit base 22a causes the expiring roll 14 to reach the expiring roll position, and the unit housing 416 is moved back to its first position for the next splice sequence. The roll core 16 is taken off of shaft 34 for discard, and the waiting roll 14 is thereafter loaded onto the shaft 34.

[0040] In an embodiment, after severing the material 18 to form the free end 54, and prior to the complete expiration of the material 18 from the roll 14, the vacuum structure 424 is stopped and the rotation of the shaft 34 is reversed in order to rewind the material 18 onto the roll core 16 of the roll 12 for disposal before the web winding unit mount 24 is moved to its second position.

[0041] While the vacuum structure 424 is shown and described as being mounted on the unit housing 416, the vacuum structure 424 can be pivotally mounted on the floor so as to pivot between the base units 22a, 22b.

[0042] FIGS. 16-19 illustrate alternate structures for collecting the material 18 after the free end 54 has been severed. When these structures are used, the vacuum structure 124, 224, 324, 424 is not provided.

[0043] FIG. 13 illustrates that rollers 42, 44 have tactile surfaces 56 thereon. The tactile surfaces 56 may be formed from a sticky material, a roughened surface, a plurality of spikes extending outward from rollers 42, 44, a hook-type material, and the like. This causes the material 18 to stick to or frictionally engage with the roller 42, 44 once the tension is removed from the material 18 as a result of the severing of the material 18. To collect the material 18, the rotation of the shaft 34 is reversed in order to rewind the material 18 onto the roll core 16 of the roll 12 for disposal once the roll 12 is moved to the six o’clock position as shown in FIG. 7.

[0044] FIG. 14 illustrates that an electrostatic generator 58 is provided within the roller 42, 44. When the material 18 is severed, the electrostatic generator 58 is activated which causes the material 18 to be secured to the roller 42, 44 once the tension is removed from the material 18 as a result of the severing of the material 18. To collect the material 18, the rotation of the shaft 34 is reversed in order to rewind the material 18 onto the roll core 16 of the roll 12 for disposal once the roll 12 is moved to the six o’clock position as shown in FIG. 7. After the material 18 is collected, the electrostatic generator 58 is deactivated.

[0045] FIG. 15 illustrates that a vacuum system 60 is provided in the roller 42, 44. As an example, each roller 42, 44 has a perforated roller 62 having a plurality of openings 64 therein that rotates around a base roller 66 having a plurality of openings 68 therein and that is coupled to a vacuum. When the material 18 is severed, the vacuum system 60 is activated and when the openings 64, 68 align with each other, a vacuum is pulled on the outer surface of the roller 62 which causes the material 18 to be secured to the roller 42, 44 once the tension is removed from the material 18 as a result of the severing of the material 18. To collect the material 18, the rotation of the shaft 34 is reversed in order to rewind the material 18 onto the roll core 16 of the roll 12 for disposal once the roll 12 is moved to the six o’clock position as shown in FIG. 7. After the material 18 is collected, the vacuum system 60 is deactivated.

[0046] FIG. 16 illustrates that a pin structure 70 is provided in the roller 42, 44. As an example, pin structure 70 includes a plurality of retractable spring-loaded pins 72 which can be extended through openings 74 in the roller 42, 44 by suitable means and can be withdrawn into the roller 42, 44 by suitable means. When the material 18 is severed, the pin structure 70 is activated which causes pins 72 to extend out of the roller 42, 44 and pierce the material 18 once the tension is removed from the material 18 as a result of the severing of the material 18 and secure the material 18 to the roller 42, 44. To collect the material 18, the rotation of the shaft 34 is reversed in order to rewind the material 18 onto the roll core 16 of the roll 12 for disposal once the roll 12 is moved to the six o’clock position as shown in FIG. 7. After the material 18 is collected, the pins 72 are retracted.

[0047] The foregoing is considered as illustrative only of the principles of the disclosure. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the disclosure to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the disclosure, which is defined by the claims.