Patent Application
20220204296
Modern paper manufacturing is typically performed by producing continuous lengths of paper having widths of over 400 inches in some cases, referred to as paper webs, which are wound onto web spools for subsequent converting, storage, transfer or the like. The winding or spooling operation for the paper web, such as in the case of tissue grades, occurs at high speeds, in some cases exceeding 6000 feet per minute, and in order to maximize production by minimizing downtime and waste it is desirable to sever and simultaneously transfer the moving paper web from a full spool onto an empty spool without stopping, adjusting draws (i.e. the speed differential between the incoming and outgoing web rotating support members that are not driven by a common source) or slowing the movement of the web. Methods and apparatuses for accomplishing this severing and transfer utilizing what is known as a transfer or turn-up tape have long been known. An early example of such a system is shown in U.S. Pat. No. 2,461,246 to Weyenberg, issued in 1949. Other examples are shown in our U.S. Pat. Nos. 4,659,029, 4,757,950, 4,783,018, 5,046,675, 5,453,141, 5,637,170, and 5,954,290. Further examples and detailed discussion of such equipment, systems and methodologies are present in our U.S. Pat. Nos. 4,659,029, 4,757,950, 4,783,018, 5,046,675, 5,417,383, 5,453,141, 5,637,170, 5,954,290, 6,467,719, 6,578,788, 7,875,152, 8,124,209, 8,178,181 and 8,580,062, the disclosures of which are incorporated herein by reference.
The high-speed transfer of lightweight paper webs, such as groundwood papers (including, for example, newsprint) or tissue paper, is more difficult to accomplish due to the weaker structure of the paper. In addition, in systems using adhesive transfer tapes for the web transfer, the exposed adhesive side of the transfer tape is often contaminated with airborne dust, floating paper fibers and other debris, which are prevalent with the lightweight paper webs, such that the adhesion is weakened or even substantially blinded, which can result in a failed transfer. A failed transfer results in lost production, inconsistent winding of the product and inconsistent roll sizes, excessive waste, shorter service life of the fiber cores which are commonly used in tissue making machines, and unsafe operating conditions.
Where liquid adhesive is dispensed directly onto the spinning spool, as by a hand-held pump-fed nozzle projecting a stream, the adhesive is frequently thrown off the spool by centrifugal force, especially where it has not picked up the paper web immediately. Applying a liquid adhesive in this manner is not entirely predictable nor efficient and causes a fouling accumulation of adhesive on adjacent machinery. Efforts have been made to eliminate the shortcomings of liquid adhesive systems. Some employ fixed nozzles spaced across the width of the paper web. These nozzles can deliver a precisely controlled amount of adhesive, eliminating overuse and fouling of equipment, but must be provided with a means to catch occasional drops of adhesive that randomly fall from the nozzles and onto the web.
It is an object of this invention to provide an improved method of utilizing a liquid adhesive to sever and transfer a continuous paper web from one spool to another spool, such as may be especially useful in transferring lightweight papers such as tissue or newsprint.
Accordingly, it is an object of this invention to provide an apparatus and method addressing the contamination problem of the exposed adhesive on the transfer tape. It is a further object to provide such an apparatus and method that allows for the transfer tape to be dispensed in the desired length as needed for performing the turn-up operation. It is a further object to provide an apparatus and method adapted for use in many different industrial applications.
Therefore, the present invention relates generally in a first sense to the field of devices, apparatuses and methods of effecting the high-speed severing and transfer of a rapidly advancing paper web from a rotating full spool onto an empty spool, and more particularly where such an operation is performed on a light density or tissue paper web. More particularly, the invention relates to methods using a dispensed adhesive bead of appropriate characteristics set between adhesive strips which hold a piece of tissue paper above the adhesive bead and the use of this structure in a paper web severing/transfer method. In some examples the tissue paper may be repulpable to allow for recycling of waste materials. The tissue paper or other lightweight paper used in its place may have characteristics of sufficient strength, thickness, texture and stiffness to accomplish the turn-up transfer operation without breaking or separating throughout its subsequent use. The adhesive of the turn up construct may be squeezed to and through the tissue paper as the spool to which it has been applied advances towards the nip and the reel drum. The adhesive saturated tissue paper acts as an improved turnup transfer mechanism. The adherence of the paper web to the adhesive saturated tissue paper may become the affecting means for severing, transferring and securing the light density or tissue paper web from a rotating full web spool onto an empty web spool.
A dispensing apparatus may be used to deposit a bead of adhesive upon a new spool as well as a covering of tissue paper which is also adhered to the new spool with contact adhesive. In some examples, the tissue paper may be preassembled with pressure sensitive adhesive (PSA) strips on its edge and release coating strips on the opposite side of the paper so that it may be stored and delivered from a spooled state. The pressure sensitive adhesive may be coated, layered or laminated to the paper. The dispensing apparatus may comprise a dispensing system for dispensing the adhesive bead as well as a paper dispensing system that can press the pressure sensitive adhesive on the tissue paper to the new spool.
One general aspect includes a device for paper web turn-up. The device also includes a dispensed liquid adhesive bead deposited upon a paper spool; a paper cover, where the paper cover is positioned to cover the dispensed liquid adhesive bead. The dispensed liquid adhesive bead may be caused to flow to a surface of the paper cover when the dispensed liquid adhesive bead rotates upon the paper spool into a nip of the paper spool and a reel drum. In an example, the liquid adhesive upon the surface of the saturated paper cover attaches an advancing paper web pulling it to the paper spool and severing the paper web to complete the paper web turn-up. Implementations may include the device where the paper cover may include a paper with small pores, or perforations where the paper cover ruptures when the dispensed liquid adhesive bead is pressurized within the nip.
One general aspect includes an apparatus for preparing a liquid adhesive construct for paper web turn-up. The apparatus also may include a vessel which contains a liquid adhesive; a dispensing nozzle, where the dispensing nozzle defines a height and width of a bead of the liquid adhesive as it is applied to a paper spool; a pump, where the pump moves the liquid adhesive through a tube to the dispensing nozzle; a control to allow a user to activate the dispensing of the liquid adhesive; and a paper tape spool, where the paper tape spool stores a paper tape cover; and at least a first press pad to apply pressure to a pressure sensitive adhesive upon the paper tape cover, where applying pressure to the pressure sensitive adhesive attaches the paper tape cover to the paper spool as a cover to a dispensed liquid adhesive bead.
Implementations may include one or more of the following features. The apparatus for preparing a liquid adhesive construct for paper web turn-up may include controls and electronics to deposit the liquid adhesive in a pattern. In some examples, the operation may be automated. In other examples, a handle and trigger may be operated by a user to control deposition in a handheld manner. The pattern may include a chevron. The apparatus is configured to deposit the liquid adhesive on the surface of a paper spool at an angle relative to a long axis of the paper spool. In some examples, a hand-held apparatus may apply a system of paper and adhesive to the spool as the operator desires by positioning the apparatus at any angle before starting along the spool. The angle may not exceed that of a spiral of one revolution over the length of the spool—which in some examples may approximate 15 degrees from the long axis. Said exemplary angle may reduce the thumping that may occur if the entire length of the adhesive and paper system passed through the nip at once while accomplishing the turnup rapidly enough to only accumulate one layer of paper at any given point. In some examples such application may prevent a cone-shaped accumulation to form, said accumulation which may contribute to greater tension on one side by virtue of the greater circumference, which in turn may create wrinkles.
One general aspect includes a paper web turn-up apparatus. The paper web turn-up apparatus also includes a paper spool with a spool surface to attach the paper web. The apparatus also includes a liquid adhesive bead dispenser positioned to deposit a liquid adhesive bead across the spool surface. The apparatus includes a paper cover positioned to cover the dispensed liquid adhesive bead and attach an advancing paper web and pull the advancing paper web to the paper spool and sever the advancing paper web to complete a paper web turn-up, and wherein the dispensed liquid adhesive bead flows to a surface of the paper cover when the dispensed liquid adhesive bead rotates upon the paper spool into a nip of the paper spool and a reel drum.
Implementations may include one or more of the following features. The apparatus where the paper cover may include a paper with small perforations, and where the paper cover ruptures when the liquid adhesive bead is pressurized within the nip. In some examples, the liquid adhesive is deposited at an angle relative to a rotary axis of the paper spool.
One general aspect includes a method of performing a paper web turn-up. The method includes dispensing a liquid adhesive bead upon a paper spool; covering the liquid adhesive bead with a paper cover; wherein the paper cover is attached to a surface of a new spool. The method includes rotating the new paper spool to press the liquid adhesive bead and attached paper cover between the paper spool and a reel drum in a nip of the paper spool and the reel drum. The method includes flowing the liquid adhesive bead to a surface of the paper cover and pressing the liquid adhesive bead and attached paper cover between the paper spool and the reel drum, with the liquid adhesive upon the surface of the paper cover. The method includes attaching an advancing paper web to the paper spool and severing the paper web to complete the paper web turn-up.
One general aspect includes an apparatus for preparing a liquid adhesive construct for paper web turn-up. The apparatus includes a vessel that contains a liquid adhesive; a dispensing nozzle, where the dispensing nozzle defines a height and width of a bead of the liquid adhesive as it is applied to a paper spool. The apparatus also may include a pump, where the pump moves the liquid adhesive through a tube to the dispensing nozzle. The apparatus may also include a control to allow a user to activate a dispensing of the liquid adhesive; a paper tape spool, where the paper tape spool stores a paper tape cover. The apparatus may also include a first press pad to apply pressure to a pressure sensitive adhesive upon the paper tape cover, wherein applying pressure to the pressure sensitive adhesive attaches the paper tape cover to the paper spool as a cover to a dispensed liquid adhesive bead.
With reference to the drawings, which are provided for descriptive and illustrative purposes which are not meant to be limiting as the scope of the invention, the invention in various embodiments in a broad and general sense is an apparatus and a method for dispensing an adhesive deposit along with a lightweight paper or tissue paper covering which may be used in a paper web turn-up operation. The process may facilitate the turn up operation wherein a continuous paper web being rolled onto a first web spool is severed and transferred to an empty second web spool when the first web spool is fully wound. In the operation, the transfer may occur without requiring the flow of the paper web to be temporarily altered or stopped. It is to be understood that disclosure of the apparatus and method in relation to a paper web turn-up operation is an exemplary disclosure not meant to be limiting, as the adhesive deposit structure and associated dispenser structures may be suitable for use in different industrial applications.
It is an object of this invention to provide an improved method of utilizing a liquid adhesive to sever and transfer a continuous paper web from one spool to another spool, such as may be especially useful in transferring lightweight papers such as tissue or newsprint, wherein the use of a liquid adhesive is improved by increasing its viscosity so a standing bead may be placed directly on the empty spool. The liquid adhesive standing bead may be applied with a significant height, whereby the height of the bead above the surface of the empty spool assists in closing the nip between it and the reel drum.
In some examples, the methods may provide the bead of viscous adhesive with a cover adhered to the empty spool along the length of the bead to protect it from airborne paper fibers, dust and other debris. It may be desirable to secure the cover with pressure-sensitive adhesive tape some distance to either side of the bead.
In some examples, the methods may provide that the cover is made of a porous tissue paper whose pores are small enough to prevent the viscous adhesive from permeating the tissue while the spool is spinning above the paper web, but whose pores permit the adhesive to be discharged from the face of the tissue when the empty spool is brought into contact with the paper web on the reel drum and compresses the adhesive bead, such that the adhesion between the paper web and the viscous adhesive is sufficient to pull the paper web around the empty spool, bursting the paper web in tension to cause a turn-up.
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The rotation may create a centrifugal force that may tend to throw or expel the adhesive bead off the spool face. Such an effect may be a motivation and primary function of the light paper cover which holds the bead in place.
The rotation will bring the deposited adhesive bead and tissue paper structure 210 into the nip which will put pressure onto the adhesive bead. In some examples, the tissue paper provides a cover made of a porous tissue paper whose pores are small enough to prevent the viscous adhesive from permeating the tissue while the spool is spinning above the paper web, but whose pores permit the adhesive to be discharged from the face of the tissue when the empty spool is brought into contact with the paper web on the reel drum and compresses the adhesive bead.
In some examples, the adhesion between the paper web and the viscous adhesive is sufficient to pull the paper web around the empty spool, bursting the paper web in tension to cause a turn-up.
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In a non-limiting example, the bead of a viscous adhesive may be applied with a dimension between about 3 mm (⅛ inch) and 6 mm (¼ inch) in height and width, applied to the spool face. The covering may be an approximately 50 mm (2 inch) wide ribbon of permeable tissue paper fixed in place, centered and longitudinally oriented, over the bead by thin adhesive ribbons at both edges of the tissue paper. The tissue paper ribbon may be peaked over the bead of adhesive by lightly contacting it when applied. The process of placing the paper may generally preserve the height and width of the bead, while being pressed tightly against the thin adhesive ribbons that adhere it to the spool face.
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In some examples, an adhesive reservoir 650 may flow adhesive through a nozzle at a prescribed distance from the new spool 601 at a constant rate to create a deposited bead of adhesive 604 upon the new spool 601. Meanwhile, a tissue paper construct 660, which may be stored on a paper tape spool 661 may be affixed to the new spool 601. In the illustrated example, both sides of the tissue paper cover may be affixed to the new spool on a first pressure sensitive adhesive location 603 and a second pressure sensitive adhesive location 605 on either side of the deposited bead of adhesive 604. The operator 600 may engage a control 670 which may activate a pump to pump the adhesive from the adhesive reservoir 650 as well as activating press pads on the apparatus to create pressure on the pressure sensitive adhesive to attach the paper cover to the new spool 601. In some examples, the apparatus may include controls and electronics to allow for patterns to be formed in the deposition of the liquid adhesive. As will be described in following sections there may be numerous variations in the manner of depositing the bead of adhesive 604 and in the nature of the paper cover. The adhesive formulation may be modified with fillers and/or solvents to achieve a desired set of properties including its viscosity, its set time, and its general adhesion properties to operate in the manners described.
In some examples, the tissue paper construct may be preformed and placed on a spool. The preforming may involve a number of different processes. In a basic sense the paper may be cut into a band of the appropriate dimension such as around 2 inches wide. That paper band may have a creasing operation to emboss or crease the paper. The middle of the strip may be creased in such a manner in some examples. The paper may also have cuts made at various places, such as in the middle in a dashed pattern, or in two patterns that are each generally a line with dashed aspects. Additional examples are discussed in later sections. The paper may have holes cut into it or stamped into it. In some examples, needles or other implements may penetrate portions of the paper to create pores of defined characteristics in defined regions of the paper tape. Double sided strips of pressure sensitive contact adhesive may be applied to one or both of the edges of the paper tape to define a contact adhesive that may be applied to a new spool as has been discussed. The contact adhesive may be selected from various selections with different properties which may include adhesion, tackiness, color, or thickness, among others.
In some examples, the distal side of the paper tape from the contact adhesive strips may be treated with chemicals, such as silicones, to impart a release characteristic to them or other means may be employed to make the back of the paper tape resistant to adhering to contact adhesive strips when the treated paper tape is rolled upon a spool. A spooled paper tape thus treated may be applied by an apparatus while it dispenses adhesive beads by being pressed upon the pressure sensitive adhesive portions to the surface of the new spool. These different properties may include adhesion, tackiness, color, or thickness, among others.
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In some examples, a lightweight paper without inherent or formed pores may be used. Referring to
In another example, a covering paper may be adhered on just one side. Referring to
Accordingly, a paper ribbon being held on a single side may function better on slow machines. The adhesive bead 632 may be squeezed and push the adhesive material around 631 the paper tape as the paper and adhesive construct approaches the nip. As may be apparent a combination of different configurations may act in similar manners to these examples, such as in a non-limiting sense, an example where the paper tape is scored on one of its sides so that it ruptures along the side in a defined way rather than rupturing at a relatively random location.
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The selection of the system's components may be guided by a balance of characteristics each of which contributes to the function. For example, in some examples it may be desirable for the liquid adhesive to have a high enough viscosity to be easily controlled during application and not tend to migrate through the tissue over time or while the spool is spinning prior to the turn-up. The adhesive may also have an aggressive tack to capture the paper web instantly. The tissue paper for the paper cover may be strong enough to prevent tearing during application to the spool and to resist the centrifugal force of the adhesive bead. The pores in the paper may be small enough to prevent adhesive migration prior to the nip, but large enough to effectively disperse the adhesive in the nip.
Particular embodiments of the subject matter have been described. Other embodiments are within the scope of the following claims. In some cases, the actions recited in the claims can be performed in a different order and still achieve desirable results. In addition, the processes depicted in the accompanying figures do not necessarily require the particular order show, or sequential order, to achieve desirable results. In certain implementations, multitasking and parallel processing may be advantageous. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the claimed invention.
The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims. As used throughout this application, the word “may” is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include”, “including”, and “includes” mean including but not limited to. To facilitate understanding, like reference numerals have been used, where possible, to designate like elements common to the figures.
The phrases “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.
The term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. It is also to be noted the terms “comprising”, “including”, and “having” can be used interchangeably.
Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in combination in multiple embodiments separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.
As has been mentioned, the illustrations depict aspects of exemplary embodiments and the relative scale of illustrated features may be exaggerated for depiction of various aspects. Accordingly, the scale of features illustrated is not intended to limit the scope of the elements of the various embodiments consistent with the present application.
The present application claims the benefit of Provisional Patent Application Ser. No. 63/131,069 filed Dec. 28, 2020; the entire contents of which are hereby incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63131069 | Dec 2020 | US |
