WO2004063073A1 - Method and manufacture of cores - Google Patents

Method and manufacture of cores Download PDF

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Publication number
WO2004063073A1
WO2004063073A1 PCT/ZA2004/000003 ZA2004000003W WO2004063073A1 WO 2004063073 A1 WO2004063073 A1 WO 2004063073A1 ZA 2004000003 W ZA2004000003 W ZA 2004000003W WO 2004063073 A1 WO2004063073 A1 WO 2004063073A1
Authority
WO
WIPO (PCT)
Prior art keywords
core according
resin
core
fibre
fibrous material
Prior art date
Application number
PCT/ZA2004/000003
Other languages
French (fr)
Inventor
Michael James Bayliss
Original Assignee
Michael James Bayliss
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Michael James Bayliss filed Critical Michael James Bayliss
Publication of WO2004063073A1 publication Critical patent/WO2004063073A1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H75/00—Storing webs, tapes, or filamentary material, e.g. on reels
    • B65H75/50—Methods of making reels, bobbins, cop tubes, or the like by working an unspecified material, or several materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/022—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the choice of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/50—Details of extruders
    • B29C48/505—Screws
    • B29C48/52—Screws with an outer diameter varying along the longitudinal axis, e.g. for obtaining different thread clearance
    • B29C48/525—Conical screws
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H75/00—Storing webs, tapes, or filamentary material, e.g. on reels
    • B65H75/02—Cores, formers, supports, or holders for coiled, wound, or folded material, e.g. reels, spindles, bobbins, cop tubes, cans, mandrels or chucks
    • B65H75/04—Kinds or types
    • B65H75/08—Kinds or types of circular or polygonal cross-section
    • B65H75/10—Kinds or types of circular or polygonal cross-section without flanges, e.g. cop tubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0022—Combinations of extrusion moulding with other shaping operations combined with cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/13—Articles with a cross-section varying in the longitudinal direction, e.g. corrugated pipes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/395—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/395—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders
    • B29C48/40—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders using two or more parallel screws or at least two parallel non-intermeshing screws, e.g. twin screw extruders
    • B29C48/402—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders using two or more parallel screws or at least two parallel non-intermeshing screws, e.g. twin screw extruders the screws having intermeshing parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/16—Fillers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2311/00—Use of natural products or their composites, not provided for in groups B29K2201/00 - B29K2309/00, as reinforcement
    • B29K2311/14—Wood, e.g. woodboard or fibreboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2023/00—Tubular articles
    • B29L2023/22—Tubes or pipes, i.e. rigid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/704—Bobbins, spools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2701/00—Handled material; Storage means
    • B65H2701/50—Storage means for webs, tapes, or filamentary material
    • B65H2701/51—Cores or reels characterised by the material
    • B65H2701/512—Cores or reels characterised by the material moulded
    • B65H2701/5126—Particles of fibres, e.g. lignocelluloses material

Definitions

  • This invention relates to a core for use in the paper industry and a method of manufacture thereof.
  • cores are produced by gluing wide strips of Kraft Paper and winding many layers onto a mandrel.
  • the external diameter of the mandrel forms the internal diameter of the core.
  • Core crush strength must conform to SABS and in certain cases, international standards.
  • Cores made by this method are costly. It is therefore an object of this invention to provide a core comprising an alternative material and manufactured according to a different method, which is significantly less expensive to produce than traditional cores.
  • a core for paper reels or board comprises a tube of compressed, blended fibrous material and resin.
  • the tube is formed by extrusion.
  • a conical counter rotating twin screw extruder is the preferred extruder for the tube; although a single screw extruder may be used.
  • wood fibre of moisture content between 0,5 and 1,0% by mass, the fibre preferably comprising sanding dust of particle size less than or equal to 200 mesh.
  • particle board, MDF waste and other suitable fibrous waste may be used.
  • the resin used preferably comprises a polyethylene, polyvinylchloride, polypropylene, polystyrene or acrylonitrite / butadiene / styrene resin, singly or in combination.
  • Urea formaldehyde resin may not be used because the amount of heat generated is too high.
  • the ratio of fibre to resin may vary up to a maximum of 70: 30 fibre to resin.
  • a method of manufacture of a core as described above includes the steps of: heating a mixture of fibre and resin in a predetermined ratio by mass, to melt the resin; mixing the melted resin and fibre under pressure to encapsulate the fibre in the resin; and extruding the molten mixture into the profiling tool to form the core, and curing the core in a cooling chamber.
  • the core is then cut to length by a flying saw.
  • the process may include prior steps of passing the fibrous waste through a hammer mill to reduce it to flour sized at 200 mesh or smaller.
  • the flour may then be dried in a vacuum drier to achieve the desired moisture content.
  • the preferred extruder comprises a conical counter rotating twin screw extruder, as it has been found to be useful in efficiently plasticising the wood fibre together with good pressure generation, resulting in the wood fibre being encapsulated with melted plastic.
  • the twin screw extruder described above generates sufficient pressure to extrude a core of density in excess of 800 Kg / m 3 and inhibits the porosity characteristics of wood fibre by coating it with plastic. The result is a product which has improved porosity, integrity (it is moulded so no delamination can occur) and cost of production (in that the wood fibre is waste material), in comparison to the traditional paper wound core.
  • the inner and outer walls of the core may be ribbed or corrugated to allow the paper or board to adhere to the outer walls and reel in wind equipment to exit traction by gripping the inside wall.
  • the rate of production by this method may reach 730 kg/hour.
  • the cores produced by this process are particularly suited to indoor use or in conditions of low atmospheric moisture content.
  • the cores produced by this method are particularly suited to outdoor use or in high atmospheric moisture content environments.

Abstract

A core for paper reels in particular is extruded from waste fibrous materials, for example sawdust, and resin which are blended and compressed into a tube of low porosity, high integrity, and excellent core strength at substantially reduced cost.

Description

METHOD AND MANUFACTURE OF CORES
TECHNICAL FIELD OF THE INVENTION
This invention relates to a core for use in the paper industry and a method of manufacture thereof.
BACKGROUND ART
In order to sell a reel of paper or board, it is necessary to wind a continuous sheet thereof onto a core comprising a hollow tube of standardised internal diameter and having a strong wall. This facilitates transport and handling to and by the customer.
Currently, cores are produced by gluing wide strips of Kraft Paper and winding many layers onto a mandrel. The external diameter of the mandrel forms the internal diameter of the core. Core crush strength must conform to SABS and in certain cases, international standards.
Cores made by this method are costly. It is therefore an object of this invention to provide a core comprising an alternative material and manufactured according to a different method, which is significantly less expensive to produce than traditional cores.
In this specification, the term "moulded" is taken to mean "extruded" as well.
DISCLOSURE OF THE INVENTION
According to the invention, a core for paper reels or board comprises a tube of compressed, blended fibrous material and resin.
In the preferred form of the invention, the tube is formed by extrusion. A conical counter rotating twin screw extruder is the preferred extruder for the tube; although a single screw extruder may be used. In this form of the invention, it is preferred to use wood fibre of moisture content between 0,5 and 1,0% by mass, the fibre preferably comprising sanding dust of particle size less than or equal to 200 mesh. Alternatively, particle board, MDF waste and other suitable fibrous waste may be used.
The resin used preferably comprises a polyethylene, polyvinylchloride, polypropylene, polystyrene or acrylonitrite / butadiene / styrene resin, singly or in combination. Urea formaldehyde resin may not be used because the amount of heat generated is too high.
The ratio of fibre to resin may vary up to a maximum of 70: 30 fibre to resin.
According to a second aspect of the invention, a method of manufacture of a core as described above includes the steps of: heating a mixture of fibre and resin in a predetermined ratio by mass, to melt the resin; mixing the melted resin and fibre under pressure to encapsulate the fibre in the resin; and extruding the molten mixture into the profiling tool to form the core, and curing the core in a cooling chamber.
The core is then cut to length by a flying saw. The process may include prior steps of passing the fibrous waste through a hammer mill to reduce it to flour sized at 200 mesh or smaller. The flour may then be dried in a vacuum drier to achieve the desired moisture content.
In this form of the invention, the preferred extruder comprises a conical counter rotating twin screw extruder, as it has been found to be useful in efficiently plasticising the wood fibre together with good pressure generation, resulting in the wood fibre being encapsulated with melted plastic. The twin screw extruder described above generates sufficient pressure to extrude a core of density in excess of 800 Kg / m3 and inhibits the porosity characteristics of wood fibre by coating it with plastic. The result is a product which has improved porosity, integrity (it is moulded so no delamination can occur) and cost of production (in that the wood fibre is waste material), in comparison to the traditional paper wound core.
Also in the preferred form, the inner and outer walls of the core may be ribbed or corrugated to allow the paper or board to adhere to the outer walls and reel in wind equipment to exit traction by gripping the inside wall.
In addition, the rate of production by this method may reach 730 kg/hour.
The cores produced by this process are particularly suited to indoor use or in conditions of low atmospheric moisture content.
The cores produced by this method are particularly suited to outdoor use or in high atmospheric moisture content environments.

Claims

CLAIMS:
1. A core for reels of sheet material and in particular, paper characterised in that it comprises a tube of compressed, blended fibrous material and resin.
2. A core according to claim 1 characterised in that the tube is formed by extrusion.
3. A core according to claim 2 characterised in that a conical counter rotating twin screw extruder is used to extrude the tube.
4. A core according to claim 2 characterised in that a single screw extruder is used to extrude the tube.
5. A core according to claim 1 characterised in that the fibrous material comprises wood fibre having a moisture content of 0,5 to 0, 1 % by mass.
6. A core according to claim 5 characterised in that the wood fibre comprises sanding dust of particle size less than or equal to 200 mesh.
7. A core according to claim 1 in which the fibrous material comprises particle board.
8. A core according to claim 1 in which the fibrous material comprises MDF waste.
9. A core according to claim 1 characterised in that the resin comprises a polyethylene, polyvinylchloride, polypropylene, polystyrene and/or acrylonitrile/butadiene/styrene resin, singly or in combination.
10. A core according to claim 1 characterised in that the ratio of fibre to resin is less than or equal to 70:30 fibre to resin.
11. A method of manufacture of a core according to claims 1 to 10 characterised in that it includes the steps of : heating a mixture of fibre and resin in a predetermined ratio by mass to melt the resin; mixing the melted resin and fibre to encapsulate the fibre in the resin, extruding the molten mixture into a profiling tool to form the core, and curing the core in a cooling chamber.
12. A core according to claim 11 characterised in that the core is cut to length using a flying saw.
13. A core according to claim 11 characterised in that it includes prior steps of milling the fibrous material using a hammer mill to obtain a particle size of 200 mesh or less, and drying the milled material.
14. A core according to claim 11 characterised in that a conical counter rotating twin screw extruder is used to extrude the molten mixture.
15. A core according to any of the above claims in which the inner and/or outer walls of the core are ribbed or corrugated.
PCT/ZA2004/000003 2003-01-16 2004-01-16 Method and manufacture of cores WO2004063073A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ZA200300437 2003-01-16
ZA2003/0437 2003-01-16

Publications (1)

Publication Number Publication Date
WO2004063073A1 true WO2004063073A1 (en) 2004-07-29

Family

ID=32713967

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/ZA2004/000003 WO2004063073A1 (en) 2003-01-16 2004-01-16 Method and manufacture of cores

Country Status (1)

Country Link
WO (1) WO2004063073A1 (en)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007015092A1 (en) * 2005-08-04 2007-02-08 Ultra-Core Ltd. Web-winding core
US9505179B2 (en) 2013-02-21 2016-11-29 The Procter & Gamble Company Method of manufacturing fibrous cores
US9561929B2 (en) 2013-02-21 2017-02-07 The Procter & Gamble Company Fibrous cores
US9756991B2 (en) 2013-02-21 2017-09-12 The Procter & Gamble Company Fibrous cores

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB380308A (en) * 1930-12-06 1932-09-15 British Celanese Improvements in manufacturing textile package supports
GB1370544A (en) * 1971-07-06 1974-10-16 Ugine Kuhlmann Bobbin made of high density cellular thermoplastic material
FR2564374A1 (en) * 1984-05-15 1985-11-22 Grepp Solid profiles based on wood and recycled thermoplastics and their method of manufacture
US5474722A (en) * 1992-11-13 1995-12-12 The Governing Council Of The University Of Toronto Oriented thermoplastic and particulate matter composite material
WO2000009317A1 (en) * 1998-08-12 2000-02-24 Proteus Inc. Ribbed core dual wall structure
EP1035061A2 (en) * 1999-03-08 2000-09-13 Wwj, L.L.C. Reel assembly
US6344504B1 (en) * 1996-10-31 2002-02-05 Crane Plastics Company Limited Partnership Extrusion of synthetic wood material

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB380308A (en) * 1930-12-06 1932-09-15 British Celanese Improvements in manufacturing textile package supports
GB1370544A (en) * 1971-07-06 1974-10-16 Ugine Kuhlmann Bobbin made of high density cellular thermoplastic material
FR2564374A1 (en) * 1984-05-15 1985-11-22 Grepp Solid profiles based on wood and recycled thermoplastics and their method of manufacture
US5474722A (en) * 1992-11-13 1995-12-12 The Governing Council Of The University Of Toronto Oriented thermoplastic and particulate matter composite material
US6344504B1 (en) * 1996-10-31 2002-02-05 Crane Plastics Company Limited Partnership Extrusion of synthetic wood material
WO2000009317A1 (en) * 1998-08-12 2000-02-24 Proteus Inc. Ribbed core dual wall structure
EP1035061A2 (en) * 1999-03-08 2000-09-13 Wwj, L.L.C. Reel assembly

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007015092A1 (en) * 2005-08-04 2007-02-08 Ultra-Core Ltd. Web-winding core
US9505179B2 (en) 2013-02-21 2016-11-29 The Procter & Gamble Company Method of manufacturing fibrous cores
US9561929B2 (en) 2013-02-21 2017-02-07 The Procter & Gamble Company Fibrous cores
US9756991B2 (en) 2013-02-21 2017-09-12 The Procter & Gamble Company Fibrous cores

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