The present disclosure relates generally to rotary cutting apparatuses and, more particularly, relates to methods and apparatuses using anvil roll having a relatively small diameter and being laterally removable from a frame to allow online replacement.
Rotary cutting apparatuses can comprise a frame, a die roll rotatably mounted to the frame, and an anvil roll rotatably mounted to the frame. The die roll can comprise at least one cutting member for cutting and creasing material against an anvil roll when the material is passed between the die roll and the anvil roll. As the cutting member on the die roll cuts the material, an outer surface of the anvil roll may wear owing to the pressure applied by the cutting member to the outer surface of the anvil roll. Eventually, the anvil roll may need to be replaced after a sufficient amount of the outer surface of the anvil roll has been worn away. Additionally, as the die roll engages the anvil roll, undesirable deflection in the anvil roll may occur. In order to help reduce this deflection, anvil rolls may be used that have a relatively large diameter. With the increase of diameter, however, the overall mass of the anvil roll is also increased. As the size of the anvil roll increases, difficulties in controlling the rotation of the anvil roll may result. For instance, as the mass of the anvil roll increases, it is typically more difficult to start, stop, or otherwise control the rotation of the anvil roll. Anvil rolls having a larger diameter may also be relatively expensive to manufacture and/or refurbish.
The process of replacing a large anvil roll can be time consuming since many components of the rotary cutting apparatus must be disassembled to access the anvil roll. A production line relying on the rotary cutting apparatus may have to be down for an extended period of time which could result in an undesirable loss in production. Additionally, due to the mass of the anvil roll, removing the anvil roll from the rotary cutting apparatuses and/or handling the anvil roll may require additional manpower and/or mechanical assistance. In view of the importance of anvil roll maintenance and/or the cost of anvil roll replacement, this technology should be improved.
In one non-limiting embodiment of the present disclosure, a rotary cutting apparatus comprises a frame and a die roll defining a first longitudinal axis and having an outer circumferential portion comprising a cutting member. The outer circumferential portion has a maximum outer diameter and the die roll is rotatably connected with the frame and configured to rotate about the first longitudinal axis. The rotary cutting apparatus further comprises a bearer ring connected with the die roll and an anvil roll defining a second longitudinal axis. The anvil roll has an outer circumferential surface and the anvil roll is rotatably connected with the frame and is configured to rotate about the second longitudinal axis. The anvil roll is positioned relative to the die roll such that the bearer ring is in contact with the outer circumferential surface such that the first longitudinal axis is substantially parallel with the second longitudinal axis. The anvil roll has a maximum outer diameter and the maximum outer diameter of the outer circumferential portion of the die roll is at least twice the maximum diameter of the anvil roll. The rotary cutting apparatus further comprises a first bearing block and a second bearing block, with the first and second bearing blocks receiving respective first and second ends of the anvil roll. The anvil roll is selectively removable from the frame and the bearing blocks via translation along the second longitudinal axis.
In another non-limiting embodiment of the present disclosure, a rotary cutting apparatus comprises a frame and a die roll. The die roll defines a first longitudinal axis and has an outer circumferential portion comprising a cutting member. The outer circumferential portion has a maximum outer diameter. The die roll is rotatably connected with the frame and configured to rotate about the first longitudinal axis. The rotary cutting apparatus further comprises a bearer ring connected with the die roll. The rotary cutting apparatus further comprises an anvil roll defining a second longitudinal axis and comprising an outer circumferential surface. The anvil roll is rotatably connected with the frame and is configured to rotate about the second longitudinal axis. The anvil roll is positioned relative to the die roll such that the bearer ring is in contact with the outer circumferential surface such that the first longitudinal axis is substantially parallel with the second longitudinal axis. The anvil roll has a maximum outer diameter, wherein the maximum outer diameter of the outer circumferential portion of the die roll is at least twice the maximum diameter of the anvil roll. The rotary cutting apparatus further comprises a cam follower having a cam follower axis. The cam follower is in supporting contact with the anvil roll and configured to rotate about the cam follower axis when the anvil roll rotates.
In yet another non-limiting embodiment of the present disclosure, a method of cutting a web of material is provided. The method comprises the steps of advancing a web of material in a machine direction directly from a first conveyer into a nip of a rotary cutting apparatus and rotating a die roll, the die roll defining a first longitudinal axis and having an outer circumferential portion comprising a cutting member. The outer circumferential portion has a maximum outer diameter and the die roll is rotatably connected with a frame and configured to rotate about the first longitudinal axis. The method further comprises the steps of rotating an anvil roll, the anvil roll defining a second longitudinal axis and comprising an outer circumferential surface. The anvil roll is rotatably connected with the frame and is configured to rotate about the second longitudinal axis, the anvil roll positioned relative to the die roll such that the first longitudinal axis is substantially parallel with the second longitudinal axis. The anvil roll has a maximum outer diameter. The maximum outer diameter of the outer circumferential portion is at least twice the maximum diameter of the anvil roll. The method comprises the steps of supporting the anvil roll with a rotatable cam follower in frictional contact with the anvil roll, cutting at least a portion of the web of material with the cutting member, and advancing the web of material in a machine direction directly from the nip to a second conveyor.
Various non-limiting embodiments of the present disclosure will now be described to provide an overall understanding of the principles of the structure, function, manufacture, and use of the apparatuses and methods disclosed herein. One or more examples of these non-limiting embodiments are illustrated in the accompanying drawings. Those of ordinary skill in the art will understand that the apparatuses and methods specifically described herein and illustrated in the accompanying drawings are non-limiting example embodiments and that the scope of the various non-limiting embodiments of the present disclosure are defined solely by the claims. The features illustrated or described in connection with one non-limiting embodiment may be combined with the features of other non-limiting embodiments. Such modifications and variations are intended to be included within the scope of the present disclosure.
The present disclosure provides rotary cutting apparatuses and methods utilizing an anvil roll having a relatively small diameter and being laterally removable from a frame. More specifically, the apparatuses and methods may be useful for providing added control to the anvil roll, decreased deflection of the anvil roll, and online changeability. Those of ordinary skill in the art will recognize other suitable uses for the apparatuses and methods of the present disclosure.
In general, a rotary cutting apparatus may comprise a frame, a die roll assembly rotatably attached to the frame, and an anvil roll assembly rotatably attached to the frame. The die roll assembly may comprise a die roll and the anvil roll assembly may comprise an anvil roll. The die roll assembly may also comprise at least one cutting member configured to be forced against the anvil roll, as the anvil roll rotates relative to the die roll, to cut a material being fed through the nip of the die roll and the anvil roll. The force of the cutting member on an outer surface of the anvil roll can cause the outer surface of the anvil roll to wear over time, thereby reducing the diameter of the anvil roll. Eventually, due to wear on the anvil roll, the anvil roll will need to be replaced and/or reconditioned. Additionally, due to the cutting member exerting force upon the anvil roll, the anvil roll may tend to deflect away from the force. Such deflection may lead to degradation in the cutting function of the rotary cutting apparatus.
In accordance with various embodiments, a rotary cutting apparatus is described having an anvil roll that is laterally removable from the frame. The anvil roll may be removable without necessarily needing to remove the die roll assembly from the frame. Additionally, the anvil roll may be sized such that it can be handled by a single person. In some embodiments, the anvil roll may be supported by one or more rolling members to decrease deflection of the anvil roll during operation of the rotating cutting apparatus. The anvil roll may be supported by thrust bearings that apply axial pressure to either end of the anvil roll. In one embodiment, spring loaded bolts, or other biasing elements are used to supply the axial pressure to the thrust bearings. Due to the axial support of the anvil roll, the configuration of the thrust bearings may help to reduce deflection of the anvil roll during operation of the rotary cutting apparatus.
In one embodiment, referring to
The side plate 20 of the frame 12 may also house an anvil bearing block 32. As is to be appreciated, the anvil bearing block 32 may be coupled to the frame 12, as illustrated, or the anvil bearing block 32 may be integral with the side plate 20. In any event, the anvil bearing block may define an opening 33, which may receive bearings 34 for accepting an anvil roll 36 of an anvil roll assembly 38. The bearings 34 may be configured to move relative to the frame 12 to allow the anvil roll 36 to rotate relative to the frame 12 along a longitudinal axis (L2). In some embodiments, the bearer rings 29 of the die roll 28 are used to deliver rotational energy from the die roll 28 to the anvil roll 36 through a frictional engagement with an outer radial surface of the anvil roll 36. In such an embodiment, the anvil roll 36 can be considered a “walking” anvil roll.
The bearings 34 may be any suitable rotary bearing. As is to be appreciated, bearings 34 may be coupled to each end of the anvil roll 36. In one embodiment, the bearings 34 are thrust bearings, such as ball thrust bearings, roller thrust bearings, or tapered roller bearings, for example. The thrust bearings may apply axial pressure to either end of the anvil roll 36. In one embodiment, spring loaded bolts, or other biasing elements, such as a disc spring 158 (
As illustrated in
In one embodiment, still referring to
In one embodiment, referring to
Referring to
In one embodiment, referring to
As illustrated in
In one embodiment, the material being cut and/or creased by the rotary cutting apparatus 10 may be a web configured for use in fabricating absorbent articles, such as diapers, training diapers, pull-up pants, incontinence briefs, and undergarments, for example. In various other embodiments, the material being cut may comprise any material that may be processed by a rotary cutting apparatus, such as corrugated plastic, corrugated fiberboard, card stock, and/or any other suitable material.
The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”
Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
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