The present invention relates to methods and machines for producing logs of web material. More specifically, although not exclusively, the present invention relates to methods and machines for producing tissue paper, for example rolls of toilet paper, kitchen towels or the like.
To produce rolls of web material, for example kitchen towels, toilet paper or the like, rewinding machines are used. These machines are fed with a web material, formed by one or more plies of tissue paper or the like, unwound from a reel of large diameter. Predefined quantities of web material are wound on winding cores to form logs, the axial length of which is equivalent to the width of the web material fed to the rewinding machine and many times greater than the axial length of the small finished rolls intended for use. These logs are subsequently cut into individual rolls of the desired dimension, which are subsequently packaged.
Modern rewinding machines work continuously, i.e. with feed of the web material at substantially constant speed. Substantially constant is intended as a speed that does not require to be substantially modified upon completion of winding a log and before starting to wind the subsequent log, i.e. during the exchange step.
The exchange step performed upon completion of winding each log is a step in which the web material is severed (preferably along a transverse perforation line) to form a final edge that finishes winding around the completed log, and an initial edge that must be transferred to a new winding core to give rise to forming a subsequent log.
To sever the web material various devices are known, which are normally activated by an actuator to perform severing of the web material upon completion of winding each log, forming an initial edge and a final edge, controlled in synchronism with other members of the rewinding machine.
For example, U.S. Pat. No. 5,979,818, U.S. Pat. No. 5,7689,352 and U.S. Pat. No. 5,853,140 describe rewinding machines in which the web material is severed between a completed log and the new core, during insertion into a channel, by means of a severing member or separator device that acts on the web material, cutting or tearing it. This separator device is moved by a motor synchronized with the other parts of the rewinding machine and in particular with the system for insertion of the cores.
In other known devices (GB-A-1,435,525) severing of the web material takes place with pressurized air jets synchronized with insertion of the cores into the winding area. In U.S. Pat. No. 4,487,377 and in EP-A454633 the web material is cut upon completion of winding each log by means of a knife or a blade activated in synchronism with insertion of the new winding core.
U.S. Pat. No. 5,137,225 describes a rewinding machine in which the web material is torn as a result of cooperation between a new core inserted into an insertion channel and a fixed surface, the core pinching the web material against the fixed surface and consequently causing a tension exceeding the breaking point of the web material.
GB-A-2,105,688 and EP-A-524158 describe rewinding machines in which the web material is torn by acceleration of one or the winding rollers forming the winding cradle.
Timing the action of the separator device with the other members of the rewinding machine to obtain tearing, cutting or in general severing of the web material, in a predetermined instant is a constructionally complex and delicate aspect.
An object of an embodiment of the invention is to provide a method and a machine which, with means that are simple, inexpensive and easy to control, make it possible to obtain severing of the web material correctly timed, i.e. synchronized, with the insertion of the winding cores upon completion of each log forming cycle.
According to a possible embodiment, the method of the present invention provides that upon completion of winding a log the web material is severed to form a final edge which is wound around the log and an initial edge which is wound around a new winding core inserted in an insertion path, in which the web material is severed by means of a separator device, which is controlled directly by passage of the new winding core along the insertion path. In substance, according to a possible embodiment, the separator device is a passive member, which is activated by the thrust of the winding core during the movement thereof. According to a different embodiment, the separator device can be activated indirectly by passage of the core, for example by means of a sensor that detects passage of the core in a specific position of the path thereof and generates an activation signal (by means of a suitable actuator) of the separator device. Activation to cause severing of the web material can be caused by the thrust of the core being fed, while an actuator causes withdrawal of the separator device when the core must move beyond said device towards the winding unit or winding cradle.
According to a possible embodiment the method according to the invention includes the steps of:
In substance, the invention is based on the principle of activating the separator device not by means of an actuator to synchronize with the other members of the machine through a specific controller, but by making the core interact directly with the separator device which is in substance a passive device. Passive device is intended, within the scope of the present description, as a device without an actuator thereof, which is controlled by passage of the core in a specific position along the insertion path thereof.
According to a particular embodiment of the invention, the method comprises the steps of:
In a possible embodiment of the invention, after severing of the web material continuation of feed of the core along the insertion path thereof causes temporary withdrawal of the separator device with respect to the insertion path to allow passage of the winding core.
In a possible embodiment of the invention, by interacting with the separator device the core pushes this device against the web material causing pinching of the web material between the separator device and the guide member. The latter can be formed by a belt or another flexible element, an assembly of belts parallel to one another, or the like, with which the web material is in contact. The feed speed of the web material is substantially the same as, with the exception of acceptable slipping, the feed speed of the guide device or member. In a different embodiment the guide member can be constituted by one of the winding rollers that define the winding cradle of a peripheral or surface rewinding machine.
The separator device can be rotatingly or oscillatingly supported about an axis of oscillation or rotation and the core with the passage thereof along the insertion path causes oscillation of the separator device against the web material to cause tearing or severing thereof.
Severing preferably takes place along a perforation line. Alternatively, severing can take place where there is no perforation, for example using a sharp or toothed blade.
The separator device can be maintained in an idle position by means of a counterweight or, according to a preferred embodiment of the invention, by means of a resilient member, for example a mechanical spring, a pneumatic spring (such as a pneumatic piston-cylinder system) or by means of another suitable device. The separator device is operated, i.e. taken td the operating position to cooperate with the web material, as a result of the thrust exerted thereon by the core fed along the insertion path thereof. The separator device can advantageously have a second withdrawn position with respect to the feed path of the core, thereby allowing the core to be fed freely and without obstruction along the path to the log forming area.
According to a different aspect, in a preferred embodiment of the invention there is provided a rewinding machine for producing logs of web material wound around a winding core comprising:
According to a different embodiment, the invention relates to a method for producing logs of web material around the winding core, comprising the steps of:
Also forming the object of the invention is a rewinding machine comprising in combination:
According to the invention, the separator device is advantageously disposed along the insertion path of the cores and is produced and disposed to act in combination with the winding cores during passage thereof along said insertion path, so that the winding cores activate the separator device to cause severing of the web material. More specifically, according to a specific aspect of the present invention, the winding cores exert a thrust on the separator device while they roll along an insertion channel. This thrust activates the separator device, causing it to sever the web material.
According to a different aspect, the invention relates to a rewinding machine comprising in combination:
Further characteristics, embodiments and advantages of the method and of the device according to the invention are indicated hereunder with reference to some examples of embodiment illustrated in the accompanying drawings.
The invention will be better understood by following the description and accompanying drawing, which shows practical non-limiting embodiments of the invention. More specifically, in the drawing, where the same or equivalent parts are indicated with the same reference numbers:
The accompanying figures show the members of the rewinding machine in different embodiments of the invention, limited to those parts of the machine that are necessary in order to understand the principle on which the invention is based. Other parts of the machine can be designed in a manner known per se to those skilled in the art and, for example, in particular as described in the publications mentioned in the introductory part of this description, the content of which is fully incorporated herein. More specifically, the operating sequence illustrated in the figures of the drawing show the members of the winding head, i.e. those members used to feed the web material and to insert the cores, as well as to sequentially form the individual logs of web material around the respective tubular cores.
With initial reference to
Between the rollers 1 and 3 a nip 9 is formed, through which the web material N passes (for example a cellulose web material, such as a sheet of tissue paper), which is fed through a perforator unit (not shown) that generates a series of transverse perforation lines to divide the web material N into individual sections or sheets which, in the final using step, can be detached individually.
The web material N is fed along a feed path that extends partly around a winding roller 1 as well as adhering to a movable guide member 13 formed, in this embodiment, by a belt or by a series of belts parallel to one another suitably supported by sliding surfaces or shoes. The belts forming the guide member 13 of the web material N are fed around the winding roller 1, preferably housed in respective annular grooves, and around a roller 15 rotating about an axis 15A approximately parallel to the axis 1A of the roller 1 with a peripheral speed approximately the same as the peripheral speed of the winding roller 1 and as the feed speed of the web material N. This speed preferably remains approximately unchanged during the winding cycle and in particular during the exchange step.
Between the rollers 1 and 15, inside the path defined by the belts forming the guide member 13, there is disposed a fixed counter element 17 which can have sliding and guide grooves for the belts forming the guide member 13.
In front of the lower branch of the guide member 13 there extends a rolling surface 19 formed by a series of sections 21 parallel to one another and relatively thin, as shown by way of example in
In an intermediate position along the extension of the channel 23 a separator device 25 is arranged, which is used to sever the web material N upon completion of winding each log. The separator device is shown in a schematic front view in
In a preferred embodiment, a simple elastic member can be used (such as a pneumatic spring constituted by a piston-cylinder system 33), which constrains the separator device 25 in an idle position, the activation movement being controlled entirely by passage of the core. A shock absorber can be combined with the elastic member to dampen the return movement of the separator device 25, after the core A has moved beyond this device (passage from
In the idle position in
Downstream of the separator device 25 there is disposed a movable mechanical member 41 intended to form or facilitate forming of the first turn of web material around each winding core that is fed towards the winding area along the channel 23. This movable mechanical member 41 has the shape shown in
Each bracket 43 has a projection 43A which, in non-operating or idle conditions, projects as shown in
Preferably each bracket 43 is associated with a member that maintains said bracket in an idle position shown in
The machine described above operates in the manner illustrated hereunder with reference to the sequence in
The core A rolls along the rolling surface 19 following an insertion path that extends inside the channel 23. During this movement the core A encounters (
Continuing to travel by rolling along the channel 23, the winding core A comes into contact with the pressers 27 and, as a result of the rolling imparted by the guide member 13 (which also constitutes the feed member of the winding cores along the insertion path), exerts a thrust on the pressers 27. Consequently, these are withdrawn under the rolling surface 19 overcoming the force of the return member 33. This allows the core A to travel beyond the separator device 25 rolling over the loop of web material T1
In the subsequent
In substance, the distal ends of the arms 43B are shaped and dimensioned so as to push the edge T1 of web material N in the area in which the web material is in contact with the winding roller 1 and tangent to the winding core A. Continuation of rolling of the core along the surface 19 and then in contact with the winding roller 3 completes insertion of the core through the nip 9 and takes this core into the winding cradle 1, 3, 5 where the new log continues to be formed and to increase in a manner known per se around the new winding core A.
From the description above it is understood how the use of the members 25 and 41 radically simplify the structure of the machine with respect to prior art rewinding machines both as regards severing of the web material and as regards the start of winding the initial free end on each new core A. Severing and forming of the first turn of web material around the new core both take place as a result of interaction between the winding core and mechanical devices which can be devoid of actuators making it unnecessary to power the respective motors and also to synchronize them with the other machine members, in particular the core inserter. It would also be possible to replace both or only one of the return members 33 and 47 with an actuator, such as a movement and control member in synchronism with the movement of the core. Nonetheless, the embodiment described above is more advantageous due to elimination of these actuator mechanisms.
The representation in
It must be understood that the separator device 25 can also be used in the absence of the mechanical member 41 and combined with other and different systems to start winding the web material N on the new core. For example, the separator device 25, preferably of passive type, i.e. represented by a mechanical element oscillating as a result of the thrust of the new core inserted in the insertion path, can be combined with a system to glue the cores, or to glue the free edge. Otherwise, an electrostatic, suction or blowing system can be used to start winding the first turn, although the mechanical device 41 is more advantageous for the reasons set forth previously.
Conversely, the mechanical member 41 can also be used in combination with systems for severing or separating the material of a different type with respect to the one shown in
In the example of embodiment shown in
The separator device 25 and the movable mechanical member 41 for forming or completing the first turn of web material around the new winding core A are produced and operate as described with reference to
It is understood that the drawing only shows an example given by way of a practical demonstration of the invention, as said invention can vary in forms and arrangements without however departing from the scope of the concept underlying the invention. Any reference numbers in the appended claims are provided to facilitate reading of the claims with reference to the description and to the drawing, and do not limit the scope of protection represented by the claims.
Number | Date | Country | Kind |
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FI2006A0140 | Jun 2006 | IT | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/IT2007/000390 | 6/4/2007 | WO | 00 | 11/24/2008 |
Publishing Document | Publishing Date | Country | Kind |
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WO2007/141819 | 12/13/2007 | WO | A |
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Number | Date | Country | |
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20090173819 A1 | Jul 2009 | US |