[0001] The present invention relates to methods and apparatus for unwinding web materials.
More particularly, the invention pertains to methods and apparatus for unwinding web
materials having a plurality of narrow lanes.
[0002] US 4,304,371 discloses an existing process for peeling sheet metal strips from a wound construct.
[0003] The manufacture of products such as disposable absorbent articles involves the use
of narrow webs of flexible material. Such flexible materials can include, by way of
illustration, nonwoven materials, elastic materials, adhesive tapes, polymeric films,
release paper, mechanical fastening materials or the like. Due to their narrow widths,
these flexible materials and others of this type present special handling difficulties.
[0004] For example, narrow web materials are sometimes processed in the form of planetary
wound rolls, often called "cookie rolls" or "cookies" where the narrow web material
is wound directly upon itself to form a narrow roll. Given the width of the web material,
however, these very narrow rolls can be unstable and tend to warp or fall apart when
lifted. Support members can be used to protect the cookie from distortion or damage,
but that introduces a new structure and increases the processing cost of the web material
and the cost to change rolls. Moreover, individual cookie rolls have a relatively
short run time, which undesirably leads to frequent roll changes.
[0005] To circumvent these difficulties, narrow web materials can be level wound. By oscillating
the narrow web material back and forth across the roll during winding, the level winding
process yields a stable roll form that resists damage. Again, however, the level winding
process can add significant expense to the web material.
[0006] Certain web materials such as molded hook fasteners have been formed into wide intermediary
tapes. These wide tapes include strips of hook material separated by splitting channels
or perforations. Processing of such wide tapes has to date required simultaneously
separating the strips of hook material using specialized equipment such as splitting
combs or slitting blades. Not only is such specialized equipment expensive to obtain
and operate, but its use is practical only for converting operations that can accommodate
simultaneous processing of multiple strips.
[0007] In view of these deficiencies and limitations with conventional manufacturing operations,
it would be desirable to have improved methods and apparatus for unwinding narrow
web materials.
[0008] In response to the above-referenced deficiencies and limitations, a new method of
unwinding a web material has been discovered. The method includes providing a roll
of web material that defines a plurality of integral lanes with a separator disposed
between the lanes, and tearing the web material along the separator to disconnect
at least one lane from at least one other lane. The selected lane is unwound from
the roll while continuing to tear the web material along the separator and maintaining
the other lane on the roll.
[0009] With this method, the parent roll can contain a relatively wide web of material that
consists of a plurality of lanes of web material. The parent roll can provide a high
degree of roll stability to minimize damage to the material during handling and storage
operations. The individual lanes of web material can be unwound sequentially from
the parent roll. In this way, only the number of lanes that are required for immediate
processing need to be unwound. The remainder of the lanes can remain wound on the
parent roll. This method can provide a stable roll form for delivering narrow lanes
of material, without requiring an additional slitting operation and without the added
expense of level winding or support members.
[0010] It is especially significant that the web material includes separators that enable
the web material to be torn into individual lanes or groups of lanes. The terms "torn"
and "tearing" in the context of this application mean that at least one lane of the
web material can be or is separated from at least one other lane of the web material
without using a cutting or slitting device. Separators can comprise any structure
or treatment that causes the web material to tear into distinct lanes. In particular
embodiments, suitable separators can comprise perforated regions, intermittently cut
or slit regions, score marks, reduced thickness or reduced integrity regions, including
splitting channels, creased regions, added elements or treatments that direct or limit
tearing to a defined area, molded or embossed indentations, or the like. Perforation
or scoring devices can be incorporated into the web production process or as a later
converting step for the web material. The perforation or scoring devices can continuously
or intermittently perforate, cut, or indent the web material. Alternatively, for molded
web materials the material can include integral, molded-in splitting channels. The
splitting channels can comprise generally longitudinal regions that have a relatively
lower basis weight or less durable structure, so that the lanes can be separated along
the splitting channels. Forming the web material so that it can be torn without the
use of a cutting or slitting device simplifies the unwinding operation and reduces
equipment and maintenance costs.
[0011] The manner in which the remaining lanes of web material are maintained on the parent
roll will depend to some extend of the nature of the web material. In most cases,
it may be sufficient to hold the leading ends of the remaining lanes of web material
against the roll. Various means can be used to hold the remaining lanes in place,
including but not limited to items such as tape, clips, clamps, bands, adhesives,
cords, covers, or the like.
[0012] The present method is particularly suited for narrow webs of flexible material. The
individual lanes can have any desired width, such as about 5 cm. or less or about
2 cm. or less. The parent roll on the other hand can be relatively wide and can contain
any number of lanes depending upon the width of the lanes. For lane widths on the
order of 2 cm., for example, the web material on the parent roll can comprise 2 or
more lanes, particularly 4 or more lanes, more particularly 8 or more lanes, such
as 10 to 60 lanes or more.
[0013] The present method can be used for unwinding a variety of flexible materials, such
as nonwoven materials, elastic materials, adhesive tapes, polymeric films, release
paper, mechanical fastening materials, or the like. Mechanical fastening materials
can comprise interlocking geometric shaped materials, such as hooks, loops, bulbs,
mushrooms, arrowheads, balls on stems, male and female mating components, buckles,
snaps, or the like. In particular embodiments, the mechanical fastening materials
comprise hook-and-loop fastening elements. Loop type fasteners typically comprise
a fabric or material having a base or backing structure and a plurality of loop members
extending upwardly from at least one surface of the backing structure. The loop material
can be formed of any suitable material, such as acrylic, nylon or polyester, and can
be formed by methods such as warp knitting, stitch bonding or needle punching. Suitable
loop materials are available from Guilford Mills, Inc., Greensboro, North Carolina,
U.S.A. under the trade designation No. 36549. Another suitable loop material can comprise
a pattern un-bounded web as disclosed in
U.S. Patent 5,858,515 issued January 12, 1999 to Stokes et al.
[0014] Hook type fasteners typically comprise a fabric or material having a base or backing
structure and a plurality of hook members extending upwardly from at least one surface
of the backing structure. In contrast to the loop type fasteners which desirably comprise
a very flexible fabric, the hook material advantageously comprises a more resilient
material to minimize unintentional disengagement of the fastener components as a result
of the hook material becoming deformed and catching on clothing or other items. The
term "resilient" as used herein refers to an interlocking material having a predetermined
shape and the property of the interlocking material to resume the predetermined shape
after being engaged and disengaged from a mating, complementary interlocking material.
Suitable hook material can be molded or extruded of nylon, polypropylene or another
suitable material. Hook materials are available from commercial vendors such as Velcro
Industries B.V., Amsterdam, Netherlands or affiliates thereof, including specific
materials identified as Velcro HTH-829 with a uni-directional hook pattern and having
a thickness of about 0.9 millimeters (35 mils) and HTH-851 with a uni-directional
hook pattern and having a thickness of about 0.5 millimeters (20 mils); and Minnesota
Mining & Manufacturing Co., St. Paul, Minnesota U.S.A., including specific materials
identified as CS-600.
[0015] Hence, in another embodiment, the invention concerns a method of unwinding a mechanical
fastener material. The method includes providing a roll of mechanical fastener material
comprising a base and a plurality of engaging elements projecting from the base. The
mechanical fastener material defines at least 3 lanes containing engaging elements
with integral separators disposed between the lanes. The lanes can have a width of
about 5 cm. or less. The method also includes tearing the mechanical fastener material
along a separator to disconnect at least one lane from a plurality of other lanes,
and unwinding the one lane from the roll while continuing to tear the mechanical fastener
material along the separator. The plurality of other lanes are maintained on the roll
while the one lane is unwound.
[0016] In particular embodiments the web material can comprise a hook material. The multiple
lane configuration can be produced in-line in the hook production process. The parent
rolls can be produced in relatively wide widths, for example from about 7 to about
100 cm. depending on the manufacturer's width constraints and tension tolerances.
In one particular embodiment, by way of illustration, the web material can be divided
into lanes having a width of about 1.3 cm. with separators disposed between the lanes.
The separators can comprise longitudinal channels or splitting lanes of reduced thickness.
For example, the base of the hook material can have a nominal thickness of about 0.3
millimeters (mm.) and the separators can have a nominal thickness at their center
of about 0.05 mm. The separators can be very narrow, such as on the order of about
0.2 mm. Alternatively, the web material can comprise loop material or other mechanical
fastening material.
[0017] In another aspect, the present invention also concerns an apparatus for unwinding
a roll of web material having first and second integral lanes. The apparatus includes
at least one roll unwind stand comprising a shaft defining an unwind axis and a drive
mechanism adapted to rotate the shaft. A repositioning device, which is adapted to
redirect a lane as it is unwound, is movably mounted and positionable at a plurality
of positions along an axis generally parallel to the unwind axis. The plurality of
positions correspond to different lane positions. The apparatus also includes a control
system adapted to: move the repositioning device to a first location corresponding
to at least one first lane, rotate the drive mechanism to unwind the at least one
first lane, move the repositioning device to a second location corresponding to at
least one second lane, and rotate the drive mechanism to unwind the at least one second
lane. The second lane can remain on the roll while the fist lane is unwound.
[0018] The apparatus can also employ sensors that provide roll diameter information. Thus,
in another embodiment, an apparatus for unwinding rolls of web material having a plurality
of integral lanes can comprise first and second roll unwind stands. The unwind stands
comprise shafts defining unwind axes and one or more drive mechanisms adapted to rotate
the shafts. A repositioning device is associated with each roll unwind stand and,
is adapted to redirect a lane as it is unwound. The repositioning devices are movably
mounted and positionable at a plurality of positions along an axis generally parallel
to the respective unwind axis. The plurality of positions correspond to different
lane positions. A sensing device is associated with each roll unwind stand and is
adapted to provide roll diameter information. The sensing devices are movably mounted
and positionable at a plurality of positions along an axis generally parallel to the
respective unwind axis. Again, the plurality of positions correspond to different
lane positions. The apparatus also includes a control system adapted to: move the
repositioning and sensing devices of the first roll unwind stand to a first location
corresponding to at least one first lane, rotate the drive mechanism of the first
roll unwind stand to unwind the at least one first lane, move the repositioning and
sensing devices of the first roll unwind stand to a second location corresponding
to at least one second lane, rotate the drive mechanism of the first roll unwind stand
to unwind the at least one second lane, move the repositioning and sensing devices
of the second roll unwind stand to a first location corresponding to at least one
first lane, rotate the drive mechanism of the second roll unwind stand to unwind the
at least one first lane, move the repositioning and sensing devices of the second
roll unwind stand to a second location corresponding to at least one second lane,
and rotate the drive mechanism of the second roll unwind stand to unwind the at least
one second lane. The second lanes can remain on their corresponding rolls while the
first lanes are unwound.
[0019] In particular embodiments, the sensing devices can detect the position of the next
lane to be unwound. Further, the control system can use sensor feedback information
to control the position of the repositioning devices.
[0020] The apparatus as described herein can be used to unwind a roll of web material having
first and second integral lanes, including the steps of: positioning a repositioning
device at a first position corresponding to the position of the first lane, where
the repositioning device is adapted to redirect a lane as it is unwound; initiating
separation of the first lane from the integral second lane; feeding the first lane
onto the repositioning device; rotating the roll to unwind the first lane while tearing
the first lane from the second lane and maintaining the second lane on the roll; moving
the repositioning device to a second position corresponding to the position of the
second lane; feeding the second lane onto the repositioning device; and rotating the
roll to unwind the second lane.
[0021] The present invention facilitates high-speed manufacturing of products such as absorbent
articles, including diapers, training pants, incontinence products, diaper pants,
feminine care products, swim pants, disposable underwear, or the like. The multiple
lane configuration of the web material is particularly suited for use with production
of such garments, which often employ two or more pieces formed of narrow web material
such as mechanical or adhesive fasteners. In manufacturing such garments, it can be
advantageous to unwind a single lane of web material and subsequently tear or cut
the single lane into two or more individual strips. The strips can then be cut and
applied to the garment so that there are two fasteners per product.
[0022] Particular training pants suitable for use with the present invention are disclosed
in
U.S. Patent Application Serial No. 09/444,083, filed on November 22, 1999 (corresponding to
PCT application WO 00/37009 published June 29, 2000) by A. Fletcher et al. and titled "Absorbent Articles With Refastenable Side Seams;". This reference describes
various materials and methods for constructing training pants. Other methods and apparatus
concerning the manufacture of training pants are disclosed in
U.S. Patent 4,940,464 issued July 10,1990 to Van Gompel et al.; and
U.S. Patent 5,766,389 issued June 16, 1998 to Brandon et al..
[0023] The above-mentioned and other features and advantages of the present invention and
the manner of attaining them will become more apparent, and the invention itself will
be better understood by reference to the drawings and the following description of
the drawings.
Definitions
[0024] Within the context of this specification, each term or phrase below will include
the following meaning or meanings.
[0025] "Bonded" refers to the joining, adhering, connecting, attaching, or the like, of
two elements. Two elements will be considered to be bonded together when they are
bonded directly to one another or indirectly to one another, such as when each is
directly bonded to intermediate elements.
[0026] "Comprising" is inclusive or open-ended and does not exclude additional, unrecited
elements or method steps.
[0027] "Connected" refers to the joining, adhering, bonding, attaching, or the like, of
two elements. Two elements will be considered to be connected together when they are
connected directly to one another or indirectly to one another, such as when each
is directly connected to intermediate elements.
[0028] "Disposable" refers to articles which are designed to be discarded after a limited
use rather than being laundered or otherwise restored for reuse.
[0029] "Disposed," "disposed on," and variations thereof are intended to mean that one element
can be integral with another element, or that one element can be a separate structure
bonded to or placed with or placed near another element.
[0030] "Elastic," "elasticized" and "elasticity" mean that property of a material or composite
by virtue of which it tends to recover its original size and shape after removal of
a force causing a deformation.
[0031] "Fabrics" is used to refer to all of the woven, knitted and nonwoven fibrous webs.
[0032] "Flexible" refers to materials which are compliant and which will readily conform
to the general shape and contours of the wearer's body.
[0033] "Force" includes a physical influence exerted by one body on another which produces
acceleration of bodies that are free to move and deformation of bodies that are not
free to move. Force is expressed in grams per unit area.
[0034] "Integral" is used to refer to various portions of a single unitary element rather
than separate structures bonded to or placed with or placed near one another.
[0035] "Layer" when used in the singular can have the dual meaning of a single element or
a plurality of elements.
[0036] "Member" when used in the singular can have the dual meaning of a single element
or a plurality of elements.
[0037] "Nonwoven" and "nonwoven web" refer to materials and webs of material which are formed
without the aid of a textile weaving or knitting process.
[0038] "Surface" includes any layer, film, woven, nonwoven, laminate, composite, or the
like, whether pervious or impervious to air, gas, and/or liquids.
[0039] These terms may be defined with additional language in the remaining portions of
the specification.
[0040] The above-mentioned and other features of the present invention and the manner of
attaining them will become more apparent, and the invention itself will be better
understood by reference to the following description and the accompanying drawings,
wherein similar features in different figures have been given the same reference numeral.
Figure 1 schematically illustrates one embodiment of a process and apparatus for unwinding
a web material according to the present invention.
Figure 2 illustrates a top plan view of a web material of the type shown in Figure
1.
Figure 3 illustrates a sectional side view of an exemplary hook fastening material
for use with the methods and apparatus of the present invention.
Figure 4 illustrates a sectional end view of the hook fastening material shown in
Figure 3.
Figure 5 illustrates a front elevation of a further embodiment of a process and apparatus
for unwinding a web material according to the present invention.
Figure 6 illustrates a top plan view of the process and apparatus of Figure 5.
Figure 7 illustrates a right side view of the process and apparatus of Figure 5.
Figure 8 illustrates a left side view of the process and apparatus of Figure 5.
[0041] The principles of the present invention can be used with a variety of material webs
that can be incorporated into an even greater variety of products. For ease of explanation,
the description hereafter will be in terms of a hook fastener material for use in
disposable training pants.
[0042] One embodiment of a process and apparatus for unwinding web materials is schematically
illustrated in Figure 1. The web material 20, separately shown in Figure 2, includes
a plurality of narrow lanes 22 with separators 24 disposed between the lanes. The
web material can be torn along a separator in order to disconnect at least one selected
lane 26 from one or more remaining lanes 28. As the selected lane is unwound from
the roll, the web material can be further torn along the separator so that the remaining
lanes remain on the roll. The ends of the remaining lanes 28 can be taped down to
the roll to keep them from unwinding prematurely.
[0043] To facilitate high speed operations, the process can include two or more driven rolls
30, 32 of multi-lane web material. As shown in Figure 1, a selected lane from a first
parent roll 30 can be led around a turnbar 34 to a splicing unit 36. From there the
selected web can enter a festoon section 38, past a driven roll 40 and into a dancer
roll 42. Upon exiting the dancer roll, the selected lane can be divided at a slitter
station 44 into first and second individual strips 46, 48. Each strip can be transported
to an application station 50 for incorporation into an intermediate or finished product.
In this way, the present process allows two very narrow strips of material to be supplied
to a garment assembly machine simultaneously from a stable roll configuration with
a long run time. The selected lane can alternatively be incorporated directly into
an intermediate or finished product without slitting into individual strips and/or
without the other intervening steps.
[0044] In the process illustrated in Figure 1, a selected lane 52 from a second parent roll
32 can be partially unwound and led around the turnbar 34 to the splicing unit 36.
As described in greater detail below, the selected lane 52 from the second parent
roll can be spliced to the tail of the selected lane 26 from the first parent roll
for continuous high speed operation. This sequence can be repeated by selecting adjacent
remaining lanes from the rolls 30, 32 and separating and unwinding such lanes relative
to the other remaining lanes. Conventional equipment can be used for the various web
handling operations, provided it is suitable for the particular web material being
processed. Such web handling equipment is available from a variety of commercial vendors,
such as Martin Automatic, Inc. of Rockford, Illinois U.S.A.
[0045] As used herein, the term "lane" refers to the width of material that is unwound from
a parent roll which has multiple lanes across its width; the lanes can but need not
comprise narrower "strips" that jointly form a lane. With reference to Figure 2, which
represents a top plan view of an exemplary web material, a web material can be formed
with a plurality of lanes 22 with a separator 24 disposed between each lane. Each
lane 22 comprises two strips 56, 57 with another separator 58 disposed between each
strip of each lane. The illustrated web material could alternatively be unwound in
lanes that each comprise a different number of strips. For particular operations,
it might be desirable to consecutively unwind lanes with a different number of strips
from a single roll.
[0046] The separators 24 used between lanes 22 can be the same as or different than the
separators 58 used between individual strips 56, 57. For instance, it may be desirable
for the separators 24 used between lanes to tear more easily than the separators 58
used between individual strips. Different separators can comprise splitting channels
formed with different depth or width dimensions; score marks or perforations with
different dimensions or penetration depths; or the like.
[0047] The web material 20 can comprise a hook fastening material such as the type illustrated
in Figures 3 and 4. The side section view of Figure 3 is taken from a plane parallel
to the separators 24, and the end section view of Figure 4 is from a plane perpendicular
to the separators 24. The exemplary hook fastener material 20 can comprise groupings
60 of hooks 62 that are arranged in a plurality of rows. The hooks desirably extend
upward from a base 64 of the hook material. Rip-stops 66 which are known and commonly
employed in the art can be incorporated in the hook material between the hooks. The
hooks can all face in the same direction as illustrated or can face in multiple directions.
The groupings of hooks can but need not be separated from one another by selvage areas
68. Longitudinal separators 24 in the form of narrow splitting channels can be disposed
between the groupings of hooks, such as in the selvage areas. The hooks, base, rip-stops
and separators can be integrally formed, in a wide variety of sizes, shapes and patterns.
Examples of particular hook materials and their method of manufacture are disclosed
in
U.S. patents 4,794,028 issued December 27, 1988 to Fisher and
5,997,522 issued December 7, 1999 to Provost et al.. Suitable hook materials are available from various commercial vendors such as Velcro
Industries B.V., Amsterdam, Netherlands or Minnesota Mining & Manufacturing Co., St.
Paul, Minnesota, U.S.A.
[0048] A further embodiment of the present process and apparatus is illustrated in Figures
5-8. The first and second parent rolls 30, 32 of web material 20 are shown mounted
on shafts 70 of a dual roll unwind stand 72. The unwind stand comprises a base plate
74 and a frame structure 76 mounted on the base plate. Rotary drive mechanisms 78
are attached to the frame and operatively connected to the shafts to unwind the parent
rolls. The unwind stand can include backing plates 80 connected to each shaft to support
and/or limit axial movement of the drive side of the rolls 30, 32.
[0049] With particular reference to Figure 5, a selected lane 26 is illustrated being unwound
from the first parent roll 30 in the direction of arrow 82. The selected lane 26 can
be led over upper idler rolls 84 and 85, twisted 90 degrees, and fed onto an upper
repositioning device 86. The term "repositioning device" as used herein refers to
a driven roll, idler roll, turn bar, dead bar, web guide or the like that is adapted
to redirect a lane as it is unwound. In the illustrated embodiment, the upper repositioning
device comprises an upper idler roll 86 which redirects the selected lane 26 so that
it is transported in a direction into the page of Figure 5. With additional reference
to Figures 6 and 8, the selected lane 26 thereafter travels through the splicing unit
36, into a festoon section 38, past a driven roll 40 and to a dancer roll 42.
[0050] A selected lane 52 from the second parent roll 32 is illustrated as having been threaded
in the direction of arrow 88 and is to be fed to the splicing unit 36. This selected
lane 52 is pulled off the second parent roll over lower idler rolls 90, 91 and 92,
twisted 90 degrees, and fed onto a lower repositioning device 94. In the illustrated
embodiment, the lower repositioning device comprises a lower idler roll 94 which redirects
the selected lane 52 from the second parent roll 32 generally parallel to the selected
lane 26 from the first parent roll 30 and into the splicing unit 36. As further illustrated,
idler rolls 84-85 and 90-91 can be positioned to form S-wrap configurations to provide
consistent entry and exit points to the change in web direction, and could alternatively
comprise two free turning idler rolls, fixed shafts, turn bars, or the like.
[0051] Upper and lower trolley members 100 and 102 are used in the illustrated embodiment
to carry the upper and lower idler rolls 86 and 94, respectively. The trolley members
100 and 102 can be slideably mounted on a beam member 104 (Figures 6 and 8), which
can be fixedly mounted at one end to the frame structure 76. Various mechanisms can
be used to permit movement of the trolley members 100 and 102 along the beam member
104, such as a dovetail slide with a locking mechanism, a ball-slide, a combination
ball-slide arrangement with a ball-screw mechanism for movement, a slotted mounting
bracket, a cantilevered piece of bar stock with a clamping device, or the like. The
upper trolley member 100 (Figures 5,6 and 8) can be movably mounted on an upper portion
of the beam member 104. The upper idler roll 86 can be rotatively mounted on the upper
trolley member 100. Similarly, the lower trolley member 102 can be movably mounted
on a lower portion of the beam member 104, and the lower idler roll 94 can be rotatively
mounted on the lower trolley member 102. The upper trolley member 100 can be adapted
to move along the beam member 104 so that it is properly positioned for unwinding
of each lane 22 of the first parent roll 30. Likewise, the lower trolley member 102
can be adapted to move along the beam member 104 so that it is properly positioned
for unwinding of each lane 22 of the second parent roll 32. In particular, the trolley
members 100 and 102 can be positioned at a plurality of positions along an axis generally
parallel to the axis of the unwind shafts 70, so that the idler rolls 86 and 94 can
be radially aligned with the particular lane being unwound. The upper and lower trolley
members 100 and 102 are desirably capable of moving independently of one another.
[0052] Each trolley member can be adjusted by sliding it along the beam so that the center
of the idle roll 86 or 94 is approximately aligned with the center of the lane being
unwound. The trolley member can be reversibly locked in position with a hand-tightened
set screw or other suitable means. The trolley members 100 and 102 can be adjusted
manually, mechanically or electromechanically to correspond with the position of a
diameter sensor 130, 132. Suitable mechanical position control devices can comprise
a ball-screw linear actuator, pneumatic, hydraulic or servo cylinder, rack and pinion
gear assembly, or the like, which can but need not necessarily use the sensors to
detect the position of the unwinding lane.
[0053] The unwind process and apparatus desirably but not necessarily employ sensors 130,
132 to provide greater opportunity for automated operation. The sensors can detect
the presence and location of the web material 20. The sensors can be used to detect
the presence and location of the unwinding lane and provide feedback on the diameter
of the lane, allowing accurate speed calculations as the lane diameter diminishes.
Feedback from the diameter sensors 130, 132 can be used in combination with a microcontroller,
computer or the like to provide automatic tracking of the successive unwind lanes,
thereby minimizing operator intervention between parent roll changes. One particular
sensor that is suitable for the present process is a laser sensor available from SICK
OPTIK ELECTRONIK, Inc., a business having offices in St. Paul, Minnesota U.S.A. Narrow
beam or contact sensors can be used and are preferred to broad parabolic beam type
sensors. Data from the sensors is desirably provided to a control system 140 (schematically
illustrated in Figure 5) that controls the unwinding process. Suitable control systems
are available from various commercial vendors, such as Allen-Bradley, Milwaukee, Wisconsin
U.S.A.
[0054] In the illustrated embodiment, first and second sensors 130, 132 are moveably mounted
on rails 110 attached to the frame 76. With particular reference to Figures 5 and
7, the first sensor 130 and the second sensor 132 can each be mounted on brackets
112 that are slideable along the rails 110. The brackets can move independently from
one another and independently from the idler rolls 86 and 94. Position control devices
control movement of the sensors and brackets along the rails. The position control
device can comprise a motorized ballscrew as illustrated, pneumatic cylinder, or the
like, which can but need not necessarily provide position feedback data to the control
system 140. The sensors can thus be adapted to move parallel to the axis of the shafts
70 so that they can be located at positions corresponding to each of the lanes of
the parent rolls. The first and second sensors 130, 132 are desirably capable of moving
independently from one another.
[0055] Various sequences for unwinding lanes 22 from the parent rolls 30, 32 are possible
and particular sequences will be described in relation to Figure 6. The lanes 22 of
the first parent roll 30 have been labeled L1 through L5, where L5 is closest to the
backing plate 80. Similarly, the lanes 22 of the second parent roll 32 have been labeled
L6 through L10, where L10 is closest to the backing plate 80. It should be understood
that the rolls can comprise any number of two or more lanes and that the illustrated
embodiment includes five lanes 22 per roll solely for purposes of explanation.
[0056] In one embodiment, the lanes 22 can be unwound from the parent rolls 30, 32 in a
sequence that alternates back and forth between the rolls one lane at a time. For
example, the sequence can be L1, L6, L2, L7, L3, L8, L4, L9, L5 and L10. While L1
is being unwound, L2 through L5 remain on the first parent roll. The beginning of
L6 is spliced to the tail of L1; the beginning of L2 is spliced to the tail of L6;
and so forth. Of course, other variations include reversing the starting order of
the rolls, unwinding the rolls from the drive side toward the operator side, or the
like. Additionally, the idler rolls 86 and 94 and the sensors 130 and 132 could be
maintained stationary while the parent rolls 30, 32 are moved to create the desired
relative movement. Accordingly, references herein to positioning or moving the idler
rolls or sensors also encompasses positioning or moving the parent rolls to create,
such relative movement.
[0057] After each selected lane is torn from the remaining lanes and fully unwound, the
position of the idler roll 86, 94 can be changed to correspond to the position of
the next lane to be unwound from the same parent roll. Further, the position of the
sensor 130, 132 for the roll being unwound can be changed to correspond to the position
of the next lane to be unwound from the same parent roll. These operations can be
completed after splicing the finished lane to the head of a lane on another parent
roll and during the run time of the lane from the other parent roll. Desirably, the
sensor can detect the position of the next lane to be unwound from the roll and the
position of the idler roll can be established based on the position detected by the
sensor. After a sensor 130 or 132 is in position, the sensor can provide diameter
information, which in combination with a festoon 38 position feedback signal, can
be used to modulate roll unwind speed. The sensor can also provide a signal to initiate
a splice sequence. The driven roll 40 feeds the web based on machine speed, and the
speed of the driven roll is trimmed by the position of the dancer roll 42, as is known
in the art.
[0058] It will be appreciated that details of the foregoing embodiments, given for purposes
of illustration, are not to be construed as limiting the scope of this invention.
Although only a few exemplary embodiments of this invention have been described in
detail above, those skilled in the art will readily appreciate that many modifications
are possible in the exemplary embodiments without materially departing from the novel
teachings and advantages of this invention. Accordingly, all such modifications are
intended to be included within the scope of this invention, which is defined in the
following claims and all equivalents thereto. Further, it is recognized that many
embodiments may be conceived that do not achieve all of the advantages of some embodiments,
particularly of the preferred embodiments, yet the absence of a particular advantage
shall not be construed to necessarily mean that such an embodiment is outside the
scope of the present invention.
1. A method of unwinding a roll (30, 32) web material (20) having first and second integral
lanes (22, 26, 52) comprising:
positioning a repositioning device at a first position corresponding to the position
of the first lane (26, 52) the repositioning device adapted to redirect a lane as
it is unwound;
initiating separation of the first lane (25, 52) from the integral second lane (22);
feeding the first lane (26, 52) onto the repositioning device;
rotating the roll (30, 32) unwind the first lane (26, 52) while tearing the first
lane (26, 52) from the second lane (22) and maintaining the second lane (22) on the
roll (30, 32),
moving the repositioning device to a second position corresponding to the position
of the second lane (22);
feeding the second lane (22) onto the repositioning device; and
rotating the roll (30, 32) to unwind the second lane (22).
2. An apparatus for unwinding rolls (30, 32) of web material (20) having a plurality
of integral lane (22, 26, 52) comprising:
first and second roll unwind stands (72) each comprising a shaft (70) defining an
unwind axis, the roll unwind stands (72) also comprising one or more drive mechanisms
(78) adapted to rotate the shafts (70);
a repositioning device associated with each roll unwind stand (72) and adapted to
redirect a lane (26, 52) as it is unwound, the repositioning devices being movably
mounted and positionable at a plurality of positions along an axis generally parallel
to the respective unwind axis, the plurality of positions corresponding to different
lane positions;
a sensing device associated with each roll unwind stand (72) and adapted to provide
roll diameter information, the sensing devices being movably mounted and positionable,
at a plurality of positions along an axis generally parallel to the respective unwind
axis, the plurality of positions corresponding to different lane positions; and
a control system (140) adapted to move the repositioning and sensing devices of the
first roll unwind stand (72) to a first location corresponding to at least one first
lane (26); rotate the drive mechanism (78) of the first roll unwind stand (72) to
unwind the at least one first lane (26) move the repositioning and sensing devices
of the first roll unwind stand (72) to a second location corresponding to at least
one second lane, rotate the drive mechanism (78) of the first roll unwind stand (72)
to unwind the at least one second lane, move the repositioning and sensing devices
of the second roll unwind (72) stand to a first location corresponding to at least
one first lane (52), rotate the drive mechanism (78) of the second roll unwind stand
(72) to unwind the at least one first lane (52), move the repositioning and sensing
devices of the second roll unwind stand (72) to a second location corresponding to
at least one second lane, rotate the drive mechanism (78) of the second roll unwind
stand (72) to unwind the at least one second lane;
wherein the second lanes remain on their corresponding roll (30, 32) while the first
lanes (26, 52) are unwound.
3. The apparatus of claim 2, wherein the repositioning devices are selected from driven
rolls, idler rolls, turn bars, dead bars, or web guides.
4. The apparatus of claim 2 or 3, wherein the repositioning devices move independently.
5. The apparatus of claim 2, 3 or 4 wherein the sensing devices are moveably mounted
on rails (110).
6. The apparatus of any of claims 2 to 5, wherein the sensing devices move independently.
7. The apparatus of any of claims 2 to 6, wherein the positioning device and the sensing
device associated with each roll unwind stand (72) move independently.
8. The apparatus of any of Claims 2 to 7, wherein the control system (140) signals position
control devices to change the position of the repositioning devices.
9. The apparatus of any of claims 2 to 8, wherein the control system (140) signals position
control devices to change the position of the sensing devices.
10. The apparatus of any of claims 2 to 9, wherein the control system (140) uses sensor
feedback information to control the position of the repositioning devices.
1. Ein Verfahren zum Abwickeln einer Rolle (30, 32) von Bahnmaterial (20), welches eine
erste und zweite integrierte Bahn (22, 26, 52) aufweist, umfassend:
Positionieren einer Repositioniervorrichtung bei einer ersten Position, die der Position
der ersten Bahn (26, 52) entspricht, wobei die Repositioniervorrichtung eingerichtet
ist, eine Bahn umzulenken, während sie abgewickelt wird;
Initiieren einer Trennung der ersten Bahn (26, 52) von der integrierten zweiten Bahn
(22);
Führen der ersten Bahn (26, 52) auf die Repositioniervorrichtung;
Rotieren der Rolle (30, 32), um die erste Bahn (26, 52) abzuwickeln während des Ziehens
der ersten Bahn (26, 52) von der zweiten Bahn (22) und des Verbleibens der zweiten
Bahn (22) auf der Rolle (30, 32);
Bewegen der Repositioniervorrichtung zu einer zweiten Position, die der Position der
zweiten Bahn (22) entspricht;
Führen der zweiten Bahn (22) auf die Positioniervorrichtung; und
Rotieren der Rolle (30, 32), um die zweite Bahn (22) abzuwickeln.
2. Ein Gerät zum Abwickeln von Rollen (30, 32) von Bahnmaterial (20), welche eine Vielzahl
von integrierten Bahnen (22, 26, 32) aufweisen, umfassend:
einen ersten und einen zweiten Rollenabwickelstand (72), von welchen jeder einen Schaft
(70) umfasst, der eine Abwickelachse definiert, wobei die Rollenabwickelstände (72)
auch einen oder mehrere Antriebsmechanismen (78) umfassen, die eingerichtet sind,
den Schaft (70) zu rotieren;
eine Repositioniervorrichtung, die mit jedem Rollenabwickelstand (72) in Beziehung
steht und eingerichtet ist, eine Bahn (26, 52) umzulenken, während sie abgewickelt
wird, wobei die Repositioniervorrichtung beweglich montiert ist und bei einer Vielzahl
von Positionen entlang einer Achse positionierbar ist, die generell parallel zur jeweiligen
Abwickelachse ist, wobei die Vielzahl von Positionen verschiedenen Bahnpositionen
entspricht;
eine Wahrnehmvorrichtung, die mit jedem Rollenabwickelständer (72) in Beziehung steht
und eingerichtet ist, Rollendurchmesserinformation bereitzustellen, wobei die Wahrnehmvorrichtungen
beweglich montiert sind und bei einer Vielzahl von Positionen entlang einer Achse
positionierbar ist, die generell parallel zur jeweiligen Abwickelachse ist, wobei
die Vielzahl von Positionen verschiedenen Bahnpositionen entspricht; und
ein Kontrollsystem (40), welches eingerichtet ist, die Repositioniervorrichtung und
Wahrnehmvorrichtung des ersten Rollenabwickelstands (72) zu einer ersten Position
zu bewegen, die mindestens einer ersten Bahn (26) entspricht; den Antriebsmechanismus
(78) des ersten Rollenabwickelstands (72) zu rotieren, um die mindestens eine erste
Bahn (26) abzuwickeln; die Repositioniervorrichtung und Wahrnehmvorrichtung des ersten
Rollenabwickelstands (72) zu einer zweiten Position zu bewegen, die mindestens einer
zweiten Bahn entspricht; den Antriebsmechanismus (78) des ersten Rollenabwickelstands
(72) zu rotieren, um die mindestens eine zweite Bahn abzuwickeln; die Repositioniervorrichtung
und Wahrnehmvorrichtung des zweiten Rollenabwickelstands (72) zu einer ersten Position
zu bewegen, die mindestens einer ersten Bahn (52) entspricht; den Antriebsmechanismus
(78) des zweiten Rollenabwickelstands (72) zu rotieren, um die mindestens eine erste
Bahn (52) abzuwickeln; die Repositioniervorrichtung und Wahrnehmvorrichtung des zweiten
Rollenabwickelstands (72) zu einer zweiten Position zu bewegen, die mindestens einer
zweiten Bahn entspricht; den Antriebsmechanismus (78) des zweiten Rollenabwickelstands
(72) zu rotieren, um die mindestens eine zweite Bahn abzuwickeln;
wobei die zweiten Bahnen auf deren entsprechenden Rollen (30, 32) bleiben, während
die ersten Bahnen (26, 52) abgewickelt werden,
3. Das Gerät gemäß Anspruch 2, wobei die Repositioniervorrichtungen ausgewählt sind aus
angetriebenen Rollen, Führungsrollen, Drehstäben, Stumpfstäben oder Bahnführungen.
4. Das Gerät gemäß Anspruch 2 oder 3, wobei sich die Repositioniervorrichtungen unabhängig
bewegen.
5. Das Gerät gemäß Anspruch 2, 3 oder 4, wobei die Wahrnehmvorrichtungen beweglich auf
Schienen (110) angebracht sind.
6. Das Gerät gemäß einem der Ansprüche 2 bis 5, wobei sich die Wahrnehmvorrichtungen
unabhängig bewegen.
7. Das Gerät gemäß einem der Ansprüche 2 bis 6, wobei sich die Repositioniervorrichtung
und die Wahrnehmvorrichtung, die mit jedem Rollenabwickelstand (72) in Beziehung stehen,
unabhängig bewegen.
8. Das Gerät gemäß einem der Ansprüche 2 bis 7, wobei es das Kontrollsystem (140) Positionskontrollvorrichtungen
signalisiert, die Position der Positioniervorrichtungen zu ändern.
9. Das Gerät gemäß einem der Ansprüche 2 bis 8, wobei es das Kontrollsystem (140) Positionskontrollvorrichtungen
signalisiert, die Position der Wahrnehmvorrichtungen zu ändern.
10. Das Gerät gemäß einem der Ansprüche 2 bis 9, wobei das Kontrollsystem (140) Sensorfeedbackinformation
nutzt, um die Position der Repositioniervorrichtungen zu kontrollieren.
1. Procédé de dévidage d'un rouleau (30,32) de matériau en voile (20), définissant une
première et une seconde bandes d'un seul tenant (22,26,52), comprenant :
le positionnement d'un dispositif de repositionnement au niveau d'une première position
correspondant à la position de la première bande (26,52), le dispositif de repositionnement
étant adapté à rediriger une bande tandis qu'elle est dévidée ;
l'amorçage de la séparation de la première bande (26,52) d'avec la seconde bande (22)
d'un seul tenant ;
l'introduction de la première bande (26,52) dans le dispositif de repositionnement
;
la rotation du rouleau (30,32) pour dévider la première bande (26,52) tout en séparant
par déchirure la première bande (26,52) de la seconde bande (22) et en maintenant
la seconde bande (22) sur le rouleau (30,32) ;
le déplacement du dispositif de repositionnement vers une seconde position correspondant
à la position de la seconde bande (22) ;
l'introduction de la seconde bande (22) dans le dispositif de repositionnement ; et
la rotation du rouleau (30,32) pour dévider la seconde bande (22).
2. Appareil pour dévider des rouleaux (30,32) de matériau en voile (20), définissant
une pluralité de bandes d'un seul tenant (22,26,52), comprenant :
des premier et second postes de dévidage (72) de rouleaux, dont chacun comprend un
axe (70) définissant un axe de dévidage, les postes de dévidage (72) de rouleaux comprenant
également un ou plusieurs mécanismes d'entraînement (78) adaptés à faire tourner les
axes (70) ;
un dispositif de repositionnement associé à chacun des postes de dévidage (72) de
rouleaux et adapté à rediriger une bande (26,52) tandis qu'elle est dévidée, le dispositif
de repositionnement étant monté mobile et positionnable au niveau d'une pluralité
de positions le long d'un axe généralement parallèle à l'axe de dévidage respectif,
la pluralité de positions correspondant aux différentes positions de bande ;
un dispositif capteur associé à chacun des postes de dévidage (72) de rouleaux et
adapté à fournir une information de diamètre de rouleau, les dispositifs capteurs
étant montés mobiles et positionnables au niveau d'une pluralité de positions le long
d'un axe généralement parallèle à l'axe de dévidage respectif, la pluralité de positions
correspondant aux différentes positions de bande ; est
un système de commande (140) adapté à déplacer les dispositifs de repositionnement
et capteurs du premier poste de dévidage (72) de rouleau vers une première position
correspondant à au moins une première bande (26), faire tourner le mécanisme d'entraînement
(78) du premier poste de dévidage (72) de rouleau pour dévider ladite au moins une
première bande (26), déplacer les dispositifs de repositionnement et capteurs du premier
poste de dévidage (72) de rouleau vers une seconde position correspondant à au moins
une seconde bande, faire tourner le mécanisme d'entraînement (78) du premier poste
de dévidage (72) de rouleau pour dévider ladite au moins une seconde bande, déplacer
les dispositifs de repositionnement et capteurs du second poste de dévidage (72) de
rouleau vers une première position correspondant à au moins une première bande (52),
faire tourner le mécanisme d'entraînement (78) du second poste de dévidage (72) de
rouleau pour dévider ladite au moins une première bande (52), déplacer les dispositifs
de repositionnement et capteurs du second poste de dévidage (72) de rouleau vers une
seconde position correspondant à au moins une seconde bande, faire tourner le mécanisme
d'entraînement (78) du second poste de dévidage (72) de rouleau pour dévider ladite
au moins une seconde bande,
appareil dans lequel les secondes bandes restent sur leur rouleau correspondant (30,32)
tandis que les premières bandes (26,52) sont dévidées.
3. Appareil selon la revendication 2, dans lequel les dispositifs de repositionnement
sont sélectionnés parmi les rouleaux entraînés, les rouleaux fous, les barres tournantes,
les barres fixes ou les guides de voile.
4. Appareil selon la revendication 2 ou 3, dans lequel les dispositifs de repositionnement
se déplacent indépendamment.
5. Appareil selon la revendication 2, 3 ou 4, dans lequel les dispositifs capteurs sont
montés mobiles sur des rails (110).
6. Appareil selon l'une quelconque des revendications 2 à 5, dans lequel les dispositifs
capteurs se déplacent indépendamment.
7. Appareil selon l'une quelconque des revendications 2 à 6, dans lequel le dispositif
de repositionnement et le dispositif capteur associés à chacun des postes de dévidage
(72) de rouleau se déplacent indépendamment.
8. Appareil selon l'une quelconque des revendications 2 à 7, dans lequel le système de
commande (140) envoie des signaux aux dispositifs de commande de position pour modifier
la position des dispositifs de repositionnement.
9. Appareil selon l'une quelconque des revendications 2 à 8, dans lequel le système de
commande (140) envoie des signaux aux dispositifs de commande de position pour modifier
la position des dispositifs capteurs.
10. Appareil selon l'une quelconque des revendications 2 à 9, dans lequel le système de
commande (140) utilise des informations de retour du capteur pour commander la position
des dispositifs de repositionnement.