IL36710A - Machine and process for compacting web of material - Google Patents

Description

-ion mow ntf†n i» nm naiao Machine and procesa for compacting a web of material JOSEPH BANCROFT & SONS COMPANY This invention relates to a machine for mechanically treating materials having a movable friction surfmee. More particularly, this invention relates to a machine for longitudinally compressing fabric materials utilizing movable frlctional surfaces on the materials.

Mechanical compression of materials such as textiles, paper, films and the like which are capable of being mechanically compressed to a fractional proportion of original length has been known, for example, as described in U. S. patent application Serial No. 525, 039, filed February 4, 1966 and now U. S. patent No. 3, 2,409 granted July 1, 1969. The machines which have been utilized to mechanically compress materials in the manner suggested above have usually relied on a first surface to confine the material to a predetermined thickness relative to a driving surface on the opposite side of the first surface as well as a second surface opposite the driving surface to define a cavity which decreases in the direction of movement of the material from the first surface and in which the material is compressed. In many instances, this second surface has been formed of a wearable material such as rubber. However, it has been found that the wearable second surfaces,especially when made of rubber, tend to wear out rapidly and require a change, for example, after each 0 to 100 yards of material is processed.

Because of the need to change the wearable second surfaces of these machines at such frequent intervals, these machines have not been capable of extended efficient use. Further, these machines have required a relatively long period of down-time in order to permit replacement of the wearable second surfaces.

Accordingly, it is an object of the invention to increase the operational time of mechanical compressing machines.

It is another object of the invention to reduce the down-time for replacing wearable friction surfaces in mechanical compressing machines.

Briefly, the invention provides a movable friction surface for a mechanical material compressing machine which utilizes a driving surface, a primary surface, and a flexible retarder to define a cavity in which the material is compressed. The driving surface in such machines functions as a driving means for driving the material through the compression cavity. The primary surface serves to confine the material to a pre-determined thickness before entry into the compression cavity and the flexible retarder serves to slow the movement of the material in passing through the cavity relative to the speed at which the material enters the cavity.

The flexible retarder, according to the invention, is mounted in a manner to be moved relative to the primary surface so as to present different wear surfaces thereof to the cavity area. In one embodiment, the flexible retarder is formed as an elongated strip and is mounted to be moved either in the direction of movement of the material being processed or the opposite direction.

In another embodiment, the flexible retarder ±s mounted in strip form transversely across the material so as to be moved perpendicularly to the direction of movement of the material being processed.

In still another embodiment, the flexible retarder is constructed as an endless belt and is mounted so as to be moved parallel to the direction of movement of the material being processed. Further, in this embodiment, the flexible retarder is mounted on a frame which permits the flexible retarder to be adjusted horizontally and vertically with respect to the primary surface and driving surface.

In still another embodiment, the flexible retarder is constructed in cylindrical form as the peripheral surface of a roller and is mounted to rotate in a direction with or against the direction of movement of the material being processed.

In all of the above embodiments of the invention, the flexible retarder is moved with respect to the characteristics of the processed material which influence wear on the flexible retarder surface within the compression cavity. For example, the flexible retarder is moved with respect to such material characteristics as the type of the material, thickness, fiber content, weave and the like. The amount and time of movement are such that a fresh surface of the flexible retarder is presented to the processed material within the compression cavity before the prior flexible retarder becomes worn to a degree which inhibits efficient and adequate processing of the material. In this way, the material can be processed substantially continuously without interruption on account of wear in the flexible retarder. Further, the movement of the flexible retarder can be effected in a continuous or interrupted manner. Where the movement is continuous, the flexible retarder is synchronized with the processing speed of the material, for example, at a speed reduction at 50 to 1, so as to be directly dependent on the movement of the processed material. Where the movement is interrupted, the flexible retarder can be initiated manually or automatically. For instance, after a predetermined length of material has been processed, as determined by a counting or measuring mechanism, a suitable transmission system can be activated to cause the flexible retarder to move an increment of length and then stop. Similarly, a timing mechanism can be used to indicate when a certain length of material has been processed, for example, by lighting or sounding a signal, so that the flexible retarder can be moved manually or semi-automatically.

By moving the flexible retarder relative to the processed material, the down-time which would otherwise be required for replacement of a worn surface is reduced con-slderably. Further, once an adjustment has been made for the flexible retarder relative to the compression cavity, succeeding sections of the flexible retarder surface exposed within the compression cavity can be moved within the compression cavity with little or no further adjustment. Thus, the processing of a material or materials can be carried out in a rapid efficient manner.

These and other objects and advantages of the invention will become more apparent from the following detailed description and appended claims taken in conjunction with the accompanying drawings in which: Fig. 1 illustrates a schematic view of a machine for mechanically treating materials having a movable flexible retarder according to the invention; Fig. 2 illustrates a fragmentary perspective view of the flexible retarder of Fig. 1; Fig. 3 illustrates a view taken on line 3-3 of Fig. 2 showing the relationship of the movable flexible retarder relative to the compression cavity; Fig. illustrates a fragmentary perspective view of a modified flexible retarder according to the invention; Fig. 5 illustrates a view taken on line 5-5 of Fig. 4; Fig. 6 illustrates a side view of another modified flexible retarder of the invention in endless form; Fig. 7 illustrates an enlarged detail of Fig. 6 taken through the compression cavity; Fig. 8 illustrates another modified flexible retarder of the invention in endless form; and Fig. 9 illustrates an enlarged detail of Fig. 8 taken through the compression cavity.

Referring to Figs. 1 and 2, a machine 10 for mechanically compressing materials, for example, a web 11 of textile material, includes a drive roller 12 of knurled surface for driving the web 11, a shoe apparatus 13 containing a primary surface Ik in the form of a resilient plate for confining the web 11 against the roller 12 and a movable flexible retarder 15 in the form of a strip for retarding the forward motion of the web 11. The web 11 is delivered onto the knurled surface of the drive roller 12 in flattened form from a supply roll 16 positioned below the drive roller 12, as shown, or spaced horizontally from the drive roller 12 (not shown). In addition, the web 11, after processing, is taken up by a take-up system 17 located outside the machine 10 over a series of guide rollers 18 as is known.

Referring to Fig. 2, the shoe apparatus 13 is plvotally mounted on a fixed frame 19 of the machine 10 over the drive roller 12 and is pressed towards the drive roller 12 under the influence of a pneumatic or hydraulic press 20 also mounted on the frame 19. The press 20 which can include a plurality of spaced rams 21 abuts on the top of the shoe apparatus 13 so as to prevent upward movement of the shoe apparatus above a predetermined spacing from the drive roller 12. The rams 21 are adjustable with respect to the shoe apparatus 13 so as to permit the spacing of the shoe apparatus 13 from the drive roller 12 to be varied.

The shoe apparatus 13 is freely pivoted on suitable links 22 at the ends of the frame 19 to rest on the drive roller 12 and mounts the primary surface 14 in the form of a flexible steel plate at the bottom. The primary surface plate is mounted in a cantilever manner to extend over the drive roller 12. Additionally, the shoe apparatus 13 is slotted at the rear to permit passage of the flexible retarder 15.

The flexible retarder 15 is disposed in a plane above the primary surface plate and extends past the free edge 23 of the primary surface 14. A pair of rigid pressure plates 24 are secured in the shoe apparatus 13 on an inclined plane and press against the flexible retarder 15 and primary surface 14 to ensure a pressure contact between the web 11 and these parts. In order to facilitate the positioning of the flexible retarder 15 and to avoid sharp corners, a back-up blade 25 is secured, as by recessed screws or. by welding, to the underside of the plates 24 and extends out from the plates 24 over the flexible retarder 15.

The flexible retarder 15 is in the form of a strip or belt and is of a frictional material such as rubber having a Duroraeter of about 50 and a coefficient of friction higher than the primary surface 1 . The strip, is mounted on and between a pair of rollers 26, 27 so as to be wound and unwound from the respective rollers to traverse a path passing through the shoe apparatus 13.

Referring to Fig. 3> the drive roller 12, primary surface 14 and flexible retarder 15 define a compression cavity C in which the web 11 is longitudinally compressed.

The cavity C beginsat and extends from t he free edge 23 of the primary surface 1 forwardly between the drive roller 12 and flexible retarder 15 at a decreasing rate of height. The cavity C at the edge 23 of the primary surface 1 is of greater height than the space between the primary surface 14 and drive roller 12 so that the web 11 which is slowed in passing between the drive roller 12 and flexible retarder 15 can begin to longitudinally compress immediately upon entry into the cavity C. Depending on the rate of wear on the flexible retarder 15 within the cavity C, the flexible retarder 15 is moved relative to the cavity C to present fresh surfaces to the cavity C.

The movement of the flexible retarder 15 is accomplished in an intermittent manner so as to move in Increments equal to the length of the flexible retarder surface within the cavity C. Alternatively, the flexible retarder 15 can be moved continuously at a rate relative to the speed of the travelling web 11. For example, where the flexible retarder surface would wear out after exposure to about 100 yards of web, the flexible retarder 15 is moved at a rate to present a fresh surface within the cavity after passage of about 80 to 90 yards of web. This will further ensure against any wearing out of the flexible retarder surface which might cause imperfections in the compressed web.

The movement of the flexible retarder 15 is accomplished by rotating the rollers 26, 27 so that as the retarder 15 unwinds from one roller it also winds up on the other roller. In order to rotate the rollers 26, 27, a suitable manually operated handle (not shown) is connected to one roller to allow manual rotation of the roller. In this case, the other roller can be freely mounted so as to rotate under the pulling force of the retarder 15. Also, this latter roller can be suitably braked so as to avoid an excessive rate of unwinding of the flexible retarder 15.

Alternatively, the rollers 26, 27 can be connected mechanically to the drive (not shown) of the drive roller 12 via suitable transmission. That is, the drive of the drive roller 12 which is connected thereto by an endless belt arrangement 28 also drives at least one of the rollers 26, 27 at a reduced rate with respect to the drive roller 12. In order to allow intermittent movement of the flexible retarder, a clutch mechanism is interconnected in the drive so as to selectively engage and disengage the drive to and from the rollers 26, 27.

Referring to Pig. 4, wherein like numerals indicate like parts as above, the flexible retarder 15 is mounted transversely of the drive roller 12. As above, the flexible retarder 15 is in strip form and is positioned to pass between the primary surface 1 and the back-up blade 25 of the shoe apparatus 13. The flexible retarder strip is of a width to extend from a point between the primary surface 14 and shoe apparatus 13 past the free edge 23 of the primary surface 1 to a point sufficient to permit formation of the compression cavity C as above described. Additionally, the shoe apparatus 13 is under sufficient pressure to clamp the flexible retarder 15 between the back-up blade 25 and primary surface 1 to prevent a pull out of the flexible retarder in the direction of travel of the web 11 under the forces generated by the web 11. However, the clamping forces on the flexible retarder 15 are such as to permit longitudinal sliding of the flexible retarder 15 so as to facilitate a change in the surface of the flexible retarder presented to the compression cavity C.

Alternatively, the flexible retarder 15 can also be clamped against such longitudinal sliding. In this alternative case, the pressure exerted by the shoe apparatus 13 on the flexible retarder 15 is periodically relieved so as to permit longitudinal displacement of the flexible retarder strip.

Referring again to Pig. , the strip of flexible retarder 15 is mounted on a pair of rollers 29 of the flanged-type to be wound and unwound thereon as above. The rollers 29, 30 are rotatably mounted and are rotated either by manual or mechanical controls as described above. Further, the longitudinal displacement of the flexible retarder 15 is carried out, as above, either in increments or continuously. Accordingly, since the movement and controls for movement of the flexible retarder 15 are similar to those described above, further description of such is not believed to be necessary hereat.

Referring to Figs. 6 and 7, an alternate machine 30 for mechanically compressing a web 31 of material includes a drive roller 32, a primary surface 33 and an endless flexible retarder 3^ . The drive roller 32 is constructed as above with a knurled surface 35 for initially receiving the web 31 and for driving the received web through the compression cavity C (Fig. 7) formed between the drive roller 32 on one side and the primary surface edge 36 and flexible retarder 34 on the other side. The primary surface 33 is formed of a resilient plate such as a stainless steel plate which is cantilevered over the drive roller 32 from the frame 37 of the machine 30. The flexible retarder 34 is formed of a resilient endless belt which passes under the lower point of the surface of a pressing roller 38, for example, of steel.

The roller 38 is slidably mounted at opposite ends via stub shaft 39 in a guideway 40 for vertical displacement. In addition, a second roller 41 of greater weight and diameter than the roller 38 is likewise slidably mounted via stub shafts 42 in the guideway 40 so as to place a weighted load on the roller 38 and consequently on the flexible retarder 34 within compression cavity C (Fig. 7). The latter roller 4l is replaceable so that different loads can be imposed on the flexible retarder 34. The diameter of the pressing roller 38 is such as to concentrate the weight pressing down on the flexible retarder strip within the limited area of the compression cavity C.

The guideway 40 which freely mounts the rollers 38* 41 is mounted in the frame 37 so as to be slidable in a horizontal plane. For example, the guideway 40 is secured to the top of the frame 37, as by a screw 45, passing through a suitably slotted opening in the guideway. In addition, the guideway 40 is supported by a pair of arms 44 which are mounted on opposite ends of the guideway 40 and which are secured, as by a screw 46 passing through a suitably slotted opening in each arm 44, to the frame 37. The rollers 42 are journalled in 47 _ £ support members -1-7 which are mounted on the top of the % guideway frame 40 so as to move therewith. Thus, depending on the material make-up of the web 31 being processed, the size of the compression cavity C can be varied by moving the guideway 40 horizontally as well as by changing the weights of the rollers 38* 41 or the size of the roller 38.

The endless belt flexible retarder 34 is also mounted to pass over a pair of rotatable mounted rollers 42 suitably journalled in the machine 30 so as to form a triangular shaped path. At least one of the rollers 38, 2 is driven so as to intermittently or continuously cause the endless belt retarder 3^ to move in a direction with or against the direction of movement of the travelling web 31.

In this regard, the drive for these rollers 38, 2 is taken off the main drive of the machine 30 in a manner similar to that above described.

Referring to Pigs. 8 and 9* a further alternate machine 50 for mechanically compressing a web 1 of material as above includes a drive roller 2* a primary surface 53 and an endless flexible retarder 54. The drive roller is constructed as above with a knurled surface as above for driving the received web 51 through the compression cavity C (Fig. 9). The primary surface 53 is mounted in cantilevered fashion from a frame 55 of the machine 50 so as to confine the web 51 to a predetermined thickness, for example, in the case of textile fabrics to a thickness slightly less than the normal thickness of the web immediately prior to entry into the compression cavity C and in the case of paper, to the free thickness of the paper. As above, the primary surface 53 is formed by a resilient plate such as a stainless steel plate. The flexible retarder 54 is formed as a flexible coating, sleeve or strip over the surface of a roller 56 of non-resilient material such as steel. The roller 56 is driven, for example, from the main drive of the machine 0 either intermittently or continuously to cause the flexible retarder 5 to move in the direction of or opposite to the travelling web 51. The roller 56 is further mounted in a manner which directs a constant force during operation downwardly against the primary surface 53 towards the drive roller 52.

This force can be developed by mounting the ends of the roller 56 in an adjustable yoke arrangement (not shown) or by spring mounting the ends of the roller 6.

In operation, the roller 56 is synchronized with the movement of the drive roller 52 so that in the case of continuous motion the roller 6 rotates at a* predetermined relative speed with respect to the drive roller 53. In the event of an intermittent motion the roller 56 is intermittently driven in an increment sufficient to present a fresh surface of the flexible retarder 5 within the compression cavity C. As shown, the compression cavity extends from the free edge 57 of the primary surface 53 across the respective surfaces of the flexible retarder 54 and drive roller 52 in a decreasing manner.

It is noted that the compression cavity C in all of above described embodiments, assumes a configuration such that at the entry, the cavity is of its largest height and thereafter decreases to the end. Additionally, the passage leading to the compression cavity C is of less height than the entrance of the v cavity. Consequently, the web which is being processed initially enters the cavity C at a predetermined thickness, thereafter is abruptly increased in size due to the added height of the cavity C at the entrance, and is subsequently decreased in height under the influence of the convergence of the cavity C. At the same time, the material is slowed in travel in passing through the cavity due to the increase in frfction and corresponding drag forces on the web from the flexible retarder.

It is further noted that in those embodiments above where the flexible retarder moves across the edges of the primary surface that the corners of the respective primary surfaces can be slightly rounded so as to avoid scoring of the flexible retarder surface during relative movement. It is also noted that in order to avoid any scoring of the flexible retarder by the corners of the primary surfaces that the flexible retarders can be moved in incremental fashion after the pressure between the flexible retarders and primary surfaces is relieved.

The invention thus provides a means of processing a large quantity of material before replacement of the flexible retarder is necessary. Because of this, the down-time of the machinery is considerably reduced so that a much more efficient operation can be carried out than otherwise possible.

The invention also provides a system wherein the flexible retarder can be manipulated to present fresh unworn surfaces to the compression cavity of the machine without reliance upon extraordinary skill on the part of the machine operators. Furthermore, the system can be fully automated so that continuous operation can be carried out.

Claims (1)

1. A machine for mechanically longitudinally compressing a web of material having driving means for receiving and conveying the web; first means for confining the we between said first means and said driving means to a predetermine thickness immediately prior to mechanical compression thereof: a flexible retarder downstream of said first means for confining the web and for slowing the movement of the web between sai flexible retarder and said driving means, said driving means , first means and flexible retarder defining a continuously confined compression cavity. for accumulation and compression of the web therein; and means for moving said flexible retarder relative to said driving means to present fresh surfaces of said flexible retrader to the conveyed web in said compression cavity for compression of the conveyed web. 2ί. A machine as set forth in claim.1 wherein said flexible retarder comprises an elongated strip disposed longitudinally of said driving means, and said means for moving said flexible retarder includes a pair of rotatably mounted rollers mounting the respective ends of said strip thereon in wound-up manner whereby said strip is adapted to be wound from one of said rollers onto the other of said rollers. 3. A machine as set forth in claim 1 wherein said flexible retarder comprises an elongated strip disposed transversely of said driving means, and said means for moving said flexible retarder includes a pair of rotatably mounted rollers mounting the respective ends of said strip thereon in wound-up manner whereby said strip is adapted to be wound from one of 1 4. A machine as set forth in claim 1 wherein said 2 machine furtherincludes a back-up plate disposed over said 3 flexible ret.arder to extend over a portion of the planes of said 4 means for confining the web and said drivin means 9 and a shoe 5 apparatus connected to said back-up plate for imposing a load on β said flexible retarder to deflect said flexible retarder rela¬ 7 tive to said means for confining the web in a direction towards 8 said driving means. 1 5. A machine as set forth in claim 1 wherein said 2 flexible retarder is resiliently deformable . and said first means 3 is pressed into said flexible retarder. 1 6. A machine as set forth in claim 1 wherein said 2 flexible retarder is made of rubber. 1 7. A machine as set forth in claim 1 wherein said 2 flexible retarder comprises an endless belt. 1 . 8. A machine as set forth in claim 7 wherein said 2 means for moving said flexible retarder includes at least a 3 pair of rotatably mounted rollers, said flexible retarder pass4 ing over each of said rollers to be moved thereby. 1 9. A machine as set forth in claim 8 which fur2 ther includes a pressing roller mounted over said flexible re¬ 3 tarder on an opposite side from said driving means for press4 ing said flexible retarder towards said driving means. 10. A machine as set forth in claim 9 which further includes a guideway slidably mounting said pressing roller therein for vertical movement relative to said driving surface said guideway being slidably mounted in said machine for horizontal movement relative to said driving surface to change the size of said compression cavity. 11. A machine as set forth in claim 10 which further includes a weighted roller of larger diameter than said pressing roller mounted over said pressing roller in weighted contact therewith to transmit a load onto said pressing roller 12. A machine as set forth in claim 1 wherein said flexible retarder is a roller- having an endless^ strip mounted the periphery thereof. 13. A machine as set forth in claim 1 wherein said means for moving said flexible retarder is synchronized with said driving means to move said flexible retarder relative to said driving means at a speed less than the speed of said driv ing means during mechanical compression of the conveyed web. A machine 14. as set forth in claim 1 wherein said means for moving said flexible retarder moves said flexible retarder intermittently in predetermined increments during mechanical compression of the > conveyed web. r 1 15.' In combination with a machine for mechanically 2 compressing a travelling web of material within a compression 3 cavity defined by a drive surface on one side, an edge of a 4 first surface spaced from said drive surface to confine the 5 travelling web to' a predetermined thickness prior to entry into 6 said cavity, and a friction surface of a flexible retarder 7 spaced from said drive surface, said friction surface extending 8 from said edge to define a continuous surface opposite said 9 drive surface, said cavity having a greater height therein than 0 the ■ spacing between said first elongated surface and said drive 1 surface adjacent said edge and being of decreasing height down2 stream thereof; means for moving said flexible retarder relative 3 to said drive surface to present different portions of said ' flexible retarder within said compression cavity to form said 5 friction surface for mechanical compression of a travelling 6 web . ' l 16. The combination as set forth in claim 15 vherein 2 said means for moving said flexible retarder moves said flexible 3 retarder longitudinally of said drive surface. 1 17. The combination as set forth in claim 15 wherein 2 said means for moving said flexible retarder moves said flexible 3 retarder transversely . of said drive surface. ■ 1 18. The combination as set forth in claim 15 wherein 2 said flexible retarder is an elongated strip. 1 19. The combination as set forth in claim 15 wherein 20. The combination as set forth in claim 15 wherein said flexible retarder is a sleeve and said means for moving said flexible retarder includes a rotatably mounted roller mount ing said sleeve around the periphery thereof. 21. The combination as set forth in claim 15 wherein said flexible retarder is resiliently deformable. 22 . The combination as set forth in claim 15 wherein said means moves said flexible retarder continuously relative to said drive surface during mechanical compression of a travelling web. 23. The combination as set forth- in claim 1 wherein said means moves said flexible retarder intermittently in predetermined increments relative to said drive _surface during mechanical compression of a travelling web. 24. The combination as set forth in claim 15 wherein said means moves said flexible retarder at a speed reduction of about 50 : 1 with respect to said drive surface. 25. A process for mechanically compacting a material of predetermined thickness including the steps of driving a length of the material under a driving force while confining the material to maintain the predetermined thickness and substantial! undistorted state of the material thereafter driving the length of material under said driving force into an accumulation cavity 7 having a first clearance therein greater than the predetermined 8 thickness of the material and an outlet of a second clearance 9 less than said first clearance; fractionally engaging the ma10 terial being advanced through the accumulation cavity on one 11 side of the material with a surface of a flexible retarder 12 throughout the . accumulation cavity to impose a friction force 13 thereon in a direction substantially opposite to the direction .14 in- which- the material is advanced for slowing the forward move¬ 15· ment of the material while simultaneously supporting- the material ιβ on the opposite side on a. moving member throughout the accumula17 tion cavity to increase the thickness of the -material within the 18 cavity and to accumulate and compress the material longitudin¬ 19 ally within the cavity as the material is advanced through the 20 cavity; and moving the flexible retarder relative to the moving 21 member at a speed less than the speed of the driving means dur22 ing mechanical compaction of the web to present fresh surfaces 23 thereof to the drive material. 26. A process as set forth in claim 25 wherein the flexible retarder is moved through an endless path. 27. A process as set forth in claim 25 wherein the flexible retarder is moved at a speed ratio of about 1 : 50 1 28. A process as set forth in claim 25 wherein the 2 flexible retarder is moved continuously during movement of said 3 moving member. 1 29. A process as set forth in claim 25 wherein the 2 flexible retarder is moved intermittently during movement of 3 said moving member. 1 30. In a process of mechanically compacting a material 2 of predetermined thickness which comprises driving the material 3 into an accumulation cavity having an inlet of a predetermined 4 clearance greater than the predetermined thickness of the ' 5 material and an outlet of a predetermined clearance less than 6 the predetermined clearance of the inlet and- while simultane¬ ,7 ously supporting the material on one side of a moving member 8 throughout the accumulation cavity5 frictionally engaging the 9 material on the opposite side with a surface of a flexible re10 tarder throughout the accumulation cavity to impose a friction 11 force thereon opposite to the direction in which the material 12 is driven for slowing the forward movement of the material to 13 increase the thickness of the material and to accumulate and 14 longitudinally compress the material within the accumulation 15 cavity as the material is driven through the cavity, and pre16 venting the accumulated material from backing up out of the 17 accumulation cavity; the step of moving the flexible retarder 18·,· during movement of the moving member to present fresh surfaces 19 of the flexible retarder to the web during compaction of the web. I . 31. A machine aa set forth in Claim 1 furthe characterized in that said elongated surface is pressed into said flexible retarder. EHArOB