MXPA05014159A - Spiral wound tubes, method and apparatus for forming the same - Google Patents

Abstract

Spiral wound tubes (20) may be formed utilizing the method and apparatuses (100) described herein. The method includes providing a mandrel (110) and a web material (10) having a first overlap region (14) and a second overlap region (18). A binding agent (30) is applied to at least one of the overlap regions. The mandrel (110) is wrapped with the web material (10) such that the second overlap region (18) covers the first overlap region (14) of the previously wound web and the binding agent (30) is disposed between the previously wound first overlap region and the currently wound second overlap region. The spiral wound tubes (20) of the invention demonstrate improved axial crush resistance.

Description

PIPES ROLLED IN SPIRAL. METHOD AND APPARATUS TO FORM THEMSELVES REFERRAL TO A RELATED APPLICATION This application is a continuation in part of the US patent application. no. 10 / 610,044 filed on June 30, 2003.

FIELD OF THE INVENTION This invention relates to spirally wound tubes. More particularly, it relates to single-leaf spiral wound tubes, and to methods and apparatus for winding the tubes.

BACKGROUND OF THE INVENTION Spirally wound tubes are well known. Weft materials, such as aluminum foil, tissue paper, hard grades of paper and the like, are supplied to consumers rolled into spirally wound paper tubes. The typical spiral wound tubes are composed of at least two sheets of paper web. The outer sheet is completely superimposed on the inner sheet and a layer of binder agent is placed between the outer and inner layers. These tubes comprise fully superposed sheets, which is why the outer circumferential surface of the tubes is generally smooth. A tube comprising a single sheet of weft material requires less Weft material and less binder to form the tube. Less equipment is needed since only one roll of weft material is provided at a time. For the same reason, less time is spent changing the rolls of raster material.

BRIEF DESCRIPTION OF THE INVENTION Spirally wound tubes comprising a single sheet of paper weft material can be formed by the method and apparatus described herein. In one embodiment, the method comprises the steps of providing a mandrel and a single sheet of weft material. The weft material comprises an outer surface having a first region, and an inner surface, opposite the outer surface having a second region. A binding agent is applied to at least one of the first region and the second region. The weft material is wound around the mandrel The first region of the previously wound weft is covered with the second region of the weft currently wound. The binder is placed between the first region of the previously coiled web and the second region of the currently coiled web and joins the successive coils of web one to the next. In one embodiment the apparatus comprises a mandrel, a binder agent applicator, and a binder container attached to the applicator. In another embodiment, the apparatus further comprises a binder pump and a binder duct coupling the outlet of the pump and the applicator.

BRIEF DESCRIPTION OF THE FIGURES Figure 1a is a side schematic view of the compliance apparatus with an embodiment of the invention. Figure 1b is a schematic side view of the opposite side of the embodiment of the invention illustrated in Figure 1a. Figure 2 is a cross-sectional view of a spiral wound tube according to the method of the invention. Figure 3 is a side schematic view of a second embodiment of the apparatus of the invention. All test methods and patents cited in the detailed description of the invention are hereby incorporated by reference.

DETAILED DESCRIPTION OF THE INVENTION As illustrated in Figure 1a and Figure 1b, the weft material 10 is supplied to a winding apparatus 100 at an angle A. The weft material 10 is supplied from a matrix roll and the length of the weft material 10 is substantially greater than the width or thickness of the material. The thickness of the weft material across its width may be uniform or may vary due to the method used to manufacture the weft material 10. The weft material 10 has a first surface 12 that forms the outer surface 22 of the rolled tube 20. The first surface 12 has a first overlap region 14 adjacent a first lateral edge 15 of the weft material 10. The weft material 10 has a second surface 16 that forms the anterior surface 26 of the rolled tube 20. The second surface 16 has a second overlap region 18 adjacent a second side edge 19 of the weft material 10. In accordance with Figure 1a the weft material 10 is sent proximally to an applicator 200. A binding agent 30 is applied to the weft material 10. from the applicator 200. In the embodiment illustrated in Figure 1a, the binding agent 30 is applied to the first overlap region 1 4 of the weft material 1 0. In another embodiment, the binding agent 30 can be applied to the second overlay region. overlap 18 of the weft material 10. In yet another embodiment, illustrated in Figure 3, the binder 30 can be applied to both the first overlap region 14 by means of a first applicator 200 and the second overlap region 18 by means of a second applicator 300. In this embodiment, a single-component binder can be applied to both the second overlap region 18 and the first overlap region 14. Alternatively, a first component of a two-part binder system can applied to the first overlap region 14 by means of a first applicator 200 and a second component of a two-component binder system can be applied to the first Overlap region by means of a second applicator 300. The binder may comprise a single-component adhesive, a multi-component adhesive, a single-component coherent, or a multi-component coherent. An illustrative binder is Resyn ™ 32-1357, available from National Starch and Chemical, Bridgewater, NJ. The applicator 200 may comprise a slot extruder. The slot extruder comprises a pair of opposed plates spaced a predetermined distance by a spacer or set of spacers. A space is cut in the spacer or set of spacers so that a slot as wide as space and as long as the thickness of the spacer (s) is present between the opposing plates. The binder 30 is placed on the weft material 10 from the groove. The weft material 10 can be sent to contact the slot extruder so that the deposited binder film is maintained at a desired thickness of the film and so that a layer of binder of generally uniform thickness is deposited on the weft. 10 In another embodiment the slot extruder comprises a groove worked on a plate and does not include spacers. In any of the embodiments the size of the groove must be adequate to allow the application of sufficient adhesive to the core material while maintaining the application of a thin film of adhesive. As shown in Figure 3, a binder conduit 210 can connect the slot extruder to the outlet of a binder pump 220. The inlet of the binder pump 220 is positioned to receive the binder from the receptacle of binder 240. In another embodiment, the slot extruder may be incorporated within a lower portion of a binder container. Then the binder continues from the slot extruder under the influence of gravity. The applicator 200 applies a thin film of binder to the weft material 10. The width of the film may correspond to the width of the overlap region to which the binder agent is applied. In another embodiment, the width of the binder film 30 may be less than the width of the overlap region, to allow some extension of the binder film 30 after application and before the final binding of the binding agent. In another embodiment, the width of the film may be wider than the width of the overlap region. The additional binder 30 is placed along the seam on the outer surface of the tube 20. The presence of the additional binder 30 can reduce the possibility of the tube 20 separating into sheets at the seam if the tube 20 is cut off. in different lengths. The width of the binder film 30 can have a width that is from about 0.76 to about 3.17 mm (about 0.03 to about 0.125 inches) wider than the overlap region. If the width of the film is excessively wider than the width of the overlap region, they can be created hygiene problems in the rolling machine. As illustrated in Figure 1a and Figure 1b, the weft material 10 is sent from the binder applicator 200 to the mandrel 110. The weft material 10 is wound around the mandrel 110. The first overlap region of a previous winding can be covered by the second overlap region of the next successive winding. The previous winding and the successive winding respectively refer to sequential windings of 360 ° of the mandrel, by the weft material 10. A new winding can start after a winding of 360 ° as the weft material 10 begins to overlap the winding. Previous rolled up The width of the weft, the tension of the weft and the angle of the winding each can have an effect on the degree of overlap of the weft. The concept of a coiled spiral core can be based on the equations of a helix. The helical equation produces a geometry that will produce the ideal spiral given a specific mandrel diameter and frame width. This geometry ignores the thickness of the frame 10 and assumes that the edges of the frame 10 limit perfectly to the top. Each element of the width of the weft 10 travels the same distance around the mandrel. This results in equal tension across the width of the weft 10. Theoretically, the single-ply cores maintain the same geometry as they add to the width of the weft 10. The additional width 10"overlaps" creating the overlap closure that produces the core of a single leaf. Since the frame 10 overlaps itself, the leading edge must travel an additional distance of one revolution, equal to twice the thickness of the frame 10. Since the frame 10 is basically inelastic, the edge of the frame 10 which normally the shortest distance is displaced, try to compensate by moving a distance equal to the other edge. This can produce a "bubble" where the two edges meet. The bubble can be compressed under the winding band, and can be seen throughout the length of the finished core (trunk) as a wrinkle. To compensate for this phenomenon, additional tension (resistance) can be added to the weft 10 before winding. This tension can stretch the weft 10, by plasting it as soon as it is wound up. L ating (measured at the end of the rolling winding) applied to the weft 10 may be in the range of about 8 N / cm to about 27 N / cm of the width of the weft 10 (between about 5 to about 15.5 lbs. per inch). A two-leaf winding process can apply a weft tension in the range of about 4 N / cm to about 27 N / cm of the width of weft 10 (between about 2.5 to about 6 pounds per inch of weft width) 10). As the speed of the core furler changes by means of changes in the speed of the winding band, the tension of the core web 10 may change. This can result in a small change in the amount of overlap in the core. As speed increases, tension may increase and overlap may decrease. As the speed decreases, the tension of the frame 10 may decrease and the overlap may increase to the limit of the helical equation. The typical overlap is approximately 9.5 mm (0.375 inches), and may increase or decrease depending on the helical equation of the width of the weft 10 and the winding angle. During a change of speed and at different speeds the tension of the frame 10 can affect the amount of overlap. A small change in overlap of only 0.254 mm (0.01 inches) will result in a change in core length of 6.35 mm (0.25 inches) for each of the 25 overlaps in the coiled core. To produce a consistent core length the tension of the frame 10 must be substantially constant. A controlled tension of the weft 10 can produce a consistent core strength and a consistent core length with a single-leaf core process with variable speeds and splicing of the plot 10. Several different methods can be used to produce and control the tension. In one embodiment a device for measuring the voltage (i.e., load cell) with a feedback loop can control a roller driven by a servo motor, a pair of rollers or grip point, a simple pneumatic brake, or an electromagnetic brake. particles. In another embodiment the tension can be provided by sending the frame 10 around a set of static friction bars. The mandrel 110 may be stationary, or the mandrel 110 may be able to rotate around the spindle of the bearing hub and bearing and the bearing cushions. A rotating mandrel 110 can rotate freely or can be actuated. The driven mandrel 110 can be driven directly by a motor integrated in the mandrel or it can be directly coupled to a motor. The mandrel can be driven indirectly through the use of bands, chains, or gears, as is known in the industry. The driven mandrel 110 can be operated by means of a variable speed transmission system. The speed of the mandrel 110 can be varied according to the speed of the weft material 10 by being wound around the mandrel 110. The surface of the driven mandrel can be a low friction or high friction surface. A high friction surface may comprise a knurled surface or a surface coated with a high friction material, or the mandrel may be composed of a high friction material. A low friction surface can be used to reduce heat build-up caused by sliding of the weft material 10 beyond the surface of the mandrel. A low friction surface can be achieved by the use of a low friction material in the manufacture of the mandrel 110 or by means of the coating of the mandrel 110 with a low friction material. The winding of the weft material 10 around the mandrel 110 can achieved by any means known in the industry. In one embodiment, the weft material 10 can be wound by imparting an appropriate torque to the weft material 10 by hand, or hands, or a human being. In an alternative embodiment, the torque can be imparted to the weft material 10 through the use of a web, or a plurality of webs, as these methods are known in the industry. The high-friction mandrel described above can be used to drive the weft material 10 during the winding of the tube 20. The weft material 10 is wound around the mandrel 110 to produce a tube 20 having consistent dimensions. Wax can be applied to at least a portion of the inner surface of the weft material 10 to reduce the friction between the weft material and the mandrel during the high speed wrapping operations. An illustrative wax is Cerelube ™, available from Stevenson-Cooper, Inc., Philadelphia, PA. The wax can be applied by contacting a block of wax with the frame in motion. In another embodiment, silicone can be applied to a portion of the inner surface of the weft or the mandrel. An illustrative silicone is Masil ™ SF 500, available from P PG I ndustries, Pittsburg, PA. Figure 2 illustrates the cross sectional side section of a portion of a tube 20 manufactured in accordance with the present invention. Figure 2 shows a previous winding superimposed by a subsequent winding b. The binder 30 is placed between the first overlap region 14 of an anterior winding and the second overlap region 18 of a subsequent winding b. The winding core or tube 20 can be cut to the desired length using a mechanical core cutter (not shown) or a "servo cutter" rotary cutter (not shown). As an alternative, the winding core 20 can be wound up until the supply of weft material 10 is exhausted.

The nucleus or the core servo rotary cutter can traverse a path parallel to the apron while carrying the cutting blade in contact with the tube 20. The mechanical cutter comprises a razor blade and the blade freely rotates about a central axis. The "servo" rotary cutter comprises a drive motor for actively rotating the cutting blade against the tube 20. Both the mechanical cutter and the "servo" cutter are known in the industry. An optional aspect of the method and apparatus of the invention comprises the treatment of the weft material before winding the weft material 10 around the mandrel 110 to increase the flexibility of the weft material 10. The weft material 10 may be wetted by means of a misting water or applying steam to the weft material. The mist of water or steam can be applied to the weft material 10 through the use of an adapted spray nozzle to handle water or steam. The flexibility of the weft material 10 can also be increased by the application of a softening agent to the weft material 10. Applicants have discovered that the axial crushing strength of the single-ply tubes of the present invention is greater than the resistance to axial crushing of tubes of two sheets of similar diameter. Tubes comprising a single sheet of 22.5 g / 100 m2 (46 lb./1000 sq. Ft.) Cardboard demonstrate an increase of more than 20% in the resistance to axial crushing compared to tubes comprising two sheets of fibreboard. 12.7 kg / 100 m2 (26 pounds / 1000 square feet). The tubes were tested using the axial crushing test of the CT-107 end of Composite Can and Tube Institute (CCTI). A factor of axial crushing strength can be calculated by dividing the results of the CT-107 test by the basis weight of the carton of the tube in kg / 92 m2 (pounds / 1000 square feet). For the single-ply tubes of the invention, the axial crushing resistance factor has an average value of 0.46. The resistance factor to the Axial crushing for the tubes that comprise two sheets of cardboard of 11.8 kg / 92 square meters (26 pounds / 1000 square feet) averaged 0.33. The following method of the invention is described by means of the following non-limiting examples.

Example 1: A single sheet of kraft paper of 22.5 kg / 100 m2 (46 pounds / 1000 square feet), from 9,842 cm (3-7 / 8 inches) wide to approximately 5334 m (17,500 feet) approximately in length is supplied in a roll of 1,524 m (60 inches) approximately in diameter. The roll is unwound and fed to a core winding mandrel. A code is printed on the bottom surface of the paper. The paper rotates a coder wheel and the paper speed is determined and transmitted to a programmable logic controller (CLP). Wax is applied to the underside of paper and Resyn ™ 32-1357 adhesive from National Starch and Chemical, to the first overlap region of the paper. The paper is captured between the surface of a driven strip and the outer surface of the mandrel and wrapped around the mandrel. The paper is wound at an angle A so that the second overlap region of the paper overlaps the first overlap region of the previous winding by about 9.52 mm (0.375 inches). Therefore, the adhesive is placed between the first overlap region and the second overlap region of the paper. The adhesive is applied using an ITW tape coating nozzle Dynatec Ribbon-coater, model no. 106945 A2 V2, which has a slot size of 9.52 X 0.38 mm (0.375 X 0.015 inch). This nozzle is mounted on an ITW Dynatec Mod Plus glue gun, model no. BF0441 BD2S. The adhesive is supplied to the glue gun from a tank of hot melt material, ITW Dynatec Model no. S05, by means of a glue hose ITW Dynatec Model no. 06X12, 20-24, HD / A, DO The hot melt tank, glue hose and glue gun all heat at a temperature between 40.5-43.3 ° C (105 ° F and 110 ° F) . All of the aforementioned components are available from Hendersonville, TN, USA. The tubes were manufactured on a core winding device of Model no. CM-12 from Paper Converting Machine Company, available from Paper Converting Machine Company of Green Bay, Wl, USA. The tubes were cut to a length using a core cutter model number ECM-14 from Paper Converting Machines.

Example 2: A single sheet of kraft paper of 22.5 kg / 100 m2 (46 pounds / 1000 square feet), 9,842 cm (3-7 / 8 inches) wide and approximately 5334 m (17,500 feet) approximately long is supplied on a roll of 1524 m (60 inches) to approximately one meter. The roll is unwound and fed to a core winding mandrel. A code is printed on the bottom surface of the paper. The paper rotates a coder wheel and the paper speed is determined and transmitted to a programmable logic controller (CLP). Tension is applied to the weft before winding mandrel using S-shaped static wrapping. Wax is applied to the bottom surface of paper and Resyn ™ 32-1357 adhesive from N ational Starch to nd C hemical, to the first overlap region of the paper. The paper is captured between the surface of a driven strip and the outer surface of the mandrel and wrapped around the mandrel. The paper is wound up at an angle A to m ain that the second overlapping region of the paper overlaps the first overlap region of the previous winding by about 9.52 mm (0.375 inches). Therefore, the adhesive is placed between the first overlap region and the second paper overlap region. The adhesive is applied using a ribbon coating nozzle ITW Dynatec Ribbon-coater, model no. 106945 A2 V2, which has a slot size of 9.52 X 0.38 mm (0.375 X 0.015 inch). This nozzle is mounted on an ITW Dynatec Mod Plus glue gun, model no. BF0441 BD2S. The adhesive is supplied to the glue gun from a tank of hot melt material, ITW Dynatec Model no. S05, by means of a glue hose ITW Dynatec Model no. 06X12, 20-24, HD / A, DC. The hot melt tank, the glue hose and the glue gun are all heated to a temperature between (40.5 ^ 13.3 ° C) (105 ° F and 110 ° F). All the components described above are available from ITW Dynatec of Hendersonville, TN, USA. The tubes were manufactured on a core winding device of Model no. CM-2 of Paper Converting Machine Company, available from Paper Converting Machine Company of Green Bay, Wl, USA. The tubes were cut to a length using a core cutter model number ECM-14 from Paper Converting Machines Although particular embodiments of the present invention have been illustrated and described, it will be apparent to those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the invention. It has been intended, therefore, to cover in the appended claims all changes and modifications that are within the scope of the invention.

Claims (7)

1. A method for winding a spiral tube; the method comprises the steps of a) providing a mandrel, b) providing a frame comprising a first region of overlap, and a second region of overlap, c) applying a layer of binding agent to at least one overlap region, d ) winding the mandrel with the weft, characterized in that the binder is placed between the second overlap region and the first overlap region.

2. The method according to claim 1, further characterized in that the step of applying a layer of binder to at least one overlap region further comprises extruding the binder agent over the overlap region.

3. The method according to claim 1, characterized in that it further comprises a step of heating the binder.

4. The method according to claim 1, further characterized in that the step of applying a binder layer to at least one overlap region comprises applying a binder layer to the second overlap region.

The method according to claim 1, further characterized in that the step of applying a layer of binder to at least one overlap region comprises applying a layer of binder to the first overlap region.

6. An apparatus for winding a single-leaf spiral wound tube; characterized the apparatus because it comprises: a) A mandrel capable of receiving a weave to be wound, b) a binder receptacle for supplying a binder, c) a slot extruder in fluid communication with the binder receptacle and capable of supplying the binder to the web associated with the mandrel.

7. A spiral wound tube comprising: a) A single sheet of weft material; the weft material comprises a second overlap region, and a first overlap region; characterized in that the weft material is placed around a circular cross section along the lateral axis, wherein the second overlap region overlaps the first overlap region b) a thin film of a binder is placed between the second overlap region and the first overlap region.