US3853279A

US3853279A - Method and apparatus for forming lightweight web material into a coreless roll

Info

Publication number: US3853279A
Application number: US00334844A
Authority: US
Inventors: D Gerstein
Original assignee: Individual
Current assignee: Individual
Priority date: 1971-12-23
Filing date: 1973-02-22
Publication date: 1974-12-10
Anticipated expiration: 1991-12-10

Abstract

A method and apparatus for winding very lightweight web material e.g., paper, tissue and the like into coreless rolls which comprises the feeding of one or more continuous webs of the web material into juxtaposition whereby the juxtapositioned webs are transversely perforated or scored at spaced intervals to define easy tear lines and longitudinally split to sever the respective webs into a plurality of distinct lengths of connected sheets. The web thus scored and split is then fed along a feed path so that the juxtapositioned webs are separated and thereafter wound into coreless rolls on a winding mandril. The winding of the web material about the winding mandril is effected by securing the free end of the web to the winding mandril and thereafter rotating the mandril as the web is being fed. The web is wound into a roll about the mandril to a predetermined thickness and is then broken away from the continuous web along the adjacent score line as the material rolled about the mandril is removed. Thereafter the mandril is removed from the material roller thereon thus rendering the rolled material coreless. It is also contemplated that the web material after being slit and prior to winding on the mandril may be guided through a folding gauge in which the severed lengths are folded with one or more longitudinal folds prior to winding into a roll upon the mandril.

Description

United States Patent [191 Gerstein [4 1 Dec. 10, 1974 [76] Inventor: David E Qerstein, 63-33 98th Forest Hills, NY. 11374 [22] Filed: Feb. 22, 1973 [21] Appl. No.: 334,844

Related US. Application Data [63] Continuation-impart of Se'r. No. 211,319, Dec. 23,

[52] US. Cl 242/56.2, 242/56 A, 242/74 [51] Int. Cl B65h 35/02 [58] Field of Search 242/74, 56 A, 56.2, 56.6,

[56] References Cited UNlTED STATES PATENTS 2,237,759 4/1941 Kwitek 242/56.6

2,366,999 1/1945 Campbell 242/56.6

2,575,631 11/1951 Link 242/74 2,585,226 2/1952 Christman,.. 242/74 X 2,712,933 7/1955 Davidson 270/86 Primary Examiner-John W. Huckert Assistant ExaminerEdward J. McCarthy 57 ABSTRACT A method and apparatus for winding very lightweight web material e.g., paper, tissue and the like into coreless rolls which comprises the feeding of one or more continuous webs of the web material into juxtaposition whereby the juxtapositioned webs are transversely perforated or scored at spaced intervals to define easy tear lines and longitudinally split to sever the respective webs into a plurality of distinct lengths of connected sheets. The web thus scored and split is then fed along a feed path so that the juxtapositioned webs are separated and thereafter wound into coreless rolls on a winding mandril. The winding of the web material about the winding mandril is effected by securing the free end of the web to the winding mandril and thereafter rotating the mandril as the web is being fed. The web is wound into a roll about the mandril to a predetermined thickness and is then broken away from the continuous web along the adjacent score line as the material rolled about the mandril is removed. Thereafter the mandril is removed from the material roller thereon thus rendering the rolled material coreless. It is also contemplated that the web material after being slit and prior to winding on the mandril may be guided through a folding gauge in which the severed lengths are folded with one or more longitudinal folds prior to winding into a roll upon the mandril.

13 Claims, 21 Drawing Figures W V a 5 60 I gig),

PATENTEQ :za 1 01974 saw, our 11 m wt SEE I 0 I374 mama;

saw on or 11 FIG-5 PATENI EEC 1 01974 sum 05 0F 11 mm 1 m sum 070F11 FIG. 13 1 FIG. I7

FIG. 1e

' FIG. 15

PATENIEB DEC 1 01974 Mn as ur n VNN nmw mm kDN PATENTEUCEC 3.853.273-

' sum 11 or 11 0 METHOD AND APPARATUS FOR FORMING LIGHTWEIGHT WEB MATERIAL INTO A CORELESS ROLL RELATED APPLICATION This application constitutesa continuation-in-part application of my co-pending application Ser. No. 211,319 filed Dec. 23, 1971 for Device for Forming Lightweight Paper Into Rolls Without Any Cores.

FIELD OF THE INVENTION This invention relates in general to a method and apparatus for rolling web material, e.g., tissue, into a series of small size rolls of connected sheets so as to be free of any core, and which sheets may or may not be folded prior to winding into a roll.

PROBLEM AND PRIOR ART At the present time, there are known devices for perforating and/or slitting web material and to form such material into individual rolls onto cores as evidenced by US. Pat. No. 2,328,109 and US. Pat. No. 3,096,039. Other paper winding machines are also known, e.g., those disclosed in US. Pat. Nos. 2,736,508 and 2,237,759. However each of the known devices operated on a single web of material only in forming the web into a series of rolls, generally about a core. The core generally consisted of a fiberboard material which did not interfere with the use of the rolled material thereon. For certain present day applications, it is highly desirable that the tissue or webmaterial be wound without a core. Also it is required that such coreless rolls be wound quickly and expediently with the minimum of lost time and effort so as to enhance maximum efficiency and economy in the manufacture of such coreless rolls. In certain applications it is also highly desirable that the material wound into coreless rolls be longitudinally folded prior to winding to define a multi-layer sheet wound in a coreless roll.

OBJECTS An object of this invention is to provide a method and apparatus for effectively and economically winding one or more webs of sheet material into coreless rolls of connected sheets, connected into end to end relationship about an easy tear line.

Another object is to provide a method and apparatus for effecting scoring and splitting a plurality of juxtaposed webs and thereafter individually rolling such webs into a plurality of coreless rolls about a winding mandril.

Another object is to provide an apparatus for effectively winding coreless rolls about a mandril in a manner whereby the coreless rolls can be readily removed from the apparatus and the mandril.

Another object is to provide a method and apparatus for winding coreless rolls of folded web material.

Another object is to provide a method and apparatus for effecting the scoring, splitting and folding of a sheet of web material prior to effecting the winding of such material into a coreless roll.

SUMMARY OF THE INVENTION In accordance with this invention there is provided a method and apparatus which is capable of feeding very lightweight tissue into association with means for perforating it and for slitting it into individual lengths; and for rolling each length into a coreless roll of predetermined thickness. This is attained by feeding the individ ual lengths into association with a mandril. The web is initially secured to the mandril either by wetting the free end of the web causing it to adhere to the mandril, or by drawing a negative pressure or vacuum on the mandril to adhere the web material thereto. After winding the rolled material is severed from the remaining length of tissue or web in one embodiment by moving a fiat board upwardly through the path of movement of the tissue or web to sever it along a perforated line. In another embodiment the rolled material may be severed from the web for securing the web adjacent the rolls between a pair of nip rollers which close in engagement with the web as the rolled material is removed.

The present invention further contemplates that a plurality of web material eminating from a plurality of supply rolls is fed into juxtaposition, i.e., in superposed relationship whereby the respective webs are simultaneously scored and slit and thereafter separated so that the slit lengths of the respective webs are separately wound into coreless rolls. The rolls of material wound about the mandril are subsequently removed from the mandril. In another embodiment of the invention the web material after slitting is directed through individual folding gauges to effect the folding of the slit length into one or more longitudinally extending folds prior to winding the slit and folded lengths into coreless rolls about the mandril.

FEATURES A feature of this invention resides in the provision of a method and apparatus for forming coreless rolls of lightweight material, e.g., tissue which has been perforated and slit to define lengths of individual sheets connected into end to end relationship about an easy tear line.

Another feature resides in the provision of a method and-apparatus for winding very lightweight web material which includes the feeding of a plurality of webs into juxtaposition and then simultaneously perforating and slitting the respective webs, and thereafter effecting a separating of the respective webs for subsequent winding'of the slit lengths without a core directly onto a winding mandril.

Another feature resides in the provision of a winding apparatus for winding coreless rolls in which a vacuum mandril is provided for initiating the winding of the coreless roll onto the mandril.

Another feature resides in the provision of effecting longitudinal folds in the lengths of the slit webs prior to effecting the winding of the folded material into a coreless roll.

Another feature resides in the provision of a coreless roll winding machine which is relatively simple in operation, rugged in construction, and which greatly enhances the production of coreless rolls.

Other features and advantages will become more readily apparent when considered in view of the specification and drawings in which:

FIG. 1 is a top plan view of a device for winding lightweight papers into rolls without cores constructed in accordance with the invention.

FIG. 2 is a schematic elevational view indicating the drive mechanism forthe device shown in FIG. I.

FIG. 3 is a schematic side elevational view showing the manner in which the paper webs are fed in the device shown in FIG. 1.

FIG. 4 is an enlarged axial sectional view of a slitting mechanism.

FIG. 5 is an enlarged sectional view of the perforating mechanism.

FIG. 6 is a partial elevational view of the perforating blade used for the perforation mechanism.

FIG. 7 is a partial perspective view of the winding mandril and sheet wetting mechanism.

FIG. 8 is a view similar to FIG. 7 indicating the parts in the position at the end of the winding of one complete roll of tissue on the mandril.

FIG. 9 is a partial sectional view showing the breaking of the tissue along the perforation line.

FIG. 10 is a view similar toFIG. 9 indicating the manner in which the tissue is wrapped around the finished roll.

FIG. 11 is a partial top plan view indicating the manner in which the mandril may be swung out of an operating position for the removal of the wound tissue therefrom.

FIG. 12 is a perspective view of a complete assembly of wound rolls which have been removed from the mandril.

FIG. 13 is a partial top plan view indicating the folding gauges for folding the tissue prior to winding.

FIG. 14 is a side elevational view of the mechanism shown in FIG. 13.

FIG. I5 is a section taken along the line l5-l5 on FIG. 14.

FIGS. I6 and I7 are views similar to FIG. 15 of other embodiments of the invention.

FIG. 18 is I side elevation view of the take-off section of a modified embodiment of the invention.

FIG. 19 is a fragmentary front end view of FIG. 18.

FIG. 20 is a detailed front end view of one end of the mandril mounting of the modified embodiment of FIG. 18.

FIG. 21 is a diagrammatical showing of a modified embodiment of the invention.

DETAILED DESCRIPTION This invention is directed to a method of winding coreless rolls of lightweight material, e.g., paper or tissue, in which each roll is formed of a continuous piece of material defining a plurality of connected sheets joined together in an end to end relationship by a perforated or scored line. The coreless roll of such sheet material is preferably formed by withdrawing one or more webs from corresponding sources of web supply and feeding the respective webs into juxtaposition with respect to one anotherfThat-is, two or more webs are fed from their respective sources to overlie one another. The respective webs so juxtapositioned are then fed relative to a perforation means whereby transversely spaced score lines or perforations are formed simultaneously in the juxtaposed sheets or web. Thereafter the web material, while still in juxtaposed position, is fed past slitting means whereby the juxtaposed sheets are simultaneously split into a plurality of distinct widths.

Upon slitting, the respective juxtapositioned sheets are separated with the separated, scored and severed.

webs being fed along a separate and distinct feed path.

The respective lengths of each web are then wound about a mandril without cores; the number of mandrils being wound corresponding to the number of webs being initially withdrawn from their respective sources of supply.

After a predetermined number of windings the rolls of material formed about the mandril are removed by severing the rolls from the remainder of its associated web material along the adjacent score line nearest the rolls or bycutting at any point across the width of the web.

In accordance with this invention the free end of the respective lengths of a given perforated and slit web is initially secured to the mandril for effecting the wind ing operation either by wetting the free end of the web material to adhere to the mandril, or by providing a perforated mandril and drawing a vacuum or negative pressure on the mandril to adhere the web thereto during the initiation of the winding of the web about the mandril.

If desired the respective lengths of the perforated and slit web may be longitudinally folded along one or more longitudinally extending fold lines prior to effecting the winding of the respective lengths of the slit web into coreless rolls about the mandril. This is attained by passing the respective split lengths of a given web through a folding gauge prior to-winding. By interposing the folding step in advance of'the winding operation a coreless roll of folded sheet can be attained.

FIGS. 1 to 12 illustrate one embodiment of an apparatus by'which the foregoing method may be positively preformed. The apparatus A comprises means 24 for perforating, a means 44 for slitting, and a means 60 and 62 for winding one or more webs of lightweight sheet material, e.g., paper or tissue, into a roll without a core, and having means for effecting the separation of the wound coreless rolls from the remaining web material.

As shown in FIG. 3, preferably two light weight webs v or sheets, as for example, paper or

tissue sheets

10 and 12, each being drawn from its own respective source of supply, as for example a supply roll, are fed over respective dancer rolls l4 and 16. The respective webs l0 and 12 are fed onto a feed roll 18 and in doing so are moved into overlying, juxtaposition with respect to one another. One of the webs, as for example, web 12 is guided onto the feed roller 18 by a guide roller 20. The combined or juxtapositioned webs l0 and 12 are then fed between the nip of the feed roller 18 and an associated complementary counter-roller 22. Upon being fed through the nip of feed roller 18 and counter-roller 22, the juxtapositioned webs l0 and 12 are fed to the perforating means which is generally designated 24.

The perforating means 24 includes a rotatable perforator block 26 and an associated resilient counterroller 28 which receives the perforating projections 32 of the perforating blade 34 as the perforator block 26 and counter-roller 28 rotate relative to each other. (See FIGS. 3 and 6.) The perforating blade 34 includes a series of projections 32 spaced along the length of blade 34; the projections being separated by recesses 36 which are located at the areas in which the tissue is not perforated. The blade 34 is carried in a recess 38 formed in the rotatable block 26, and it is held in an adjusted position therein by means of a set screw 40, as best seen in FIG. 6.

The arrangement is such that the juxtapositioned webs l0 and 12 in being fed between the rotating perforator block 26 and the associated counter-roller 28 are simultaneously formed with a transversely extending perforated or scored line at spaced intervals along the length of the juxtapositioned webs, l0 and 12.

After the webs l0 and 12 in their combined or juxtapositioned arrangement, as designated by 42 in FIG. 3, are passed through the perforating means 24 they are advanced or fed into associationwith slitter means 44.

The slitter means 44 comprises a plurality of spaced cutting discs 50 journalled about a slitter shaft 52 which rotates relative to a complementary slitting roller 48. Accordingly the juxtapositioned webs, designated as 42, are fed past the cutting disc 50 by being fed over roller 48 after being fed through the nip of roller 48 and an associated nip roller 46 which are respectively journalled to shafts 56 and 54. The juxtapositioned webs 42, upon being slit into a plurality of severed lengths by the cutting discs 50, are fed through the nip of web separating rollers generally designated by 58 in FIG. 3.

The separating rollers 58 include a top roller 57 and a complementary counter rotating lower roller 59. The combined webs 42 upon being fed through the nip of

rollers

57 and 59 are thereafter separated, as best seen in FIG. 3.

As shown in FIG. 3, perforated and severed webs passing beyond

rollers

57 and 59 are generally indicated by and 12'.

The respective webs I0 and I2. which have been slit longitudinally and perforated transversely at spaced intervals are advanced so as to be wound upon associated mandril 60 and 62, respectively, to form thereon coreless rolls 64 and 66. The arrangement is such that after a predetermined length of the web material has been wound on the'respective mandrils, the respective rolls so formed are separated from the remaining portion of their associated webs I0 and 12' along the adjacent perforated scored line in preparation to effecting the removal of the rolled material.

The winding operation of the severed webs begins, as shown in FIG. 7, by securing the free end 72 of the severed and perforated webs to the mandril, e.g., 60. In the embodiment of FIGS. 1 to 12, this is attained as seen in FIG. 7 by means of a wetting arm 76 which is movably mounted adjacent the mandril 60 for movement toward and away from the mandril 60. Secured to arm 76 is a longitudinally extending sponge rubber or absorbent type material 74 which is saturated with water. To secure the free end 72 of the severed web to the associated mandril, e.g., 60, the arm 76 is moved into juxtaposition to the mandril to grip the free end 72 of the material or web between the wetting sponge 74 and the mandril 60. In doing so the web is sufficiently wetted so as to adhere to the periphery of the roller. Accordingly, when the mandril 60 is rotated, the material secured thereto by wetting is caused to wind thereon. With a predetermined thickness of web material wound or rolled upon the mandril, as for example mandril 60, the perforated or easy tear line 78 adjacent the rolled material on the mandril aligns over a breaking board 80 which is part of the web separating means. The breaking of the rolled tissue away from the remaining web 10. is effected by an operation in which the surface of the wound roll 72 is engaged by a half-cylinder shell or guide blade 84, and by moving the break board 68 upwardly in the direction of arrow 86.

Accordingly the tissue breaks along the perforated line 78 as shown in FIG. 9, when the rolled material is to be removed from the machine; the broken end of the roll being smoothed over the surface of the roll by the half-round guide plate 84, as seen in FIG. 10.

The break board is supported below each web 10', 12' feeding onto its associated mandril 60 or 62 by an upright member which is hinged to the board as by hinge 92. The upright member 90 may be orientated to engage the ground or some other fixed support as for example 94, when the break board 80 is lowered back into its normal or inoperative position, as shown in FIG.

3. The other end of the breaking board is hinged to a fixed member or frame portion 96 of the Apparatus A bya hinge 98. The hinge 98 permits pivotal movement of the respective break boards 80, as desired in order to effect the separation of the wound rolls 66 from the remainder of the associated web. After the end of the respective rolls 64 or 66 has been severed from its respective remaining web portion 10' and 12 and with the severed end of the roll deflected around the surface of the round roll 72 by the guide plate 84, as seen in FIG. 10, the respective mandril 60 or 62, which is pivotally mounted at one end to the machine frame by a pivoting joint 100, is pivoted outwardly after first lifting the opposite end of the mandril off of its holding cradle 102 as seen in FIG. 11. With the mandril so pivoted all of the wound rolls thereon can be readily removed or slipped off the free pivoted end of the mandril as indicated by the direction of arrow 104, as shown in FIG. 11. Thereafter the individual roll lengths 72 removed from the mandril are readily separated along the severed or slit lines 70. (See FIG. 12.)

The drive for operating the apparatus, as shown in FIGS. I and 2, comprises a drive motor (not shown) driving through a belt or chain 106, pulley or sprocket 108 which are journalled to a main shaft 109. Also journalled to the main shaft 109 is a driving pinion 110. The driving pinion 110 in turn is disposed in meshing engagement with a larger gear 112 which is journalled on shaft 114, which also has journalled thereon a drive gear 116. The drive gear 116 is disposed in meshing relationship with a gear 118 journalled on shaft 54 of the web complementary slitting roller 48. Journalled on shaft 54 is a sprocket 120 which drives a gear 122 through a chain drive 124. The driven gear 122 is journalledon shaft 126 to which the lower separating roller 59 is journalled, the latter being located below the shaft 128 to which the upper complementary separating roller 57 is journalled. Gear 118 also drives a gear 130 which is journalled to the slitter shaft 52 to effect the drive of the cutting discs 50 journalled to shaft 52. Gear 116 also drives a gear train composed of meshing

gears

132, 134, 136 and I38. Gears 136 and 138 are journalled on

shafts

140 and 142 respectively to which the counter roller 28 and the associated perforator block 26 are journalled respectively.

Gear 138 also drives a train of meshing gears comprising gears 144, I46 and 148.

Gears

146 and 148 are journalled to shafts 150 and 152 respectively as are

rollers

22 and 18 respectively. Shafts I54 and 156 supported in suitable slots carry the dancer rollers 14 and 16 respectively as shown in FIG. 2.

The roll winding drive istaken off the large gear 112 by meshing the latter with a driving gear 158 journalled 160 drives a chain 162 which is connected in meshing relationship with drive gears 164 and 166 which are journalled on the rewind shafts 168 and 170 of mandrils 60 and 62 respectively.

As best seen in FIG. 11 the respective mandrils 60, 62 are connected at one end to their respective winding shaft 168 or 170 by a pivoting joint or universal joint 100. The other end of the mandril is rotatably supported in a support cradle 102. The arrangement is such that the material rolled about the respective mandrils in coreless rolls can be readily removed simply by pivoting the mandril to a position as seen in FIG. 11 and sliding the rolled material off the free end of the mandril. In doing so the guide 84 provides a support for the respective rolls as they are slid off the free end of the mandril.

A tensioning sprocket 172 is disposed in meshing relationship with the drive chain 162 to adjust the tension of the chain drive 162.

FIGS. 13-15 illustrate a modified form of the invention in which the web material, after it has been severed into individual widths by the slitter rollers 174, as hereinbefore described and generally designated as are directed into association with a folding means 176. The

member 178 through which the severed length 10' of the web are guided. The arrangement is such that the slitted web 10' in being guided through the folding gage 178 exits therefrom asa folded sheet 180. The arrangement is such that the web is longitudinally folded as it passes through the folding gauge 178.

The tubular folding member, as for example gauge 178, has an initial U-shaped cross section as indicated in FIG. 15 in which the cross section is gradually diminished or reduced from one end to the other as seen in FIG. 14 to result in the overlapping of the web as it exits therefrom. Thus the web is double folded along a longitudinally extending fold line as it arrives at the mandril 182 for winding into a coreless roll thereon.

FIGS. 16 and 17 illustrate alternate embodiments to illustrate a folding guide 178' and 178" having differently shaped cross sectional shapes to effect a simple V-type double fold or a Z-type triple fold'web.

FIGS. 18, 19 and 20 illustrate a modified embodiment of an apparatus for'forming coreless rolls in accordance with the method hereinbefore described. The apparatus embodiment of FIGS. 18-20 is similar to the apparatus describedwith respect to FIGS. 1-17, with the exception that the take-off end, i.e., the portion beyond the perforating the slitting stations of the apparatus,'has been modified to illustrate an alternate means for effecting the winding of the perforated and slit web into coreless rolls about the modified mandril construction and for effecting the separation of the wound rolls from the remaining portion of its continuous web.

In the modified embodiment of FIGS. 18-20, it will be understood that the portion of the apparatus defining the feed paths of the

respective webs

10 and 12 in advancing from the supply rolls S1 and S2 located adjacent one end of the machine to the separating nip

rollers

57 and 59 is identical to that described with respect to FIG. 3. Also the modified embodiment of FIGS. 18 to 20 employs a similar drive means 106, 108, 110, 112, 116, 118, 130, 132-142, for effecting the operation of the perforating means 24 and the slitting means 44 as hereinbefore described with respect to FIG. 2.

' folding means 176 comprises a folding gage or tubular Therefore insofar as the description of the feed path of the

respective web materials

10 and 12 and the corresponding drive means 106 to 148 as described with respect to FIGS. 2 and 3 are similar to the modified embodiment of FIGS. 18-20; the need for illustrating and describing the common structure of the respective apparatus is not deemed necessary for the understanding of the modified embodiment illustrated in FIGS. 1820. The embodiment of the apparatus shown in FIGS. 18 to 20 differs in the take-off portion 200 from that hereinbefore described with respect to FIGS. 1 to 12 in that shaft 159 has journalled thereon a sprocket or pulley 201 which is connected in driving relationship to a driven sprocket or pulley 202 journalled to ajack shaft 203, by a driving chain or belt 204, the jack shaft 203 being suitably supported on frame structure of the apparatus 200. As described with respect to FIG. 2, the shaft 159 is driven by a drive sprocket 158 which is journalled thereon, and which in turn is disposed in meshing relationship with the main driving sprocket 112.

Mounted on the jack shaft 203 is a smaller sprocket 205 which is connected into driving relationship with a driven sprocket 206 which is journalled on a countershaft 207 by means of a jack shaft driving chain 208.

Journalled adjacent the outlet or discharge end of the apparatus 200 there is provided a pair of spaced

guide rollers

209 and 210 over which the respective perforated and severed webs 10' and 12' are guided upon leaving the separating

rollers

57, 59 in feeding to their respective winding mandrils.

A drive is provided for the

respective guide rollers

209, 210. The guide roller drive means comprises an endless drive chain 211 which engages with a driving sprocket 212 journalled to the jack shaft 203 and complementary driven sprockets 213, 214 which are respectively journalled to the upper and lower guide roller shafts 213A and 214A. In operation the actuation of the drive chain 211 effects a common drive for the upper and lower guide rolls 209 and 210. If desired one or more tensioning sprockets 215, 216 may be arranged to engage the guide roller driving chain 211 to impart the requisite tension thereon. In the illustrated form of FIG. 18 two such tensioning sprockets 215, 216 are shown.

Operatively associated with each of the

guide rollers

209, 210 is a complementary nip roller 217, 218 respectively. If desired complementary nip rollers 217, 218 may be either fixed to engage the web at all times, or in the alternative or movably mounted on the frame structure of the apparatus for movement toward and away from its respective driven

guide roller

209, 210. In the illustrated arrangement, the respective nip rollers 217, 218 are disposed relative to their

complementary guide rollers

209, 210, so that the respective nip rollers 217, 218 are normally spaced from the driven

guide rollers

209, 210 during a winding operation; and that the respective complementary nip rollers 217, 218 are moved toward the driven guide roller to grip and secure the

web

10 and 12 therebetween when the winding operation of the endless rolls on the mandril has been terminated. As will be more particularly described hereinafter, the complementary nip rollers 217, 218 are moved toward their complementary driven

guide rollers

209, 210 to clamp or secure the web material 10' or 12' therebetween when the winding operation has ceased to facilitate the severing of the coreless rolls wound upon the mandrils from its remaining web portion when the rolls are removed.

The means for effecting movement of the respective complementary nip rollers 217, 218 toward and away from its

complementary guide rollers

209, 210 may be attained by means of a piston and cylinder assembly. It will be understood that the piston and cylinder assembly 220 for each nip roller 217, 218 is similar in construction. Referring to FIG. 18 only one piston and cylinder arrangement is shown. The nip rollers 217 or 218 are supported on a suitable bracket 221 adjacent the nip roller operated thereby. The piston rod 221A of the piston and cylinder assembly 221 is operatively connected to the nip roller 218 so that the same is rendered responsive to the protraction and retraction of the associated piston. As herein described the piston and cylinder assembly is activated to move the complementary nip roller 218 into clamping position with the drive guide roller when the winding operation has been completed; and to shift the complementary nip roller 218 away'from the guide roller 210 during the winding operation.

As best seen in FIGS. 18 to the winding means comprises a plurality of mandrils 222, that is a mandril 222 for winding each of. the respective slit and perforated webs. In the embodiment of FIGS. 18 to 20 the respective mandrils 222 are similar in construction and each comprises a tubular member 223 having a series of perforations or openings 224 extending therethrou'gh. Referring to FIGS. 19 and 20 the respective tubular mandrils 222 are each supported between relatively movable end bearings or chucks 225, 226. One of the end bearings 225 is suitably connected to a clutch means for effecting the drive of the associated mandril 222 during a winding operation. The other end bearing 226 comprises an idling bearing means which is movably mounted on the machine frame for movement toward and away from the fixed bearing end 225.

As best seen in FIG. 20, the movable end bearing 226 comprises an end member 227 having a conical nose 228 which is adapted to be received in the end of the tubular mandril 222 for supporting the same between

end bearings

225 and 226. The end member 227 is rotatably journalled to idleon a suitable bearing 229. The bearing 229 and end bearing member 227 are supported on the end of a slide bar 230 which is slidably supported in a suitable slide support 231 whereby the end bearing 226 can be readily moved toward and away from the fixed end bearing 225 to facilitate the engagement and disengagement of the associated mandril 222 therebetween.

Means for effecting the movement of the end bearing 226 toward and away from the fixed end bearing 225, in the illustrated embodiment comprises a piston and cylinder assembly 232. As seen in FIG. 20, the slide bar 230 is secured to an end bracket 233 which is movably mounted on suitable guide bar 234 supported on the machine frame. The piston rod of the piston and cylin- .der is operatively connected to the movable bracket 233 to effect displacement of the slide bar 230 and associated end bearing as the piston rod of assembly 232 is extended and retracted accordingly.

The fixed end bearing 225 is suitably driven through a suitable clutching arrangement by a mandril drive means. As best seen in FIG. 18 the mandril drive means comprises a mandril drive sprocket 236 journalled to the countershaft 207. A driven mandril sprocket 237 is operatively connected to the respective clutch drive of the fixed end bearing. An endless chain 207A is threaded over the mandril drive sprocket 236 and the respective complementary mandril driven sprocket 237 of the respective mandrils. Accordingly, as best seen in FIG. 18 the respective mandrils 222 are driven in unison .whenever the countershaft 207 is driven in response to the drive of the jack shaft 203, through a common chain drive 207A.-

Operatively connected to one of the end bearing for the respective mandrils, e.g.,.the slide bar or tube 230 is a supply conduit 239 which is adapted to be connected to the outlet end of a negative pressure source, e.g., a vacuum pump 240 and the like. The arrangement is such that when the vacuum pump 240 is activated, a reduced pressure is drawn on the tubular mandril 222 as seen in FIG. 20 so that the free ends of the severed web will tend to adhere to the mandril to initiate the winding operation. It will be understood that the negative pressure may be maintained on the respective mandrils either throughout the winding operation if desiredor during the initial winding only.

Upon completion of the winding operation after a predetermined number of windings has been made, on the mandrils, the rolls formed thereon can be readily removed by de-activating or releasing the vacuum and moving nip rollers 217 and 218 into engagement with the web material disposed between with the driven

guide rollers

209, 210 to secure or clamp the web material therebetween. In the event the nips 217 and 218 are in constant engagement with the web, during a winding operation, the need for nips activating piston assembly 220 can be obviated. With the web material so clamped between

rollers

209, 217 and 210, 218 the respective movable end bearings supporting the mandril are retracted to permit the respective mandrils and the rolls thereon to be readily removed from between the

end bearings

225 and 226. It will be understood that the half round guide 84 has hereinbefore described may be positioned on the rolls on the mandril to effect the removal thereof. The pulling of the mandril from between its respective end bearing supports causes the material gripped between

rolls

209, 217 and 210, 218 to tear along an adjacent tear line located between the securing

rollers

209, 217, 210 and 218 and the mandril. With the mandril and the rolls thereon removed, the rolls can be readily slid off either end of the mandril whereupon the emptied mandril is repositioned between the end bearing supports whereupon a winding operation may be repeated.

If desired a folding station similar to that described with respect to FIGS. 14 to 17 may be interposed between the

guide rollers

209, 210 and the associated mandril 222 so as to effect a folding of the severed lengths of web material in a manner hereinbefore described prior to effecting the winding thereof onto the associated mandrils 222.

The apparatus as described with respect to FIGS. 1-12 and 18-20 it will be noted requires an intermittent operation of the described method or winding operation to permit a period of time between winding operations to effect removal of the wound coreless rolls formed on the mandrils.

FIG. 21 is a schematic illustration of another modified embodiment of the invention in which the winding of the coreless rolls may be continuously performed. This is attained by modifying the take-off end of the apparatus hereinbefore described with respect to FIGS. 1 to 17 and 18 to 20. The continuous operation is attained by utilizing a rotating turret 300 which has mounted thereon a plurality of winding mandrils 301. The

respective mandrils

301, 301 are rotatably journalled on the turret 300. The arrangement is such that a winding operation is occurring on one of the mandrils, as the other one which has been previously wound with web material is being removed and replaced with another mandril.

In general, the apparatus of FIG. 21 is similar to the apparatus hereinbefore described with respect to FIGS. 1 to 17 or 18 to 20, with the exception that the take-off end, i.e., the portion beyond the perforating and slitting stations has been modified to effect the continuous winding of the perforated and slit web 10' and 12' into I coreless rolls. In the embodiments of FIG. 21 it will be understood that the portion of the apparatus defining the machine structure and the feed path for the respective webs l and 12 between the supply rolls S1 and S2 located adjacent the supply end of the machine and the separating nip

rollers

57 and 59 are identical to that described with respect to FIG. 3. Also the embodiment of FIG. 21 employs a similar drive arrangement as hereinbefore described with respect to FIG. 2. For these reasons a further showing and description of the supply end of the apparatus including the perforating and slitting means is not deemed necessary to the understanding of the modified portion or take-off end of the modified embodiment of FIG. 21.

The embodiment of FIG. 21 differs from that previously described in that a turret take-off 300 is provided for each web and 12, each turret being similarly constructed and operated as will be hereinafter described. In the illustrated embodiment two turret means are shown at the discharge end of the apparatus to correspond to the number of

webs

10 and 12 which are being perforated and slit.

It will be understood that the respective turrets are driven by a common drive, e.g., a flexible chain similar to the mandril drive of FIG. 18.

The feed path of the webs l0 and 12' upon being perforated and slit, upon passing between the separating nip

rollers

57 and 59, are directed about a

respective guide roller

302, 302, and thereafter between a pair of nip

rollers

303, 304. It will be understood that one, e.g., roller 303 of the respective pair of nip

rollers

303, 304 is independently driven, as for example, by a drive chain from the main drive of the machine.

In this embodiment winding mandrils 301 are oppositely disposed and rotatably journalled on each turret means 300. Each of the mandrils 301 is similarly constructed, and it comprises a tubular member 301A having a series of circumferentially spaced openings 305 extending therethrough. The ends of the respective mandrils 301 are rotatably journalled between relatively movable end bearings or chucks similar to those described with respect to FIGS. 18 and 20. However, in this embodiment the end supporting chucks or bearings are carried on the rotatable turret 300. One of the end bearings or chucks for the respective mandrils is fixed to the turret and the other is slideably mounted for movement toward and away from the fixed mandril chuck or bearing. Accordingly the arrangement is such that by relative movement between the end bearings,

the mandril 301 may, be readily removed and/or replaced on its respective turret. Each mandril 301 is separately driven by a motor means 306 through a clutch as previously shown which is carried on the turret 300. It will be understood that the motor is suitably connected in driving relationship to one of the end bearings so as to effect rotation of the mandril.

Operatively associated with each mandril 301 is a source of negative pressure, e.g., a vacuum pump P, which is also carried on the turret. The outlet end of the pump P being operatively connected to the mandril by suitable flexible hose coupling 307. The operation of the pump P, as hereinbefore described enables the lead end of the web to adhere to the mandril to initiate winding as described.

Pivotally connected adjacent to the turret 300 is a pivoting arm 308, which carries on the free end thereof a roller 309 which is adapted to be moved into and out of rolling engagement with the mandril, when the mandril is located in a twelve oclock position as indicated in FIG. 21. It will be understood that a pivoting arm 308 is provided for each turret. It will also be understood that the nipper arm 308 is operatively connected to a suitable actuating means, for example a piston and cylinder assembly for effecting the actuation of the nipper arm between operative and inoperative position. The operative position of the arm 308 is that position in which the roller 309 is engaging in nipping relationship with the mandril 301 as seen in the solid line showing in FIG. 21. The inoperative position is indicated by the dotted line showing in FIG. 21.

Carried on the nipper arm 308 is a bracket 310 for supporting a knife edge 311. The arrangement is such that when the nipper arm 308 is moved into the operative position or solid line showing, the knife edge 31,1 effects a cutting action on the web material 10 so as to separate the sheet of web material 10 or 12' from the roll portion about the mandril 301.

Mounted on .the center of the turret 300 is an idler hub 300A which defines a guide for the web sheet.

The operation of the turret take-off assembly as illustrated in FIG. 21 is as follows:

The

web materials

10 and 12 upon being fed from their respective supply rolls are directed to the perforating and slitting stations in the manner hereinbefore described. The perforated and slit sheets which are disposed in juxtaposed position are then fed between the separating nipper rolls 57 and 59 whereupon each web 10', 12 is then directed to its individual winding station 300.

The winding station as indicated in FIG. 21 comprises an upper and lower turret take-

off

300, 300. The respective webs 10' and 12 are guided to the take-off stations 300 by rounding guide rollers 302 'whereby the respective web is guided between a pair of nip

rollers

303, 304, the latter being independently driven from the main drive of the apparatus. The free end of the web is thus guided or positioned over the mandril 301 about which the web is to be wound.

Initiation of the winding operation is effected by drawing a vacuum on the mandril 301 as described with respect to FIGS. 18 to 20, whereupon the negative pressure causes the free end of the web material to ad here thereto. With the web, e.g. l0 adhered to the mandril, the mandril is rotated to effect the winding and the turret is rotated so that as the web is being wound upon, the mandril is displaced from a 12 oclock position, as indicated in FIG. 21, toa 6 oclock position as indicated in FIG. 21. The timing is such that when the mandril winding the web material thereon has advanced to the 6 oclock position as shown in FIG. 21, the winding operation is completed. At this point in the cycle, the nipper arm 308 is actuated causing the nipper arm to be advanced to operative position.

As indicated in the solid line showing in FIG. 21, the knife edge of the nipper arm effects a severing of the rolled material from its supply sheets, at the same time permitting the severed end of the supply sheet to be in position to be wound about the empty mandril which has moved into the 12 oclock position. The arrangement is such that as the succeeding mandril in the 12 o'clock position is in position to accept the web material as the loaded mandril in the 6 oclock position can be removed.

It will be understood that the removal of the coreless rolls about the loaded mandril in the 6 o'clock position will be effected, either manually or automatically, by effecting the relative movement of the end chucks supporting the mandril to permit removal ofthe wound mandrils and the insertion of an empty mandril therebetween. If desired the loaded mandril may be dropped into a suitable hopper or magazine whereupon the wound rolls thereon may be readily removed.

With the embodiment illustrated in FIG. 21, a continuous winding operation of coreless rolls may be effected.

While the present invention has been described with respect to particular embodiments thereof it will be readily understood and appreciated that variations and modifications may be made without departing from the spirit or scope of the invention.

What is claimed is:

1. An apparatus for forming coreless rolls of tissue sheets connected in end to end relationship along a frangible tear line comprising: means for supporting a plurality of supply. rolls of continuous web of tissue material. means for guiding eachof said webs through a feed path, means for directing each of said webs into overlying juxtaposition relationship through a portion of said feed paths, perforating means and slitting means disposed adjacent the portion of said feed path through which said webs are fed in juxtaposition relationship,

said perforating means engaging said juxtapositioned web to simultaneously perforate said juxtapositioned webs transversely thereof along longitudinally spaced intervals, and said slitting means engaging said juxtapositioned webs to simultaneously slit said webs into a plurality of longitudinal lengths, means disposed in said feed path to effect separation of said juxtapositioned webs subsequent to said webs being perforated and slit, a mandril rotatably journalled for receiving the slit lengths of the respective webs. means for securing the respective slit lengths to said mandril, means for effecting the rotation of said mandrils for winding said slit lengths into distinct coreless rolls on said mandril, and clamping means to secure said slit lengths of the respective webs adjacent said mandril to facilitate the severance of said coreless rolls from the remaining respective continuous web.

2; The invention as defined in claim 1 wherein each of said mandrils comprises a tubular member having a plurality of apertures formed therein, and means connected to said tubular member for drawing a negative pressure thereon whereby said slit lengths adhere to said tubular member when said member is subjected to said negative pressure.

3. The invention as defined in claim 1 wherein said mandril comprises a tubular member having a series of holes formed therein, and said securing means comprising a source of negative pressure connected to said tubular member for drawing a reduced pressure thereon.

4. The invention as defined in claim 3 and including means for detachably supporting said mandril.

5. The invention as defined in claim 1 wherein said clamping means includes a pair of nip rollers disposed in said feed path between which said severed lengths are fed.

6. The invention as defined in claim I and including:

means for synchronizing the rotation of said turret means to the feed of said web material;

said turret means including at least a pair of mandrils supported thereon;

means for rotatably supporting each of said mandrils on said turret means;

means for effecting the rotation of said mandrils to line said web material thereon;

each of said mandrils comprising a perforated tubular member; a means for drawing a negative pressure on said mandrils for adhereing the web thereto.

7. A method of forming a plurality of individual core less rolls of a continuous web formed of connected sheets joined in end to end relationship comprising the steps of advancing several continuous webs of sheet material from their respective sources of supply through a feed path, bringing said respective webs into overlying juxtapositioned relationship. simultaneously perforating said juxtapositioned webs transversely thereof at longitudinally spaced intervals therealong, simultaneously slitting said juxtapositioned webs longitudinally to define a plurality of narrow lengths, separating said juxtapositioned webs and directing said separated webs in diverging paths, securing the slit ends of the respective webs to a mandril, rolling said lengths of the respective webs into individual rolls about said mandril to a predetermined thickness, severing said rolls from their respective web along an adjacent perforated line, and removing said rolls from their associated mandril.

8 The'method as defined in claim 7 and including the step of folding each of said slit lengths of said webs prior to securing said slit ends to the mandril.

9. The method as defined in claim 8 wherein each of said slit lengths is folded longitudinally the length of said lengths along at least one longitudinally extending foldline.

10. The invention as defined in claim 7 and including the step of securing the slit lengths of the respective webs to the mandril by drawing a negative pressure on the mandril.

11. A method of continuously forming a plurality of individual coreless rolls from a continuous web of connected sheets joined in end to end relationship comprising the steps of: continuously advancing several continuous webs of material from their respective of material from said web material as said mandril is advanced to the wound roll position whereupon the severed end of said web is secured to a second mandril to effect a continuous winding operation.

12. The method as defined in claim 11 wherein said web is secured to said mandril by drawing a vacuum thereon.

13. The method as defined in claim 11 wherein said severing of the web material from the wound rolls is effected by cutting the web.

Claims

1. An apparatus for forming coreless rolls of tissue sheets connected in end to end relationship along a frangible tear line comprising: means for supporting a plurality of supply rolls of continuous web of tissue material, means for guiding each of said webs through a feed path, means for directing each of said webs into overlying juxtaposition relationship through a portion of said feed paths, perforating means and slitting means disposed adjacent the portion of said feed path through which said webs are fed in juxtaposition relationship, said perforating means engaging said juxtapositioned web to simultaneously perforate said juxtapositioned webs transversely thereof along longitudinally spaced intervals, and said slitting means engaging said juxtapositioned webs to simultaneously slit said webs into a plurality of longitudinal lengths, means disposed in said feed path to effect separation of said juxtapositioned webs subsequent to said webs being perforated and slit, a mandril rotatably journalled for receiving the slit lengths of the respective webs, means for securing the respective slit lengths to said mandril, means for effecting the rotation of said mandrils for winding said slit lengths into distinct coreless rolls on said mandril, and clamping means to secure said slit lengths of the respective webs adjacent said mandril to facilitate the severance of said coreless rolls from the remaining respective continuous web.

2. The invention as defined in claim 1 wherein each of said mandrils comprises a tubular member having a plurality of apertures formed therein, and means connected to said tubular member for drawing a negative pressure thereon whereby said slit lengths adhere to said tubular member when said member is subjected to said negative pressure.

6. The invention as defined in claim 1 and including: a roll winding station adjacent the end of said feedpath; said roll winding station including a rotating turret means; means for synchronizing the rotation of said turret means to the feed of said web material; said turret means including at least a pair of mandrils supported thereon; means for rotatably supporting each of said mandrils on said turret means; means for effecting the rotation of said mandrils to line said web material thereon; each of said mandrils comprising a perforated tubular member; a means for drawing a negative pressure on said mandrils for adhereing the web thereto.

7. A method of forming a plurality of individual coreless rolls of a continuous web formed of connected sheets joined in end to end relationship comprising the steps of advancing several continuous webs of sheet material from their respective sources of supply through a feed path, bringing said respective webs into overlying juxtapositioned relationship, simultaneously perforating said juxtapositioned webs transversely thereof at longitudinally spaced intervals therealong, simultaneously sliTting said juxtapositioned webs longitudinally to define a plurality of narrow lengths, separating said juxtapositioned webs and directing said separated webs in diverging paths, securing the slit ends of the respective webs to a mandril, rolling said lengths of the respective webs into individual rolls about said mandril to a predetermined thickness, severing said rolls from their respective web along an adjacent perforated line, and removing said rolls from their associated mandril.

8. The method as defined in claim 7 and including the step of folding each of said slit lengths of said webs prior to securing said slit ends to the mandril.

11. A method of continuously forming a plurality of individual coreless rolls from a continuous web of connected sheets joined in end to end relationship comprising the steps of: continuously advancing several continuous webs of material from their respective sources of supply through a feed path; bringing the respective webs into overlying, juxtaposition relationship; simultaneously perforating said juxtapositioned webs transversely at spaced intervals and slitting said juxtapositioned webs longitudinally to form a series of narrow lengths of connected sheets; separating said perforated and slit juxtapositioned webs and directing said webs in diverging paths; securing the free end of the web to a mandril; rolling said web about said mandril as said mandril is rotated between a roll starting position and a wound roll position; severing the wound rolls of material from said web material as said mandril is advanced to the wound roll position whereupon the severed end of said web is secured to a second mandril to effect a continuous winding operation.