The present disclosure relates generally to methods and systems for manufacturing sheet products.
Sheet products such as, for example, absorbent sheets are often packaged in tightly wound rolls. Tightly winding sheet product allows additional sheet product to fit on a roll with a desired outer diameter. The roll is often installed in a dispenser having spindles that engage a void in the center of the roll. In some manufacturing processes, the void may become undesirably obstructed or deformed.
An effective and efficient method and system for manufacturing tightly wound rolls of sheet product that may be easily used in a dispenser is desired.
The above described and other features are exemplified by the following Figures and Description in which an embodiment of a method for forming a tubular sheet product roll includes providing a sheet product roll having a first configuration and a void, centering a rotational axis of the sheet product roll on a longitudinal axis of a first tool, and inserting the first tool into the void of the sheet product roll to define an inner diameter of the void and to form the sheet product roll having a second configuration different from the first configuration.
A tubular roll of sheet product prepared by a process includes the method of centering a rotational axis of the sheet product roll on a longitudinal axis of a first tool, and inserting the first tool into the void of the sheet product roll to define an inner diameter of the void and to form the sheet product roll having a second configuration different from the first configuration.
A system for forming a core of a tubular sheet product roll includes a first tool operative to define a first portion of the core of the tubular sheet product roll, a first linkage connected to the first tool operative to move the first tool linearly along a linear axis of the first tool, and a second linkage connected to the first tool operative to rotate the first tool axially about the linear axis of the first tool.
A method for forming a tubular sheet product roll includes providing a sheet product roll having a sheet product wound on a removable core, the removable core having a first distal end, a second distal end and a longitudinal surface, centering a rotational axis of the sheet product roll on a longitudinal axis of a first tool, and engaging the first distal end of the removable core with the first tool to slidably move the removable core relative to the sheet product roll to expose a portion of the longitudinal surface of the removable core.
A sheet product includes a length of a wound first sheet product material defining a tubular roll having an outer diameter, and a semi-rigid core portion comprising the first sheet product material defining an outer diameter of a void portion concentric to the outer diameter of the roll.
These and other advantages and features will be more readily understood from the following detailed description of preferred embodiments of the invention that is provided in connection with the accompanying drawings.
Referring to the exemplary drawings wherein like elements are numbered alike in the accompanying Figures:
Embodiments of systems and methods for manufacturing sheet products are provided.
In this regard, the term “sheet products” as used herein is inclusive of natural and/or synthetic cloth or paper sheets. Sheet products may include both woven and non-woven articles. There are a wide variety of nonwoven processes and they can be either wetlaid or drylaid. Some examples include hydroentagled (sometimes called spunlace), DRC (double re-creped), airlaid, spunbond, carded, paper towel, and meltblown sheet products. Further, sheet products may contain fibrous cellulosic materials that may be derived from natural sources, such as wood pulp fibers, as well as other fibrous material characterized by having hydroxyl groups attached to the polymer backbone. These include glass fibers and synthetic fibers modified with hydroxyl groups. Examples of sheet products include, but are not limited to, wipers, napkins, tissues, rolls, towels or other fibrous, film, polymer, or filamentary products.
In general sheet products are thin in comparison to their length and breadth and exhibit a relatively flat planar configuration and are flexible to permit folding, rolling, stacking, and the like. The sheet product may have perforations extending in lines across its width to separate individual sheets and facilitate separation or tearing of individual sheets from the roll at discrete intervals. Individual sheets may be sized as desired to accommodate the many uses of the sheet products. For example, perforation lines may be formed every 13 inches to define a universally sized sheet. Multiple perforation lines may be provided to allow the user to select the size of sheet depending on the particular need. Sheet products may also be imperforated and dispensed in a length that may be determined by a mechanical linkage, or defined in an electronic device. Imperforated sheets may be separated from a roll of sheet products by a tearing device.
In an alternate embodiment of a method, a mandrel 202 may have ports that are operative to emit a fluid such as, for example water, an adhesive mixture, or another type of fluid such as, a high molecular weight polyethylene glycol (PEG). The fluid may be injected into the moist portion 106 when the mandrel 202 is inserted into the void 104. The fluid may be heated prior to injection. The mandrel 202 may be removed, and the liquid may cool and harden resulting in a composite of sheet product and solidified adhesive or PEG that resists telescoping during removal of the roll 102 from the mandrel 202, and facilitates removal of the mandrel 202.
The method described above results in the hardened core portion 205 comprising the dried sheet product material. In an alternate embodiment, the moist portion 106 may be moistened with an alternate liquid such as a diluted adhesive mixture including, for example, cellulose glycol. Thus, a dried core portion resulting from the method described above comprises the tissue product and the impregnated dried adhesive. Other liquids having other characteristics may also be used in a similar process.
The illustrated embodiment includes the mandrels 202 having heated regions 204. Other embodiments may include mandrels 202 that are uniformly heated. Uniformly heated mandrels 202 may effectively harden and form the core portion 205 in the void 104 without rotating the mandrels 202.
In fabrication, the caliber (thickness) of the sheet product may vary—resulting in rolls 702 having different outer diameters 101 (
While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best or only mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.
This application is a divisional of the legally related U.S. application Ser. No. 12/607,195 filed Oct. 28, 2009; which is fully incorporated herein by reference.
Number | Name | Date | Kind |
---|---|---|---|
1408126 | Mumm | Feb 1922 | A |
1459596 | Mayo | Jun 1923 | A |
1882012 | Hires | Oct 1932 | A |
1922716 | Robinett | Aug 1933 | A |
1930250 | Mulligan | Oct 1933 | A |
2270806 | Johnson | Jan 1942 | A |
2332371 | Corbin et al. | Oct 1943 | A |
2380644 | Grondona | Jul 1945 | A |
2772838 | Lenz | Dec 1956 | A |
3101914 | Lorenz et al. | Aug 1963 | A |
3106362 | Sukala, Jr. | Oct 1963 | A |
3131880 | Miller et al. | May 1964 | A |
3610545 | Reifenhauser et al. | Oct 1971 | A |
3713601 | Buhrman et al. | Jan 1973 | A |
3847366 | Schmidt et al. | Nov 1974 | A |
3907476 | Reilly | Sep 1975 | A |
3924743 | Bittner | Dec 1975 | A |
3941328 | Johnson | Mar 1976 | A |
4015711 | Mason | Apr 1977 | A |
4149682 | Gustafson et al. | Apr 1979 | A |
4184648 | Mergell | Jan 1980 | A |
4254918 | Huggins | Mar 1981 | A |
4362278 | Hopkinson | Dec 1982 | A |
4487378 | Kobayashi | Dec 1984 | A |
4762061 | Watanabe et al. | Aug 1988 | A |
4783015 | Shimizu | Nov 1988 | A |
5100075 | Morand et al. | Mar 1992 | A |
5186099 | Qing et al. | Feb 1993 | A |
5271575 | Weinert | Dec 1993 | A |
5277060 | Lehman et al. | Jan 1994 | A |
5277375 | Dearwester | Jan 1994 | A |
5281386 | Weinert | Jan 1994 | A |
5322234 | Robert et al. | Jun 1994 | A |
5337895 | Mitelman et al. | Aug 1994 | A |
5352319 | Ishizu et al. | Oct 1994 | A |
5366175 | Schutz | Nov 1994 | A |
5370339 | Moody et al. | Dec 1994 | A |
5387284 | Moody | Feb 1995 | A |
5451013 | Schutz | Sep 1995 | A |
5467936 | Moody | Nov 1995 | A |
5474436 | Yamazaki | Dec 1995 | A |
5495997 | Moody | Mar 1996 | A |
5620148 | Mitchell | Apr 1997 | A |
5660349 | Miller et al. | Aug 1997 | A |
5669576 | Moody | Sep 1997 | A |
5722608 | Yamazaki | Mar 1998 | A |
5849357 | Andersson | Dec 1998 | A |
5875985 | Cohen et al. | Mar 1999 | A |
6021973 | Makino et al. | Feb 2000 | A |
6070821 | Mitchell | Jun 2000 | A |
6082664 | Phelps et al. | Jul 2000 | A |
6129304 | Biagiotti | Oct 2000 | A |
6299099 | Miller et al. | Oct 2001 | B1 |
6342297 | LaBrash | Jan 2002 | B1 |
6422575 | Czaplicki et al. | Jul 2002 | B1 |
6713184 | Ferencz et al. | Mar 2004 | B1 |
6733608 | Baggot et al. | May 2004 | B1 |
6955320 | Martinez | Oct 2005 | B2 |
7540366 | Lindberg | Jun 2009 | B2 |
7992818 | Maddaleni et al. | Aug 2011 | B2 |
20050066457 | McKay | Mar 2005 | A1 |
20050139721 | Andersson | Jun 2005 | A1 |
20050150996 | Schmidt-Hebbel et al. | Jul 2005 | A1 |
20050184191 | van de Camp | Aug 2005 | A1 |
20060196990 | Wallace | Sep 2006 | A1 |
20070054557 | Larsson | Mar 2007 | A1 |
20070057103 | Malecot et al. | Mar 2007 | A1 |
20070114321 | Cattacin et al. | May 2007 | A1 |
20070240295 | Yamada et al. | Oct 2007 | A1 |
20070262193 | Chapman | Nov 2007 | A1 |
20080105394 | Kokko | May 2008 | A1 |
20090057456 | Shannon et al. | Mar 2009 | A1 |
20090101748 | Maddaleni et al. | Apr 2009 | A1 |
20090236464 | Cittadino et al. | Sep 2009 | A1 |
20110079671 | Wojcik et al. | Apr 2011 | A1 |
20110095116 | Hada et al. | Apr 2011 | A1 |
Number | Date | Country |
---|---|---|
2528335 | Jan 2005 | CA |
3911250 | May 1990 | DE |
102008053673 | May 2009 | DE |
0842881 | May 1998 | EP |
1554619 | Oct 1979 | GB |
6191699 | Dec 1994 | JP |
09124193 | May 1997 | JP |
10001241 | Jan 1998 | JP |
2000177894 | Jun 2000 | JP |
2152752 | Jul 2000 | RU |
2189347 | Sep 2002 | RU |
2232177 | Jul 2004 | RU |
99-42393 | Aug 1999 | WO |
0240387 | May 2002 | WO |
2005005295 | Jan 2005 | WO |
2006117821 | Sep 2006 | WO |
Entry |
---|
Chinese Office Action and Search Report date of Notification Apr. 1, 2014 for CN Application No. 201080047995.7; 10 pages. |
Office Action—Final for U.S. Appl. No. 12/607,195, filed Oct. 28, 2009; First amed Inventor: Ehteshamul Haque; Mailing Date: May 23, 2013; 10 pages. |
Russian Federation Office Action dated Nov. 10, 2014 for RU Application No. 2012121890; 7 pages. |
International Preliminary Report on Patentability for International Application No. PCT/US2010/054037; Mailed May 10, 2012; International Filing Date: Oct. 26, 2010; 12 pgs. |
International Search Report for International Patent Application No. PCT/US2010/054037; International Filing Date: Oct. 26, 2010; mailed Jun. 4, 2011; 7 pages. |
Written Opinion for International Application No. PCT/US2010/054037; International Filing Date: Oct. 26, 2010; Mailed May 12, 2011; 10 pgs. |
English machine translation of JP 09124193, filed May 13, 1997. |
English machine translation of JP 10001241, filed Jan. 6, 1998. |
Number | Date | Country | |
---|---|---|---|
20130225382 A1 | Aug 2013 | US |
Number | Date | Country | |
---|---|---|---|
Parent | 12607195 | Oct 2009 | US |
Child | 13799451 | US |