CROSS-REFERENCE TO RELATED APPLICATION OOGJ j This application claims the benefit of U.S. Provisional Application No. 61 /933,439, filed on January 30, 2014. The disclosure of the above application is incorporated herein by reference.

TECHNIC AL FIELD

[ΘΘ02] The present disclosure generally relates to web material handling, and more particularly relates to web spreader rollers and methods for reducing wrinkles in web material using such web spreader rollers.

BACKGROUND

[0003] Certain web materials, such as films, nonwoven materials, textiles, papers, foils and other thin materials, are manufactured or converted using web lines. In these web lines, the web materials are transported or fed on rolls. Currently, a spreader roller may be provided in the web line before a critical process, such as prior to lamination, to remove wrinkles in the web material so that wrinkles are not found in the end product.

[ΘΘ04] Generally, spreader rollers have fixed diameters and fixed tapers. The fixed shape of these spreader rollers make each spreader roller applicable for a specific set of conditions associated with the web materials. For example, a spreader roller might have a fixed taper, which is able to remove wrinkles from a particular web material when the web material is fed through the web line at a particular speed. Any changes to the web material or feed rate, however, and the spreader roller is no longer effective to prevent wrinkles in the web material. ΘΘ05] Accordingly, it is desirable to provide web spreader rollers that are adjustable to a variety of web materials fed at a variety of feed rates. In addition, it is desirable to provide methods for reducing wrinkles in web material using such web spreader rollers. Furthermore, other desirable features and characteristics of the present invention will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background.

SUMMARY ΘΘ06] Web spreader rollers and methods for reducing wrinkles in web material using such web spreader rollers are provided. In one embodiment, a web spreader roller includes a body having a first end including a plurality of slits about a perimeter of the first end. Each of the plurality of slits is substantially parallel to a longitudinal axis of the body and define an adjustable taper portion of the first end of the body. The web spreader roller also includes a plug positioned within the first end. The plug is movable relative to the first end to move the adjustable taper portion from a first tapered position to a second tapered position. ΘΘ07] In one embodiment, a method for reducing wrinkles in a web material is provided. The method includes feeding a web material to a web spreader roller, the web spreader roller including a first end with a shaft and a plug movable relative to the shaft. The first end includes a plurality of slits defined about a perimeter of the first end extending substantially parallel to the longitudinal axis of the body. The method includes moving the plug relative to the shaft in a. direction substantially parallel to a longitudinal axis of the web spreader roller to adjust a taper of the first end.

[0008] In one embodiment, a web spreader roller is provided. The web spreader roller includes a hollow body extending along a longitudinal axis and having a first end opposite a second end. The web spreader roller includes a shaft coupled to each of the first end and the second end such that the shaft is at least partially received within the hollow body at the first end and the second end. The shaft extends along the longitudinal axis of the hollow body. The web spreader roller includes a first plug movably coupled to the shaft of the first end. The first plug is positioned within the first end. The web spreader roller includes a second plug movably coupled to the shaft of the second end. The second plug is positioned within the second end. The first plug and the second plug are movable relative to the shaft in a direction parallel to the longitudinal axis to adjust a taper associated with a respective one of the first end and the second end. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The exemplary embodiments will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:

[0010] Fig. 1 is a top view of an exemplary embodiment for a web spreader roller in accordance with various teachings of the present disclosure;

[ΘΘ11] Fig, 2 is a cross-sectional view of the exemplary web spreader roller of Fig. 1 , taken along line 2-2 of Fig. 1, illustrating an adjustable taper portion of the exemplary web spreader roller in a first position, in which a profile of the web spreader roller has a crown shape;

[ΘΘ12] Fig. 2A is a cross-sectional schematic illustration of the exemplar web spreader roller of Fig. 1 , taken along line 2.-2 of Fig. 1, illustrating another exemplary adjustable taper portion;

[0013] Fig. 3 is a cross-sectional view of the exemplary web spreader roller of Fig. 1 , taken along line 3-3 of Fig. 1 ;

[0014] Fig. 4 is a cross-sectional view of the exemplary web spreader roller of Fig. 1, taken along line 2-2 of Fig. 1 , illustrating the adjustable taper portion in a second position, in which a profile of the web spreader roller has a neutral or cylindrical shape;

[0015] Fig, 5 is a cross-sectional view of the exemplary web spreader roller of Fig. 1, taken along line 2-2 of Fig. 1, illustrating the adjustable taper portion in a third position, in which a profile of the web spreader roller has a reverse crown shape;

[0016] Fig. 6 is a cross-sectional schematic illustration of the exemplar}' web spreader roller of Fig, 1, taken along line 6-6 of Fig. 1, illustrating the adjustable taper portions in an asymmetrical position;

[0017] Fig. 7 is a top view of an exemplary embodiment for a web spreader roller in accordance with various teachings of the present disclosure; and

[ΘΘ18] Fig, 8 is a flowchart illustrating an exemplary method for reducing wrinkles in a web material. DETAILED DESCRIPTION

[0019] The following detailed description is merely exemplary in nature and is not intended to limit the present disclosure or the application and uses of the present teachings. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary, or the following detailed description. As used herein, the term module refers to any hardware, software, firmware, electronic control component, processing logic, and/or processor device, individually or in any combination, including without limitation: application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that executes one or more software or firmware programs, a combinational logic circuit, and/or other suitable components that provide the described func ionali y.

[ΘΘ2Θ] With reference to Fig. I , a spreader roller 10 according to various embodiments is shown. In one example, the spreader roller 10 is coupled to bearings 12, and rotatable about a longitudinal axis L to contact material fed to the spreader roller 10 at a desired speed. Generally, the spreader roller 10 is rotatable by the friction between a material and the spreader roller 10 or by a suitable drive mechanism known to one skilled in the art, including, but not limited to, a motor (not shown). In one embodiment, the spreader roller 10 may be used to reduce wrinkles or spread out wrinkles in the material, such as a web material, including, but not limited to a film, nonwoven material, textile, paper, foil and other thin materials. As will be discussed herein, the spreader roller 10 according to various embodiments includes an adjustable taper, which enables the spreader roller 10 to adapt to a. variety of web materials fed at a variety of speeds without requiring the use of a different spreader roller. The spreader roller 10 may be substantially cylindrical and hollow, however, the spreader roller 10 can have any desired shape.

[0021] In one example, the spreader roller 10 includes one or more shafts 14 and a hollow body 16. As the spreader roller 10 comprises a substantially identical mirror image about an axis A, the same reference numerals will be used to denote the same or similar components. W ^r ith continued reference to Figs. 1 and 2, the shafts 14 couple the spreader roller 10 to the bearings 12. The shafts 14 include a plurality of threads or threads 18, which cooperate with a portion of the body 16 to adj ust a taper associated with the spreader roller 10, as will be discussed herein. It should be noted that the use of threads 1 8 are merely exemplary, as any desirable technique can be employed to adjust the taper associated with the spreader roller 10. In addition, while the threads 18 are illustrated herein as only encompassing a portion of the shaft 14, the threads 18 may be formed along the entire length of the shaft 14, if desired. Generally, the shaft 14 is fixedly coupled to the body 16 so as to be at l east partially received within the hollow portion of the body 16.

[0022] With reference to Fig. 1, the body 16 includes at least one adjustable taper portion 20. In this example, the spreader roller 10 includes two adjustable taper portions 20, which are substantially identical about the axis A. It should be noted, however, that the spreader roller 10 can include a single adjustable taper portion 20, and further, the adjustable taper portions 2.0 need not be symmetrical about the axis A, if desired. In addition, while a single end 10b of the spreader roller 10 is illustrated in Figs. 2-5, the opposite end, end 10a, of the spreader roller 10 is substantially a mirror image of the end 10b, and thus, the below description of the end 10b is applicable to the end 10a. Generally, the body 16 is composed of a flexible material, including, but not limited to, a flexible metallic material, such as aluminum or thin walled steel, that enables the adjustable taper portion 20 to move or bend relative to the body 16 to adjust a taper associated with the ends 10a, 10b of the spreader roller 10. It should be noted, however, that one or more elements of the adjustable taper portions 20 may be coupled to the body 16 to enable the adjustment of the taper associated with the ends 10a, 10b of the spreader roller 10. For example, an element of the adjustable taper portion 20 may be pivotally coupled to the body 16 and pivotable to define the taper of the spreader roller 10. Thus, the following description is merely exemplary.

[0023] With reference to Figs. 1-3, according to one exemplary embodiment, the adjustable taper portion 20 includes at least one or a plurality of slits 22, a handle 24, a plug 26 (Figs, 2 and 3), an end plate 28 (Fig. 2), a first tapered surface 30 and a second tapered surface 32 (Figs. 2 and 3). In addition, as illustrated in Fig. 1, the adjustable taper portion 20 optionally includes a covering sleeve 34. If employed, the covering sleeve 34 extends about the spreader roller 10 to provide a uniform surface along the spreader roller 10. In this regard, the covering sleeve 34 bridges any gap created by the slits 22 to provide a uniform surface at the ends 10a, 10b. In one example, the covering sleeve 34 is composed of a suitable elastic polymeric material, including, but not limited to, a natural or synthetic rubber. It should be noted that the use of an elastic polymeric material is merely exemplary, as any suitable material, elastic or inelastic, that is suitable for covering gaps created by the slits 22 may be employed. In addition, although the covering sleeve 34 is illustrated herein as covering substantially an entire outer circumference of the spreader roller 10, the covering sleeve 34 can cover only a portion of the spreader roller 10, if desired.

[0024] With reference to Fig. 3, the slits 22 are defined in the body 16 at each end 10a, 10b of the spreader roller 10. In one example, four slits 22 are defined in the body 16 and are substantially equally spaced about the perimeter or circumference of the body 16, however, any number of slits 22 can be defined in the body 16 at any desired position along the perimeter of the body 16. With reference to Fig. 2, the slits 22 are defined in the body 16 from a distalmost end 16a of the body 16 to the end plate 28 so as to be substantially parallel to the longitudinal axis I. of the body 16. The slits 22 can be formed through any suitable technique, including, but not limited to, machining, wire cutting, laser cutting, molding, etc.

[0025] Referring to Figs. 2 and 3, the handle 24 is coupled to the plug 26. The handle 24 enables manual adjustment of the plug 26, and thus, the first tapered surface 30 associated with the respective end 10a, 10b (Fig. 1) of the spreader roller 10. The handle 24 can have any desired shape and size to enable the manual adjustment of the first tapered surface 30, and thus, the handle 24 illustrated herein is merely exemplary. In one example, the adjustable taper portion 20 can include at least two handles 24 per plug 26, which can be substantially evenly spaced about a perimeter of the plug 26, however, the adjustable taper portion 20 can include any desired number of handles 24, including, but not limited to, a single handle 2.4. Further, the shape of the handle 24 is merely exemplar}', as the handle 24 can be shaped to receive a. suitable instrument for the adjustment of the plug 26, and for example, the handle 24 can be shaped as a hex socket or other suitable tool receiving interface.

[0026] With reference to Fig. 3, the plug 26 is movable about the shaft 14 along the second tapered surface 32. Generally, the plug 26 is circular, however, the plug 26 can have any desired shape. In one example, the plug 26 includes a central bore 36 and a perimeter or circumference 38. In one embodiment, the central bore 36 includes a plurality of threads 40, which threadably engage the threads 18 of the shaft 14 to enable relative movement between the plug 26 and shaft 14, Generally, the threads 18, 40 form a locking connection, such that the plug 26 is not able to be moved relative to the shaft 14 without input to the handle 24. The end plate 28 is fixedly coupled to the shaft 14 and to an interior surface 16b of the body 16 of the spreader roller 10, The end plate 28 is generally annular, however, the end plate 28 can have any desired shape.

[0027] With continued reference to Fig. 3, the first tapered surface 30 is generally defined from the distalmost end 16a of the body 16 to the end plate 28 and extends about a perimeter or circumference of the end 10b of the spreader roller 10. In one example, the first tapered surface 30 tapers downward from the end plate 28 to the distalmost end 16a. In other words, the first tapered surface 30 has a negative slope from the end plate 28 to the distalmost end 16a. As will be discussed herein, the first tapered surface 30 is adjustable relative to the body 16 of the spreader roller 10 via the movement of the plug 26 relative to the shaft 14. In addition, it should be noted that the body 16 of the spreader roller 10 need not include the first tapered surface 30. In this regard, with reference to Fig. 2A, an exterior surface 16c of the body 16 may be uniform, such that no additional taper is defined at the end 10b of the spreader roller 10 and the movement of the plug 26 relative to the shaft 14 defines the adjustable taper associated with the spreader roller 10.

[0028] With reference back to Fig. 3, the second tapered surface 32 is defined on a portion of the interior surface 16b of the body 16, and in one example, extends from the end plate 28 to the distalmost end 16a. Generally, the second tapered surface 32 extends about a perimeter or circumference of the interior surface 16b from the end plate 28 to the distalmost end 16a, The second tapered surface 32 cooperates with the plug 26 to change or adjust the first tapered surface 30 of the spreader roller 10, as will be discussed herein. Generally, the second tapered surface 32 tapers downward from the end plate 28 to the distalmost end 16a, or has a negative slope from the end plate 28 to the distalmost end 16a.

[0029] With the spreader roller 10 assembled, the adjustable taper portion 20 is in a first position with the plug 26 at the distalmost end 16a, as illustrated in Fig. 2, When the plug 26 is in the first position, a profile of the spreader roller 10 has a crowned shape as a crown roller. In other words, the first tapered surface 30 of the adjustable taper portions 20 has a negative slope from the end plate 28 to the distalmost end 16a. In the first position, the end 10b has a first diameter. As will be discussed, the movement of the plug 26 relative to the shaft 14 changes the diameter of the ends 10a, 10b (Fig, 1) to adjust the taper of the spreader roller 10. [0030] Generally, the spreader roller 10 is effective as a crown roller when the air entrapment height is greater than a. threshold and there is little or no traction between the web material and the spreader roller 10 or the web material has slack in the center, which results in a good spreading effect. In one example, the following equation is used to determine when to adjust the adjustable taper portion 20 of the spreader roller 10:

[0031] In the above equation, h is the air entrapment height between the web material and the spreader roller 10, D is a diameter of the spreader roller 10, η is the air viscosity , W is a width of the web material, V _web is a velocity of the web material, V _mll is a speed of the spreader roller 10 and T is a tension on the web material. Generally, if h is greater than three times an average surface roughness (R _a ) of the spreader roller 10, then the web material is likely to slip on the spreader roller 10 and the adjustable taper portion 20 can be adjusted to a crown roller to improve the traction between the web material and the spreader roller 10.

[0032] In order to change or adjust the first tapered surface 30 of the adjustable taper portions 20, a force is imparted to the handles 24 to move or rotate the threads 40 of the plug 26 on the threads 1 8 of the shaft 14 until the first tapered surface 30 has reached a desired slope. Generally, the plug 26 is moved in a direction substantially parallel to the longitudinal axis L of the spreader roller 10. For example, with reference to Fig. 4, the adjustable taper portion 20 is movable to a second position, in which the plug 26 is positioned substantially in a middle of a distance defined between the end plate 28 and the distalmost end 16a of the body. In this second position, a profile of the spreader roller 10 has a neutral taper, or in other words, the spreader roller 10 has no taper or a slope of about zero at the end 10b. In the second position, the end 10b has a second diameter, which is greater than the first diameter associated with the first position. In this regard, the movement of the plug 26 relative to the shaft 14 causes an expansion of the end 10b, which is enabled by the slits 22. In this example, the body 16 of the spreader roller 10 flexes or bends at a point near the end plate 28 to enable the movement of the adjustable taper portion 20 to the second position. [0033] As a further example, with reference to Fig. 5, the adjustable taper portion 20 is movable to a third position, in which the plug 26 is adjacent to the end plate 28. When the plug 26 is moved to the third position, a profile of the spreader roller 10 has the shape of a reverse crown roller. In other words, the first tapered surface 30 of the end 10b of the spreader roller 10 has a positive slope from the end plate 28 to the distalmost end 16a. This shape of the spreader roller 10 is desirable when the air entrapment height h from Equation (1) is less than three times the average surface roughness (R _a ) of the spreader roller 10 such that there is some traction between the web material and the spreader roller 10.

[0034] In the third position, the end 10b has a third diameter, which is greater than the first diameter associated with the first position and the second diameter associated with the second position. The slits 22 enable the expansion of the end 10b to the third diameter in the third position. In addition, in this example, the body 16 of the spreader roller 10 flexes or bends at a point near the end plate 28 to enable the movement of the adjustable taper portion 20 to the third position. Thus, in the third position, or when the plug 26 is in a position between the second position (Fig, 4) and the third position (Fig. 5), it may be desirable to position the covering sleeve 34 (Fig. I) over the spreader roller 10 to bridge any gaps formed by the slits 22. In addition, it should be noted that while three positions of the plug 26 are illustrated herein, the plug 26 is movable to any desired position relative to the shaft 14 to adjust the first tapered surface 30 of the spreader roller 10. Thus, the positions of the plug 26 illustrated herein are merely exemplary.

[0035] In addition, it should be noted that the plugs 26 associated with the respective adjustable taper portions 20 need not be adjusted to the same or substantially the same position. In this regard, with reference to Fig. 6, the adjustable taper portions 20 of the spreader roller 10 may be adjusted so as to be asymmetrical with respect to the axis A. In one example, the first end 10a is adjusted to the second position such that the end 10a has a neutral taper and the adjustable taper portion 20 of the second end 10b is adjusted to the third position, such that the end 10b has a positive slope. The offset taper positions of the ends 10a, 10b of the spreader roller 10 enables the spreader roller 10 to be used to handle skewed webs, in which one side of the web material is held tight (side adjacent to end 10a) and the other side of the web material has slack (side adjacent to end 10b),

[0036] With reference to Fig. 7, an exemplary spreader roller 100 is shown. As the spreader roller 100 is similar to the spreader roller 10 described with reference to Figs, 1 -5, the same reference numerals will be used to denote the same or similar features. The spreader roller 100 is coupled to the bearings 12, and is rotatabie about the longitudinal axis L to contact material fed to the spreader roller 100 at a desired speed. Generally, the spreader roller 100 is rotatabie by the friction between the web material and the spreader roller 100 or by a suitable drive mechanism known to one skilled in the art, including, but not limited to, a motor (not shown). In one embodiment, the spreader roller 100 may be used to reduce wrinkles or spread out wrinkles in a material, such as a web material, including, but not limited to a film, nonwoven material, textile, paper, foil and other thin materials. As will be discussed herein, the spreader roller 100 according to various embodiments includes an adjustable taper, which enables the spreader roller 100 to adapt to a variety of web materials fed at a variety of speeds without requiring the use of a different spreader roller. The spreader roller 100 may be substantially cylindrical and hollow, however, the spreader roller 100 can have any desired shape.

[0037] According to various embodiments, the spreader roller 100 includes one or more shafts 14 and a body 110. The body HO includes at least one adjustable taper portion 20 and a control system 12.0. In this example, the spreader roller 10 includes two adjustable taper portions 20, which are substantially identical about the axis A. It should be noted, that the spreader roller 10 can include a single adjustable taper portion 20, and further, the adjustable taper portions 20 need not be symmetrical about the axis A, if desired. Each of the adjustable taper portions 20 are coupled to the control system 120.

[0038] The control system 120 includes a motor 130, a control module 140 and a user input device 150. The motor 130 includes an output shaft coupled to one or more of each of the handles 24 of the adjustable taper portions 20 through a suitable coupling or linkage as known to one skilled in the art. It should be noted that while a single motor 130 is illustrated herein to control each of the adj ustable taper portions 20, two motors can be used with a respective one of the motors coupled to respective ones of the handles 24 of the adjustable taper portions 20. In addition, the output shaft of the motor 130 can be directly coupled to the plug 26 of each of the adjustable taper portions 20. Generally, the motor 130 is operable to move or adjust the first tapered surface 30 of the spreader roller 10 by moving the plug 26 relative to the shaft 14. In one example, the motor 130 comprises a stepper motor, however, any suitable driving mechanism can be employed. The motor 130 is in communication with the control module 140 to receive one or more control signals to adjust a posi tion of each of the plugs 26. [0039] In one example, the control module 140 receives user input from the user input device 150. The user input device 150 includes, but is not limited to, a keyboard, a microphone, a touchscreen layer associated with a display, or other suitable device to receive data and/or commands from the user. Based on the user input from the user input device 150, the control module 140 generates one or more control signals for the motor 130 to move or adjust the position of one or more of the plugs 26 relative to the shafts 14, thereby adjusting the first tapered surface 30 of the spreader roller 100,

[0040] In one embodiment, with reference to Fig. 8 and continuing reference to Figs. 1 - 7, a method for reducing wrinkles in a web material is provided. In one example, the method starts at 200. The method includes feeding a web material to the web spreader roller 10, 100 at 210. At 220, the method includes moving one or more of the plugs 26 relative to the shafts 14 in a direction substantially parallel to the longitudinal axis L of the web spreader roller 10, 100 to adjust a taper or first tapered surface 30 of one or more of the ends 10a, 10b. In one embodiment, one or more of the plugs 26 may be moved by ihreadably advancing the one or more of the plugs 26 on the shafts 14 from a first position, in which the ends 10a, 10b have a first taper (Fig. 2), to a second position, in which the ends 10a, 10b have a second taper (Fig, 4), In another embodiment, the one or more of the plugs 26 may be ihreadably advanced using a motor (Fig. 7). The method ends at 230, when the first tapered surface 30 has reached a desired taper for the ends 10a, 10b of the spreader roller 10.

[0041] Thus, the adjustable taper portions 20 of the spreader roller 10, 100 enable the first tapered surface 30 associated with the ends 10a, 10b, 100a, 100b of the spreader roller 10, 100 to be adjustable to a variety of positions. The variable adjustment of the first tapered surface 30 enables the spreader roller 10, 100 to be used with a variety of web materials at a variety of feed rates, without requiring the use of a different spreader roller.

[0042] While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplar}' embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the present disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the present disclosure. It being understood that various changes may be made in the

I I function and arrangement of elements described in an exemplary embodiment without departing from the scope of the present disclosure as set forth in the appended claims.