The present invention relates to a web diverting apparatus capable of diverting a web from a downstream web path to a different downstream web path; more particularly, a web diverting apparatus capable of simultaneously severing and diverting a web from a downstream web path to a different downstream web path, a web diverting apparatus capable of simultaneously severing and diverting a web from a downstream web path to a different downstream web path and from the different downstream web path to another downstream web path, a web diverting apparatus capable of severing a web prior to diverting the severed web from a downstream web path to a different downstream web path, and a method for managing a web.
Web diverting systems are known in the art. For example, one system cuts an unsupported web and then folds the web back upon itself before diverting to another downstream web path.
In another example of a known web diverting system, a shoe contacts and pinches a web between it and a vacuum roll thus diverting the web to a different downstream web path before cutting of the web occurs. After cutting, the vacuum roll directs the web down the downstream web path.
In yet another example of a known web diverting system, a knife blade severs a web after the web has been pinned between a pair of nip rolls and then directs the leading edge of the severed web to a single downstream web path.
Other examples of web diverting apparatus are designed to work with narrow webs or with only a narrow threading strip on wide web processes and not the entire web. Such web diverting apparatuses are limited to diverting a web from an original web path to a different web path, but not back to the original web path.
The known web diverting systems all exhibit negatives with respect to speed, reliable control of the web and/or the range and variety of substrates for which the process is compatible.
Many of the known web diverting apparatuses require the web velocity to change, such as the web stopping and/or being pinned between two components, during diverting of a leading edge of a severed web to a downstream web path. Additionally, many of the known diverting apparatuses rely upon vacuum to control a web which may not be practical with permeable webs.
Accordingly, there exists a need for a web diverting apparatus that overcomes the negatives associated with the known web diverting systems. In particular, there exists a need for a web diverting apparatus that is more simple in both mechanical design and controls complexity thus resulting in a more robust and reliable web diverting apparatus and method and that are able to direct a web of any width down more than one downstream web path while minimizing any interruptions in the speed and/or flow of the web.
The present invention fulfills the need described above by providing a web diverting apparatus capable of simultaneously severing and diverting a web from a downstream web path to a different downstream web path, a web diverting apparatus capable of simultaneously severing and diverting a web from a downstream web path to a different downstream web path and from the different downstream web path to another downstream web path, and a method for managing a web.
In one example of the present invention, a web diverting apparatus capable of simultaneously severing and diverting a web from a downstream web path to a different downstream web path, is provided.
In another example of the present invention, a web diverting apparatus capable of simultaneously severing and diverting a web from a downstream web path to a different downstream web path and from the different downstream web path to another downstream web path, is provided.
In even another example of the present invention, a web diverting apparatus comprising a web guiding member capable of directing a web between two or more downstream web paths such that the web travels along a web path defined by the web guiding member prior to being directed down one of the two or more downstream web paths by the web diverting apparatus, is provided.
In still another example of the present invention, a web diverting apparatus capable of severing a web and then subsequently diverting the severed web from a downstream web path to a different downstream web path (in one example, along a web guiding member), is provided.
In yet another example of the present invention, a method for managing a web, the method comprising the step of passing a web through a web diverting apparatus according to the present invention, is provided.
The present invention provides a web diverting apparatus and method for managing a web that overcomes the negative associated with the prior art.
“Web” as used herein means a substantially continuous and/or greater than about 100 cm and/or greater than about 150 cm and/or greater than about 300 cm and/or greater than about 500 cm and/or greater than about 1000 cm in length material. The web may be any width. In one example, the width of the web may be greater than 10 inches and/or greater than 20 inches and/or greater than 50 inches and/or greater than 100 inches and/or greater than 150 inches and/or greater than 200 inches. Non-limiting examples of materials for the web include fibrous elements (such as fibers and/or filaments), films, metals, and textiles. In one example, the web is a highly permeable and/or high stretch web. In one example, the web is a fibrous structure such as paper or another type of non-woven.
“Web path” as used herein means a course along which the web travels through the web management apparatus.
“Web management apparatus” as used herein means a machine that functions to interact, such as move, direct and/or guide, a web along one or more web paths.
“Web diverting apparatus” or “web diverter” as used herein means a component of a web management apparatus that functions to change the direction of the web, in other words divert the web, from a first web path to a second web path different from the first web path.
“Downstream web path” as used herein means a web path that is after a web diverting apparatus of a web management apparatus.
“Upstream web path” as used herein means a web path that is before a web diverting apparatus of a web management apparatus.
“Web path surface” as used herein means a surface of web management apparatus along which the web travels. The web may be in contact with the surface during its movement. In one example, the web may not contact the web path surface during its movement, for example it may be moving on an air stream positioned between the web path surface and the web.
“Air Stream” as used herein refers to a flow of air, for example a desirably laminar flow of air along at least one web path surface with a velocity that may be equal to or greater than the web velocity. The air stream may be supplied by one or more air sources such as an air foil supplied air from a blower, or an air knife or an air nozzle, or supplied air by a compressed air source. One or more air streams may be present during the web diverting operation to help control the leading edge of the web and direct it down the appropriate downstream web path.
“Constant web velocity” as used herein means that a web travels at a constant velocity along a web path. In other words, the web does not stop, does not reverse its direction and/or does not fold back upon itself to change direction.
“Sever” and “Severing” as used herein means any process of creating separation in a web that creates two or more separate portions of the web. Examples may include, but are not limited to, typical shear cutting and/or tearing resulting from straining the web to the point of tensile failure. One or more severing elements may be used to sever the web. In one example, one or more severing elements moves at a velocity of at least 20 in/second and/or at least 40 in/second and/or at least 60 in/second and/or at least 80 in/second.
As used herein, the articles “a” and “an” when used herein, for example, “an anionic surfactant” or “a fiber” is understood to mean one or more of the material that is claimed or described.
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The web guiding member 12 is movable, as represented by the arrows, such that the web guiding member's web path 22 aligns with downstream web path 16 as shown in
The web guiding member 12 may be a chute comprising at least two walls such as a first wall 30 and a second wall 32 that define the web guiding member's web path 22. In one example, the web guiding member 12 comprises a first wall 30 and a second wall 32 that are spaced apart from one another by a sufficient amount such that the web 14 is able to pass through the web guiding member 12. In one example, the first and second walls 30, 32 are spaced apart from each other by greater than about 0.75 cm and/or greater than 1 cm and/or greater than 1.25 cm and/or greater than about 2.54 cm. The web guiding member 12 may further comprise one or more side walls (not shown) that are associated with one or more of the first and second walls 30, 32 to further define the web guiding member's web path 22 and to prevent air associated with air stream 20 from escaping out the sides of the web guiding member 12.
The web diverting apparatus 10 may comprise one or more severing elements 34, 36. The severing elements are capable of severing the web 14. One or more of the severing elements may be attached to one or more of the first and second walls 30, 32.
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The severing elements 34, 36, 42 may be non-contact severing elements such as air jets, water jets, ultrasonics, lasers and combinations thereof such that they do not contact the web during the severing operation. In another example, the severing elements 34, 36, 42 may comprise contact severing elements such as knife blades, wires, saw blades and combinations thereof such that they do contact the web during the severing operation.
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In one example, the web 14 may be tension free after it has been diverted to another downstream web path.
In another example, the web diverting apparatus 10 may divert the web from one plane to a different plane.
In still another example, the velocity at which the web 14 is moving in a downstream web path may be different from the velocity the web 14 was moving prior to being diverted to the downstream web path. In one example, the web 14 decelerates after being diverted to a downstream web path.
The web diverting apparatus 10 may be operated such that the web 14 that is being collected in a web collection device 44 may be diverted to direct the web 14 from downstream web path 18 to downstream web path 16 as shown in
In one example, the diverting of the web 14 from downstream web path 16 to downstream web path 18 by the web diverting apparatus 10, or conversely diverting of the web 14 from downstream web path 18 to downstream web path 16 by the web diverting apparatus 10, occurs at a constant or substantially constant web velocity. In another example, this diverting of the web 14 occurs such that the web 14 does not fold back upon itself and/or does have its downstream movement halted or interrupted.
One or more of the downstream web paths 16, 18 may comprise two or more walls that define a chute through which the web 14 may travel similar, if not identical to, the chute that the web guiding member 12 may comprise. One or more of the downstream web paths 16, 18 may also comprise one or more side walls (not shown) that are associated with one or more of the first and second walls of downstream web paths 16, 18 to further define the downstream web paths 16, 18 and to prevent air from escaping out the sides of the paths.
In another example of a web diverting apparatus 10 according to the present invention, air jets may be used to divert the web from a first downstream web path to a second downstream web path and vice versa.
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Once severed, the web 14 will have a trailing edge 38 of the web 14 and a leading edge 40 of the web 14. As shown in
The web diverting apparatus 10 of the present invention may be used to sever and divert and stack portions of a web into separate, discrete groups, such as for facial tissue and/or wipes and/or coupons. As shown in
The overall web management apparatus 26 and its components, for example the web diverting apparatus 10, and any materials that define the web paths 16, 18, 22, may be made of any suitable material known in the art. Non-limiting examples of suitable materials include, plastic, glass, ceramic, metal, and combinations thereof.
The examples described herein are non-limiting examples of the present invention. It should be understood by one of skill in the art that the various elements described by the exemplary embodiments may be utilized in other combinations. For example the web guides 60 and 62 of
In one example, a method for diverting a web according to the present invention comprises the steps of:
a. providing a web diverting apparatus according to the present invention; and
b. passing a web through the web diverting apparatus.
The method may further comprise the step of severing the web to produce a leading edge of the web. The method may further comprise the step of directing the leading edge of the web along a downstream web path.
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.