In-Line Formed Core Supporting a Wound Web

Abstract

A web is wound onto an in-line core instead of a separate core. At the start of the winding process, a core-forming substrate attached to the leading edge of the web is wound into an in-line core. The web is wound around the in-line core. For streaming operation, a composite substrate-web stream comprising an alternating sequence of attached core-forming substrate segments and web segments is produced. The first core-forming substrate segment is wound into a first in-line core, and the first web segment is wound around the first in-line core. The composite substrate-web stream is cut. The second core-forming substrate segment is wound into a second in-line core, and the second web segment is wound around the second in-line core. The composite substrate-web stream can be slit longitudinally to produce multiple composite substrate-web stream strips. Multiple composite substrate-web stream strips can be wound in parallel on a single mandrel.

Description

This application claims the benefit of U.S. Provisional Application No. 61/219,428 filed Jun. 23, 2009, which is incorporated herein by reference.

CROSS-REFERENCE TO RELATED APPLICATION

This application is related to U.S. patent application Ser. No. ______ (Attorney Docket No. 11356.0009), entitled Enveloper Assembly for Winding Webs, which is being filed concurrently herewith and which is herein incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

The present invention relates generally to winding of webs, and more particularly to an in-line formed core that supports a wound web.

Many products are supplied as a flexible, elongated sheet referred to as a web. Examples of webs include sheet paper, sheet fabric, plastic film, and metal foil. Webs are commonly wound into a roll for storage, shipping, processing, and consumption. In typical practice, webs are wound onto a separate component, a core formed from a rigid material such as cardboard, wood, plastic, or metal. The core serves as a support structure for initiating the winding process and for maintaining the structural integrity of the web during shipping and handling. The core also serves as a mechanism for dispensing the web during further processing and during end-user applications.

Separate cores, however, suffer from several disadvantages. For example, they incur additional costs associated with their purchase, shipping, and storage; and the additional steps required to load the separate cores onto winding mandrels increase manufacturing complexity, with attendant additional manufacturing costs. Separate cores, furthermore, add to the waste stream, since the cores are typically discarded once the web has been consumed. Various coreless winding methods have been developed; however, they are typically tailored to specific materials and require complicated steps to initiate the winding. In some instances, the final roll does not maintain sufficient structural integrity as the web is consumed; consequently, the last portions of the web are wasted. What are needed are methods and apparatus that wind webs formed from a wide range of materials, reduce manufacturing costs, and reduce waste material.

BRIEF SUMMARY OF THE INVENTION

A web is wound around an in-line core. A core-forming substrate is attached to the leading edge of the web. The core-forming substrate can be attached to the web with adhesive. The core-forming substrate is wound into an in-line core, and the web is wound around the in-line core. For streaming operation, a composite substrate-web stream comprising an alternating sequence of attached core-forming substrate segments and web segments is produced. The first core-forming substrate segment is wound into a first in-line core, and the first web segment is wound around the first in-line core. The composite substrate-web stream is then cut. The second core-forming substrate segment is wound into a second in-line core, and the second web segment is wound around the second in-line core. The composite substrate-web stream can be slit longitudinally to produce multiple composite substrate-web stream strips. Multiple composite substrate-web stream strips can be wound in parallel on a single mandrel.

These and other advantages of the invention will be apparent to those of ordinary skill in the art by reference to the following detailed description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A and FIG. 1B show a reference geometry for a core-forming substrate attached to a web;

FIG. 2A-FIG. 2D show various configurations for attaching a core-forming substrate to a web;

FIG. 3A-FIG. 3E show a sequence of steps for forming an in-line core;

FIG. 4A-FIG. 4C show different segmentations of a core-forming substrate and a web;

FIG. 5A-FIG. 5H show different configurations for attaching a core-forming substrate to a web;

FIG. 6 shows a schematic of a manufacturing system for streaming production of wound web rolls with in-line cores;

FIG. 7A-FIG. 7S show schematics of steps for producing a sequence of webs and core-forming substrates;

FIG. 8A-FIG. 8R show schematics of steps for producing wound web rolls with in-line cores;

FIG. 9A and FIG. 9B show end tabs on finished wound web rolls;

FIG. 10 shows strips of web segments and core-forming substrate segments with graphics imprinted on the core-forming substrate segments; and

FIG. 11 shows the placement of adhesive to avoid adhesive on the inner surface of a wound web roll.

DETAILED DESCRIPTION

In embodiments of the invention, an in-line core-forming substrate is attached to the leading edge of a web. At the start of the winding process, the in-line core-forming substrate is wound into a core. The web is then wound onto the in-line formed core (for simplicity, an in-line formed core is also referred to as an in-line core). Note that the term “substrate” is sometimes used as a synonym for “web”. Herein, a “web” refers to the product of interest (such as paper towels, cloth strips, photographic film, masking tape, and metal foil). As discussed above, in general, a web refers to a flexible, elongated sheet. Web materials can be homogeneous or heterogeneous, including composites and laminates. Webs can have surface coatings, including adhesives. The body of a web can be uniform or can have geometrical features such as perforations and corrugations. The surface of a web can be smooth or textured, including features such as corrugations.

“Core-forming substrate” refers to a component used to produce an in-line formed core (as described in detail below). A wide range of materials can also be used for substrates, including paper, plastic, and metal. In some instances, the substrate material can be similar to the web material. For example, the web can be thin paper, and the substrate can be a heavier weight, stiffer paper. As another example, the web can be thin plastic film, and the substrate can be a thicker plastic film or a more rigid plastic film. Substrate materials can be homogeneous or heterogeneous, including composites and laminates. Substrates can have surface coatings, including adhesives. The body of a substrate can be uniform or can have geometrical features such as perforations and corrugations. The surface of a substrate can be smooth or textured, including features such as corrugations.

FIG. 1A (View A) and FIG. 1B (View B) show a reference geometry for winding operations. In the example shown, web 104, with a width 141 and a length 143, is unwound from a web supply roll 102. Note: To simplify the figures, a roll with multiple windings is depicted as a series of concentric circles; in actual practice, a web is wound as a continuous spiral. Web 104 is then rewound for further processing (such as slitting into narrower widths) or end-user application (such as retail rolls of masking tape). To simplify the terminology, “rewinding” is referred to as “winding”. The final product is referred to as a wound web roll. Note that web 104 can also be supplied as an individual flat sheet, instead of being unwound from a web supply roll 102. Web 104 has a leading edge 130, a trailing edge 132, a longitudinal axis 121, and a transverse axis 123. In an embodiment of the invention, core-forming substrate 106 is attached to the leading edge 130 of web 104.

Details of the highlighted region 150 are shown in FIG. 2A-FIG. 2D (View B only) for several examples of attachment geometries. Shown is a portion of web 104 with leading edge 130. Web 104 has a surface 210 and a surface 212. Web 104 has a thickness 201. Core-forming substrate 106 has a leading edge 202, a trailing edge 204, a surface 206, and a surface 208. Core-forming substrate 106 has a length 211 and a thickness 213. In FIG. 2A, the leading edge 130 of web 104 is butted against the trailing edge 204 of core-forming substrate 106. In FIG. 2B, a portion of surface 208 of core-forming substrate 106 is facing a portion of surface 210 of web 104. The overlap distance 215 is the distance between the leading edge 130 of web 104 and the trailing edge 204 of core-forming substrate 106. The overlap distance 215 can range from 0 to length 211. In FIG. 2C, a portion of surface 212 of web 104 is facing a portion of surface 206 of core-forming substrate 106. The overlap distance 217 is the distance between the leading edge 130 of web 104 and the trailing edge 204 of core-forming substrate 106. The overlap distance 217 can range from 0 to length 211. In FIG. 2D, a portion of web 104 is inserted into a portion of core-forming substrate 106. The insertion distance 219 is the distance between the leading edge 130 of web 104 and the trailing edge 204 of core-forming substrate 106. The insertion distance 219 can range from 0 to length 211.

In some embodiments, a third component can be used to attach core-forming substrate 106 to the leading edge 130 of web 104. For example, in the configuration shown in FIG. 2B, component 220 is disposed along leading edge 130 and contacts a portion of surface 208 of core-forming substrate 106 and a portion of surface 212 of web 104 in the proximity of leading edge 130. Similarly, in the configuration shown in FIG. 2C, component 220 is disposed along leading edge 130 and contacts a portion of surface 206 of core-forming substrate 106 and a portion of surface 210 of web 104 in the proximity of leading edge 130. In one embodiment, component 220 is a strip of single-sided adhesive tape that sticks to both the core-forming substrate and the web. In another embodiment, component 220 is a strip of thermoplastic that can be thermally fused to both the core-forming substrate and the web. More examples of attachment configurations are discussed below.

Herein, core-forming substrate 106 is attached to leading edge 130 of web 104 if core-forming substrate 106 is attached to at least one of leading edge 130, a portion of surface 210 of web 104 in the proximity of leading edge 130, and a portion of surface 212 of web 104 in the proximity of leading edge 130. Similarly, a core-forming substrate is attached to the trailing edge of the web if the core-forming substrate is attached to at least one of the trailing edge and a portion of at least one surface of the web in the proximity of the trailing edge.

Web 104 can be attached to core-forming substrate 106 by a variety of means. For example, they can be attached with an adhesive. The adhesive can be disposed on web 104, core-forming substrate 106, or both web 104 and core-forming substrate 106. The adhesive can be a thermally-activated adhesive. In another embodiment, web 104 is attached to core-forming substrate 106 with double-sided adhesive tape disposed between web 104 and core-forming substrate 106. In another embodiment, as discussed above, web 104 is attached to core-forming substrate 106 with single-sided adhesive tape. In another embodiment, web 104 is attached to core-forming substrate 106 by thermal fusion. As discussed above with reference to FIG. 2B and FIG. 2C, web 104 can be thermally fused to core-forming substrate 106 with the use of a thermoplastic strip, component 220. Web 104 can also be thermally fused directly to core-forming substrate 106. One skilled in the art can devise other means for attaching web 104 to core-forming substrate 106, including mechanical crimping. More details of methods for attaching web 104 to core-forming substrate 106 are discussed below, with reference to FIG. 5A-FIG. 5H.

FIG. 3A-FIG. 3E (View B only) illustrate the basic process of forming an in-line core and winding a web onto the in-line core. FIG. 3A shows the initial stage with web 104 attached to core-forming substrate 106. The leading edge 202 of core-forming substrate 106 is depicted as a ball for illustration purposes only. In FIG. 3B, winding of core-forming substrate 106 is initiated. In FIG. 3C, winding of core-forming substrate 106 continues. In FIG. 3D, winding of core-forming substrate 106 is completed, and an in-line core 302 is formed. In FIG. 3E, web 104 is wound onto the in-line core 302 to form wound web roll 304.

In the example shown in FIG. 3D, the in-line core 302 is formed from one complete revolution of core-forming substrate 106. In general, an in-line core can be formed from part of a revolution, one revolution, or multiple revolutions of core-forming substrate 106.

FIG. 4A-FIG. 4C (View A only) illustrate geometrical configurations for streaming production of wound web rolls with in-line cores. In FIG. 4A, webs and core-forming substrates are attached in alternating sequence: core-forming substrate 410A, web 420A, core-forming substrate 410B, web 420B, core-forming substrate 410C, web 420C, core-forming substrate 410D, . . . . During later processing, segments are cut off. The segments can be cut off in different configurations. In a first configuration, the segments are cut off along cut line 430A-cut line 430D. In a second configuration, the segments are cut off along cut line 440A-cut line 440D.

FIG. 4B shows a representative segment according to the first configuration. Core-forming substrate 410C is attached to the leading edge of web 420C. FIG. 4C shows a representative segment according to the second configuration. Core-forming substrate 410A-1 is attached to the leading edge of web 420A, and core-forming substrate 410B-2 is attached to the trailing edge of web 420A.

As shown in FIG. 9A and FIG. 9B (View B only), core-forming substrate 410B-2 can be used as finishing tabs on the finished wound web rolls. In FIG. 9A, core-forming substrate 410B-2 is used as a pull tab 902 to release an adhesive web 904 (such as adhesive tape) from a finished wound web roll 906. For illustration, web 904 is partially unwound from wound web roll 906. In FIG. 9B, core-forming substrate 410B-2 is used as a sealing tab 912 to seal a non-adhesive web 914 (such as plastic film) to prevent the finished wound web roll 916 from unwinding. For illustration, web 914 is partially unwound from wound web roll 916.

FIG. 5A-FIG. 5H (View B only) show different composite structures of a core-forming substrate attached to a web. The composite structures are pre-configured and pre-attached in upstream processes, as described below with reference to the substrate inserter assembly shown in FIG. 7A-FIG. 7S. The figures depict the stage in which a first wound web roll 502 with an in-line core 504 is being completed, and a second in-line core is being started. In FIG. 5A-Fig. E, web 514 is an open-adhesive web such as adhesive tape. Herein, an open adhesive refers to adhesive that is already present on the material as supplied. Web 514 has a surface 510 and a surface 512. As supplied, web 514 has open adhesive 516O disposed on surface 510. Core-forming substrate 524 has a surface 520 and a surface 522. Bare mandrel 506 corresponds to mandrel 804 described below with reference to the turret winder assembly shown in FIG. 8A-FIG. 8Q.

In FIG. 5A, web 514 is continuous, and core-forming substrate 524 is applied in parallel with web 514. Core-forming substrate 524 extends from reference line 551 to reference line 557. Open adhesive 516O sticks surface 522 of core-forming web 524 to surface 510 of web 514. Applied adhesive 526A is applied on surface 520 of core-forming substrate 524 from reference line 555 to reference line 557. Herein, an applied adhesive is an adhesive that is applied to a material during processing; an applied adhesive is disposed on the surface on which it has been applied. Applied adhesive 526A can be applied either along the longitudinal axis or along the transverse axis. Applied adhesive 526A causes core-forming substrate 524 to adhere to itself as it is wound. No adhesive is applied on surface 520 between reference line 551 and reference line 555. The distance between reference line 551 and reference line 555 is approximately equal to the circumference of bare mandrel 506 so that the first wrap of the in-line core does not have exposed adhesive on the inner diameter. More details of the geometry of adhesive placement are described below with reference to FIG. 11A-FIG. 11E.

Reference line 557 is the demarcation line between the trailing edge of core-forming substrate 524 and the leading edge of web 514 for the next wound web roll. Reference line 553 is the cut line that demarcates the end of wound web roll 502 and the start of the in-line core for the next web roll. If a pull tab for wound web roll 502 is desired, reference line 553 is offset from reference line 551. If no pull tab is desired, reference line 553 coincides with reference line 551.

FIG. 11A-FIG. 11E show in more detail the geometry of adhesive placement. Refer to FIG. 11A. The core-forming substrate has a section 1102 and a section 1104. The surfaces of both sections are referenced as surface 1120 and surface 1122. There is no adhesive on either surface of section 1102. Adhesive 1126 is disposed on surface 1120 of section 1104. Section 1102 has leading edge 1101. Section 1104 is attached to the leading edge of web 1130.

In FIG. 11B, winding of section 1102 is initiated. In FIG. 11C, winding of section 1102 is completed. The length of section 1102 is sufficient for at least one complete revolution. Note that the inside surface of the first wrap is surface 1120, which has no adhesive disposed on it. In FIG. 11D, winding of section 1104 is initiated. As section 1104 is wound onto section 1102, adhesive 1126 causes section 1104 to stick onto section 1102. In FIG. 11E, winding of section 1104 is completed. In the example shown, the length of section 1104 is sufficient for two revolutions. In general, multiple revolutions can be used. As section 1104 is wound, adhesive 1126 causes it to stick to a previously wound portion of section 1104.

In the embodiment shown in FIG. 11E, the finished in-line core 1140 is a core formed from multiple wraps of a core-forming substrate bonded together with adhesive. One skilled in the art can develop other means for bonding, such as thermal fusion. The finished in-line core 1140 has a wall thickness 1141, which is the difference between the outside radius and the inside radius.

The inner wrap is formed from section 1120, which has no adhesive, and the outer wraps are formed from section 1104, which has adhesive disposed on one surface. The inside surface of the finished in-line core 1140 is therefore surface 1120, which has no adhesive disposed on it. In many applications, it is desirable to have no adhesive on the inside surface. For example, exposed adhesive would attract dirt, interfere with loading the finished wound web roll onto a dispensing spindle, and interfere with handling by a user (that is, exposed adhesive would stick to fingers). In FIG. 11E, winding of web 1130 onto the finished in-line core 1140 can then proceed, as previously shown in FIG. 3E.

The configuration shown in FIG. 5B is similar to that shown in FIG. 5A (core-forming substrate applied in parallel with web), except that core-forming substrate 524 has open adhesive 526O disposed on surface 520. Non-adhesive liner 534 is disposed on open adhesive 526O between reference line 551 and reference line 559. The length of non-adhesive liner 534 (distance between reference line 551 and reference line 559) is approximately equal to the circumference of bare mandrel 506 so that the first wrap of the in-line core does not have exposed adhesive on the inner diameter. Note that non-adhesive liner 534 can be applied to a portion of core-forming substrate 524 that is initially not covered by any non-adhesive liner. Alternatively, core-forming substrate 524 can initially be completely covered by a non-adhesive liner, and a portion of the non-adhesive liner can be stripped away and removed to leave behind non-adhesive liner 534. Non-adhesive liner 534 can be applied or stripped away along the longitudinal axis or along the transverse axis.

In the configuration shown in FIG. 5C, the web is discontinuous, and the core-forming substrate is applied in series with the web. The web includes two segments, web 514A and web 514B. Open adhesive 516O sticks surface 510 of web 514A to surface 522 of core-forming substrate 524 between reference line 551 and reference line 553. Open adhesive 516O sticks surface 510 of web 514B to surface 522 of core-forming substrate 524 between reference line 557 and reference line 561. As in the configuration shown previously in FIG. 5A, applied adhesive 526A is applied on surface 520 of core-forming substrate 524 between reference line 555 and reference line 557.

The configuration shown in FIG. 5D is similar to that shown in FIG. 5C (core-forming substrate applied in series with web), except that core-forming substrate 524 has open adhesive 526O disposed on surface 520. Non-adhesive liner 534 is disposed on open adhesive 526O between reference line 551 and reference line 559. The length of non-adhesive liner 534 (distance between reference line 551 and reference line 559) is approximately equal to the circumference of bare mandrel 506 so that the first wrap of the in-line core does not have exposed adhesive on the inner diameter.

The configuration shown in FIG. 5E is similar to the configuration shown in FIG. 5C (core-forming substrate applied in series with web), except core-forming substrate 524 has open adhesive 528O disposed on surface 522. Open adhesive 516O on surface 510 of web 514A and open adhesive 528O stick surface 510 of web 514A to surface 522 of core-forming substrate 524 between reference line 551 and reference line 553. Open adhesive 516O and open adhesive 528O stick surface 510 of web 514B to surface 522 of core-forming substrate 524 between reference line 557 and reference line 561. Note that, instead of having open adhesive 528O on surface 522, an applied adhesive can be applied to surface 522.

In FIG. 5F-FIG. 5H, web 514 is a non-adhesive web (for example, bare plastic film). In FIG. 5F and FIG. 5G, the web is continuous, and the core-forming substrate is applied in parallel with the web. In FIG. 5H, the web is discontinuous, and the core-forming substrate is applied in series with the web.

In the configuration shown in FIG. 5F, core-forming substrate 524 has open adhesive 528O on surface 522. Applied adhesive 526A is applied on surface 520 between reference line 555 and reference line 557. If a sealing tab on wound web roll 502 is desired, applied adhesive 526A is also applied on surface 520 between reference line 551 and reference line 553. Note that, instead of having open adhesive 528O on surface 522, an applied adhesive can be applied to surface 522.

The configuration shown in FIG. 5G is similar to the one shown in FIG. 5F, except core-forming substrate 524 has open adhesive 526O on surface 520 and open adhesive 528O on surface 522 (double-sided adhesive). Non-adhesive liner 534 is disposed on open adhesive 526O between reference line 553 and reference line 559. The length of non-adhesive liner 534 (distance between reference line 553 and reference line 559) is approximately equal to the circumference of bare mandrel 506 so that the first wrap of the in-line core does not have exposed adhesive on the inner diameter. If a sealing tab on wound web roll 502 is desired, reference line 553 is offset from reference line 551. If a sealing tab on wound roll 502 is not desired, reference line 553 coincides with reference line 551. Note that, instead of having open adhesive 528O on surface 522, an applied adhesive can be applied to surface 522.

In FIG. 5H, the web is discontinuous: the web includes two segments, web 514A and web 514B. Core-forming substrate 524 has open adhesive 528O on surface 522. Open adhesive 528O sticks surface 510 of web 514A to surface 522 of core-forming substrate 524 between reference line 551 and reference line 553. Open adhesive 528O sticks surface 510 of web 514B to surface 522 of core-forming substrate 524 between reference line 557 and reference line 561. If a sealing tab on wound roll 502 is desired, applied adhesive 526A is applied on surface 520 of core-forming substrate 524 between reference line 551 and reference line 553.

For streaming production, the sequence of core-forming substrate/web/core-forming substrate/web . . . is repeated. Herein, a composite substrate-web stream comprises an alternating sequence of attached core-forming substrate segments and web segments. Each core-forming substrate segment has a leading edge and a trailing edge, and each web segment has a leading edge and a trailing edge. To simplify geometrical descriptions herein, a core-forming substrate segment includes a core-forming substrate and any portion of web overlapping it or inserted into it.

For example, in FIG. 2B, a core-forming substrate segment includes core-forming substrate 106 and the portion of web 104 between leading edge 130 of web 104 and the trailing edge 204 of core-forming substrate 106. In FIG. 5A, core-forming substrate 524 is attached in parallel to continuous web 512. A core-forming substrate segment then includes core-forming substrate 524 and the section of web 512 between the leading edge 551 and the trailing edge 557 of core-forming substrate 524. In FIG. 5D, core-forming substrate 524 is attached in series between web 514A and web 514B. A core-forming substrate segment then includes core-forming substrate 524, the section of web 514A between leading edge 551 of core-forming substrate 524 and the trailing edge 553 of web 514A, and the section of web 514B between trailing edge 557 of core-forming substrate 524 and leading edge 561 of web 512.

Under this geometrical terminology, a web segment is attached to a core-forming substrate segment. The trailing edge of a core-forming substrate segment also serves as the demarcation line for the leading edge of the attached web segment. FIG. 4A then can also be viewed as a composite substrate-web stream comprising an alternating sequence of core-forming substrate segments 410A-410D and web segments 420A-420C.

FIG. 6 (View B only) illustrates an embodiment of a manufacturing system (streaming winding system) for streaming production of wound web rolls with in-line cores. The streaming winding system includes three main modules: web supplier module 602, substrate inserter module 604, and winder module 606. Web 514 is unwound from web supply roll 610 mounted in web supplier module 602. Web 514 is fed into substrate inserter module 604, passed around roller 622, and fed into substrate inserter assembly 620, which inserts core-forming substrate 524 onto web 514 (either in parallel or in series). A continuous sequence of core-forming substrate 524/web 514 is outputted from substrate inserter assembly 620, passed around roller 624, and fed into roller assembly 636 in winder module 606.

One skilled in the art can assemble the modules in various physical configurations. For example, all modules can be housed in a single frame. In another example, the winder module and the substrate inserter module can be housed in one frame, and the web supplier module can be housed in a second frame. In another example, the three modules can each be housed in individual frames. One skilled in the art can also group functions in various configurations. For example, the slitting operation (described below) can be grouped with the winding module or with the substrate module; the slitting operation can also be performed in an independent module.

Various components such as rollers and turrets are driven by drive systems such as electrical motors. The drive systems and the overall sequence of operations are controlled in response to commands issued by a control unit. The control unit, for example, can be a computerized control unit or a programmable logic controller control unit.

In the embodiment shown in FIG. 6, winder module 606 operates in a duplex mode, with twin turret winder assemblies, turret winder assembly 630 and turret winder assembly 634, which is a duplicate of turret winder assembly 630. In another embodiment, winder module 606 operates in a simplex mode, with a single turret winder assembly 630. Duplex and simplex operation are discussed in more detail below.

More details of substrate inserter assembly 620 are shown in FIG. 7A-FIG. 7S below. More details of turret winder assembly 630 are shown in FIG. 8A-FIG. 8R below.

FIG. 7A-FIG. 7S (View B only) show a sequence of operations in substrate inserter assembly 620. FIG. 7A-FIG. 7L show a sequence of operations for applying a core-forming substrate in parallel to a web. FIG. 7A shows a schematic of the basic setup. Web 514 is fed from roller 622 (see FIG. 6) and is fed around drive roller 702 and drive roller 704. Core-forming substrate 524 is fed from core-forming substrate supply roll 720 and is fed around roller 722 and roller 724. The free end of core-forming substrate 524 is initially held in place by clamp 740. In embodiments in which a non-adhesive liner is used, non-adhesive liner 534 is guided by liner peel-off roller 732 and rewound onto liner rewinder 730. In this example, non-adhesive liner is stripped away from core-forming substrate. In embodiments in which an adhesive is applied, glue head 750 is installed. In embodiments in which graphics are printed on the core-forming substrate 524, print head 760 is installed. Printing is described in further detail below with reference to FIG. 10. The functions of gripper 708, nip roller 706, and table 710 are described below. Additional components can be installed; for example, a heat source for activating thermally-activated adhesive or a heat source for fusing a core-forming substrate onto a web.

In FIG. 7B, the jaws of gripper 708 are opened and positioned around the free end of core-forming substrate 524. In FIG. 7C, the jaws of gripper 708 are closed onto the free end of core-forming substrate 524. In FIG. 7D, clamp 740 is opened. In FIG. 7E, gripper 708 pulls a user-specified length of core-forming substrate 524 over table 710. In FIG. 7F, clamp 740 closes, and cut-off knife 742 cuts off a section 524A of core-forming substrate 524. In addition to a knife, other means for cutting can be used; for example, a laser. The length of core-forming substrate 524A can be varied to produce a user-specified wall thickness of the subsequent in-line formed core. In FIG. 7G, the jaws of gripper 708 are opened. In FIG. 7H, gripper 708 is retracted, and core-forming substrate 524A lies on table 710. In FIG. 7I, table 710 is inclined to position the leading edge of core-forming substrate 524A onto web 514 at drive roller 704. Nip roller 706 is lowered to nip the leading edge of core-forming substrate 524A onto web 514. In FIG. 7J, web 514 and core-forming substrate 524A are fed through drive roller 704 and nip roller 706 to form an adhesive bond between core-forming substrate 524A and web 514. Core-forming substrate 524A is attached in parallel to web 514.

FIG. 7K and FIG. 7L show an alternate feeding mechanism for the core-forming substrate 524. Refer to FIG. 7K. Instead of the gripper 708 and clamp 740 shown in FIG. 7A, the free end of core-forming substrate 524 is gripped by nipped drive rollers 770 and 772. In FIG. 7L, nipped drive rollers 770 and 772 feed a user-specified length of core-forming substrate 524 over table 710. A section 524A of core-forming substrate 524 is cut off (not shown), and the process then continues as in FIG. 7I and FIG. 7J.

FIG. 7M-FIG. 7S show a sequence of operations for applying a core-forming substrate in series with a web. The basic setup is shown in FIG. 7M. Components common to FIG. 7A-FIG. 7L are labelled the same. Core-forming substrate 524 is fed by nipped drive rollers 770 and 772. Web 514 is fed by drive roller 704 and nip roller 706. Web 514 is supported by hinged table 780 and fixed table 782.

In FIG. 7N, cut-off knife 784 cuts a section 514A from web 514. Fixed table 782 helps support web 514A during and after the cutting operation. In FIG. 7O, table 780 is inclined to provide clearance, and web 514 is held against drive roller 702 by nip roller 786. Table 710 is inclined, and the leading edge of core-forming substrate 524 is fed onto the trailing edge of web 514A between drive roller 704 and nip roller 706. Fixed table 782 helps direct the leading edge of core-forming substrate 524 into the proper position. In FIG. 7P, cut-off knife 742 cuts a section 524A from core-forming substrate 524. The length of core-forming substrate 524A can be varied to produce a user-specified wall thickness of the subsequent in-line formed core.

In FIG. 7Q, core-forming substrate 524A continues to be fed through drive roller 704 and nip roller 706. In FIG. 7R, table 710 and table 780 are returned to horizontal. The trailing edge of core-forming substrate 524A is positioned on top of the leading edge of web 514B (new section) and clamped by clamp 788 to form an adhesive bond. Fixed table 782 helps support the trailing edge of core-forming substrate 524A during the bonding operation. In FIG. 7S, clamp 788 is released. Core-forming substrate 524A is thus attached in series to web 514A and web 514B.

In the embodiment of the substrate inserter assembly 620 shown in FIG. 7A-FIG. 7S, the core-forming substrate is fed along the longitudinal axis of the web. In another embodiment, the core-forming substrate is fed along the transverse axis.

FIG. 8A-FIG. 8R (View B only) show a sequence of operations in turret winder assembly 630 (see FIG. 6). FIG. 8A shows a turret 802 on which are mounted two mandrels: mandrel 806 and mandrel 804. As discussed below, the diameter of a mandrel can increase and decrease. For example, a mandrel can contain an air bladder that can be inflated to increase the diameter and deflated to decrease the diameter. Other means for increasing and decreasing the diameter can be used. At this stage, mandrel 806 is bare, and an in-line core 820 (formed from a core-forming substrate) has been wound on mandrel 804. The process for forming in-line core 820 is described in detail below. Web 514 is fed from roller assembly 636 (see FIG. 6). Lay-on roller 808 nips web 514 to in-line core 820.

In FIG. 8B, mandrel 804 rotates. A user-specified length of web 514 is wound onto in-line core 820 to produce wound web roll 830. In FIG. 8C, lay-on roller 808 retracts. In FIG. 8D, turret 802 is indexed 180 degrees clockwise. Wound web roll 830 is transferred to the unload position, and mandrel 806 is transferred to the wind position. In FIG. 8E, core-forming substrate 524 is fed from roller assembly 636 (as described above, substrate inserter module 604 feeds a continuous sequence of core-forming substrate/web/core-forming substrate/web . . . to winder module 606). Lay-on roller 808 nips core-forming substrate 524 to mandrel 806. Winding of web 514A (a segment of web 514) resumes until core-forming substrate 524 advances to a user-specified position.

In FIG. 8F, support arm 870 is swung around articulated joint 860 into operational position. Articulated joint 860 is coupled to a support infrastructure (not shown). Refer to FIG. 8R. Enveloper assembly 880 includes support arm 870, support arm 872 coupled to support arm 870 by articulated joint 862, support arm 874 coupled to support arm 872 by articulated joint 864, and enveloper roller 846 coupled to support arm 874. Also coupled to support arm 870 are wipedown assembly 890 and web support bar 842. Wipedown assembly 890 includes support arm 876 coupled to support arm 870 by articulated joint 866 and wipedown roller 844 coupled to support arm 876. To simplify the drawings, in FIG. 8F-FIG. 8Q, the dashed rectangle representing enveloper assembly 880 and the dashed rectangle representing wipedown assembly 890 are not shown; however, the individual components of enveloper assembly 880 and wipedown assembly 890 are called out.

In FIG. 8F, enveloper roller 846 nips core-forming substrate 524 against mandrel 806 at nip position 881. In FIG. 8G, wipedown roller 844 nips against wound web roll 830. In FIG. 8H, cut-off knife 850 severs core-forming substrate 524 at a user-specified position into segment 524A and segment 524B. If a pull tab or sealing tab (see FIG. 9A and FIG. 9B) is desired, a segment 524B of core-forming substrate is left attached to the trailing edge of web 514A. If a pull tab or sealing tab is not desired, cut-off knife 850 severs core-forming substrate 524 at the leading edge of core-forming substrate 524 (no segment 524B). In FIG. 8I, web 514A and segment 524B are wound onto wound web roll 830, which is now completely finished. Leading edge 527 is now the new leading edge of core-forming substrate 524.

In FIG. 8J, enveloper roller 846 sweeps core-forming substrate 524 around mandrel 806. Enveloper roller 846 nips core-forming 524 against mandrel 806; the nip position follows the surface of mandrel 806 from nip position 881 to nip position 883. In FIG. 8K, mandrel 806 rotates until a user-specified length of core-forming substrate 524 is wound for the tucking operation. Tail tucker 850 is brought into position. In FIG. 8L, tail tucker 850 nips core-forming substrate 524 against mandrel 806 in close proximity to lay-on roller 808. In FIG. 8M, mandrel 806 rotates, and leading edge 527 of core-forming substrate 524 is guided into the nip between mandrel 806 and lay-on roller 808.

In FIG. 8N, tail tucker 850 and support arm 870 retract from their operational positions. Mandrel 804 deflates to allow wound web roll 830 to be removed. In FIG. 8O, wound web roll 830 has been removed, and mandrel 804 is now bare. Mandrel 806 expands to hold core-forming substrate 524 as winding begins, and a new in-line core is started. In FIG. 8P, core forming is complete when the trailing edge of core-forming substrate 524 is wound onto mandrel 806. A pre-attached leading edge of web 514 follows and roll formation begins. This is the stage previously shown in FIG. 8A with mandrel 804 as the winding mandrel. In FIG. 8Q, the winding process continues until the desired roll size is achieved. This is the stage previously shown in FIG. 8B with mandrel 804 as the winding mandrel. The sequence described above then repeats.

In the example shown in FIG. 8A-FIG. 8Q, a single wound web roll was produced on a single mandrel. In general, multiple web rolls can be produced in parallel on a single mandrel. FIG. 10 shows a section of a composite substrate-web stream 1000 which has been slit along longitudinal slit line 1040 and longitudinal slit line 1050 to produce three composite substrate-web stream strips: composite substrate-web stream strip 1014, composite substrate-web stream strip 1024, and composite substrate-web stream strip 1034. Each composite substrate-web stream strip comprises an alternating sequence of attached core-forming substrate segment strips and web segment strips. Composite substrate-web stream strip 1014 includes core-forming substrate segment strip 1012A, web segment strip 1010A, core-forming substrate segment strip 1012B, and web segment strip 1010B. Composite substrate-web stream strip 1024 includes core-forming substrate segment strip 1022A, web segment strip 1020A, core-forming substrate segment strip 1022B, and web segment strip 1000B. Composite substrate-web stream strip 1034 includes core-forming substrate segment strip 1032A, web segment strip 1030A, core-forming substrate segment strip 1032B, and web segment strip 1030B. In general, the number of composite substrate-web stream strips that can be slit from a single composite substrate-web stream is user-specified.

Multiple wound web rolls can be produced in parallel on a single mandrel in a single turret winder assembly 630 (see FIG. 6). A composite substrate-web stream 524/514 is received by winder module 606 from substrate inserter module 604. Composite substrate-web stream 524/514 is fed by roller system 636, details of which are not discussed. Slitting knife 650 can be brought into position to slit composite substrate-web stream 524/514 into two composite substrate-web stream strips. In general, multiple slitting knives can be used in parallel to slit a composite substrate-web stream into a user-specified number of composite substrate-web stream strips. In addition to a slitting knife, other means for slitting can be used; for example, a laser. In general, the slitting operation can be performed at a user-specified position after the substrate insertion operation and before the winding operation.

Refer to FIG. 8A-FIG. 8Q. Multiple composite substrate-web stream strips can be wound in parallel on a single mandrel. Enveloper roller 846 can be a single full-width roller that processes multiple composite substrate-web stream strips; multiple shorter enveloper rollers mounted on a common axis can also be used. Similarly, tail tucker 850 can have a single roller or multiple rollers mounted at the end of a single pair of arms.

In one embodiment, winder module 606 can outfitted with a single turret winder assembly, such as turret winder assembly 630 (simplex mode). All composite substrate-web stream strips are processed in parallel on mandrel 804 and mandrel 806 (see FIG. 8A). In the embodiment shown in FIG. 6, winder module 606 is outfitted with dual turret winder assemblies (duplex mode). Turret winding assembly 630 and turret winding assembly 640 are duplicates. In duplex mode, multiple composite substrate-web stream strips are fed alternately to turret winding assembly 630 and turret winding assembly 640. For example, assume that composite substrate-web stream 524/514 is slit into four composite substrate-web stream strips, labelled strip 1, strip 2, strip 3, strip 4. Then strip 1 and strip 3 are fed to turret winding assembly 630, and strip 2 and strip 4 are fed to turret winding assembly 640. In the simplex mode, the multiple strips loaded onto a single mandrel are close together. In some instances, one strip can interfere with the winding of an adjacent strip (for example, if they rub against each other). In the duplex mode, the multiple strips loaded onto a single mandrel are spaced further apart.

As discussed above, auxiliary operations such as printing can be performed during the substrate insertion operation in substrate inserter module 604. In FIG. 10, graphics, including text and images are applied to the core-forming substrate segment strips (1012A, 1012B, 1022A, 1022B, 1032A, and 1032B). Examples of graphics include manufacturer's name and logo, product name, product identification number, lot number, manufacturing date, and bar code. In the finished in-line core, the graphics would be visible on the inner surface (surface 1120 in FIG. 11E). The graphics can be applied by printing directly onto the core-forming substrate via a print head (such as print head 760 in FIG. 7A). Graphics can also be applied by other means; for example, sticking a printed label onto a core-forming substrate.

The foregoing Detailed Description is to be understood as being in every respect illustrative and exemplary, but not restrictive, and the scope of the invention disclosed herein is not to be determined from the Detailed Description, but rather from the claims as interpreted according to the full breadth permitted by the patent laws. It is to be understood that the embodiments shown and described herein are only illustrative of the principles of the present invention and that various modifications may be implemented by those skilled in the art without departing from the scope and spirit of the invention. Those skilled in the art could implement various other feature combinations without departing from the scope and spirit of the invention.

Claims

1. A method for winding a web having a leading edge and a trailing edge, the method comprising the steps of:

attaching a core-forming substrate to the leading edge of the web;

winding the core-forming substrate into an in-line core; and

winding the web around the in-line core.

2. The method of claim 1, wherein the step of attaching a core-forming substrate to the leading edge of the web comprises the step of:

attaching the core-forming substrate to the leading edge of the web with an adhesive.

3. The method of claim 2, wherein the adhesive is at least one of:

an open adhesive disposed on at least a portion of a surface of the core-forming substrate;

an applied adhesive disposed on at least a portion of a surface of the core-forming substrate;

an open adhesive disposed on at least a portion of a surface of the web; and

an applied adhesive disposed on at least a portion of a surface of the web.

4. The method of claim 1, wherein the web comprises an open adhesive disposed on a surface of the web, and wherein the core-forming substrate is a first core-forming substrate, further comprising the step of:

attaching a second core-forming substrate to the trailing edge of the web, wherein the second core-forming substrate covers a portion of the open adhesive in the proximity of the trailing edge of the web.

5. The method of claim 1, wherein the web is a non-adhesive web, and wherein the core-forming substrate is a first core-forming substrate, further comprising the step of:

attaching a second core-forming substrate to the trailing edge of the web; and

attaching the second core-forming substrate to a surface of a portion of the previously wound web.

6. The method of claim 1, further comprising the step of:

applying graphics on a surface of the core-forming substrate.

7. A method for winding a web having a leading edge and a trailing edge, the method comprising the steps of:

attaching a core-forming substrate to the leading edge of the web;

slitting the web and the attached core-forming substrate along at least one longitudinal slit line to produce a plurality of substrate-web strips, each substrate-web strip comprising a strip of the core-forming substrate attached to the leading edge of a strip of the web; and

for each substrate-web strip: winding the strip of the core-forming substrate into an in-line core; and winding the strip of the web around the in-line core.

8. The method of claim 7, further comprising the step of:

applying graphics on a surface of the core-forming substrate.

9. A method for winding a plurality of webs, the method comprising the steps of:

producing a composite substrate-web stream comprising an alternating sequence of attached core-forming substrate segments and web segments, wherein each core-forming substrate segment has a leading edge and a trailing edge and wherein each web segment has a leading edge and a trailing edge;

winding at least a portion of a first core-forming substrate segment into a first in-line core;

winding a portion of a first web segment around the first in-line core, wherein the first web segment is disposed between the trailing edge of the first core-forming substrate segment and the leading edge of a second core-forming substrate segment; and

cutting the composite substrate-web stream along a first cut line.

10. The method of claim 9, wherein the first cut line is disposed along the leading edge of the second core-forming substrate segment, further comprising the step of:

winding the remaining portion of the first web segment around the first in-line core.

11. The method of claim 10, further comprising the steps of:

winding the second core-forming substrate segment into a second in-line core;

winding a portion of a second web segment around the second in-line core, wherein the second web segment is disposed between the trailing edge of the second core-forming substrate segment and the leading edge of a third core-forming substrate segment;

cutting the composite substrate-web stream along a second cut line disposed along the leading edge of the third core-forming substrate; and

winding the remaining portion of the second web segment around the second in-line core.

12. The method of claim 9, wherein the first cut line is disposed between the leading edge and the trailing edge of the second core-forming substrate segment, further comprising the step of:

winding the remaining portion of the first web segment and a first portion of the second core-forming substrate segment around the first in-line core, wherein the first portion of the second core-forming substrate segment is disposed between the leading edge of the second core-forming substrate segment and the first cut line.

13. The method of claim 12, further comprising the steps of:

winding a second portion of the second core-forming substrate segment into a second in-line core, wherein the second portion of the second core-forming substrate segment is disposed between the first cut line and the trailing edge of the second core-forming substrate segment;

winding a portion of a second web segment around the second in-line core, wherein the second web segment is disposed between the trailing edge of the second core-forming substrate segment and the leading edge of a third core-forming substrate segment;

cutting the substrate-web composite stream along a second cut line disposed between the leading edge and the trailing edge of the third core-forming substrate segment; and

winding the remaining portion of the second web segment and a first portion of the third core-forming substrate segment around the second in-line core, wherein the first portion of the third core-forming substrate segment is disposed between the leading edge of the third core-forming substrate and the second cut line.

14. The method of claim 9, wherein the step of producing a composite substrate-web stream comprises the step of:

attaching a plurality of spaced-apart core-forming substrates on a surface of a continuous web.

15. The method of claim 9, wherein the step of producing a composite substrate-web stream comprises the step of:

attaching a plurality of spaced-apart core-forming substrates to a plurality of spaced-apart webs in alternating sequence.

16. The method of claim 9, further comprising the step of:

applying graphics to a core-forming substrate segment.

17. A method for winding a plurality of webs, the method comprising the steps of:

producing a composite substrate-web stream comprising an alternating sequence of attached core-forming substrate segments and web segments, wherein each core-forming substrate segment has a leading edge and a trailing edge and wherein each web segment has a leading edge and a trailing edge;

slitting the composite substrate-web stream along at least one longitudinal slit line to produce a plurality of composite substrate-web stream strips, each composite substrate-web stream strip comprising an alternating sequence of attached core-forming substrate segment strips and web segment strips, wherein each core-forming substrate segment strip has a leading edge and a trailing edge and wherein each web segment strip has a leading edge and a trailing edge; and

for each composite substrate-web strip: winding at least a portion of a first core-forming substrate segment strip into a first in-line core; winding a portion of a first web segment strip around the first in-line core, wherein the first web segment strip is disposed between the trailing edge of the first core-forming substrate segment strip and the leading edge of a second core-forming substrate segment strip; and cutting the composite substrate-web stream strip along a first cut line.

18. The method of claim 17, wherein for each composite substrate-web strip the first cut line is disposed along the leading edge of the second core-forming substrate segment strip, further comprising the steps of:

for each composite substrate-web stream strip: winding the remaining portion of the first web segment strip around the first in-line core.

19. The method of claim 18, further comprising the steps of:

for each composite substrate-web stream strip: winding the second core-forming substrate segment strip into a second in-line core; winding a portion of a second web segment strip around the second in-line core, wherein the second web segment strip is disposed between the trailing edge of the second core-forming substrate segment strip and the leading edge of a third core-forming substrate segment strip; cutting the composite substrate-web stream strip along a second cut line disposed along the leading edge of the third core-forming substrate strip; and winding the remaining portion of the second web segment strip around the second in-line core.

20. The method of claim 17, wherein for each composite substrate-web stream strip the first cut line is disposed between the leading edge and the trailing edge of the second core-forming substrate segment strip, further comprising the steps of:

for each composite substrate-web stream strip: winding the remaining portion of the first web segment strip and a first portion of the second core-forming substrate segment strip around the first in-line core, wherein the first portion of the second core-forming substrate segment strip is disposed between the leading edge of the second core-forming substrate segment strip and the first cut line.

21. The method of claim 20, further comprising the steps of:

for each composite substrate-web stream strip: winding a second portion of the second core-forming substrate segment strip into a second in-line core, wherein the second portion of the second core-forming substrate segment strip is disposed between the first cut line and the trailing edge of the second core-forming substrate segment strip; winding a portion of a second web segment strip around the second in-line core, wherein the second web segment strip is disposed between the trailing edge of the second core-forming substrate segment strip and the leading edge of a third core-forming substrate segment strip; cutting the substrate-web composite stream strip along a second cut line disposed between the leading edge and the trailing edge of the third core-forming substrate segment strip; and winding the remaining portion of the second web segment strip and a first portion of the third core-forming substrate segment strip around the second in-line core, wherein the first portion of the third core-forming substrate segment strip is disposed between the leading edge of the third core-forming substrate strip and the second cut line.

22. The method of claim 17, wherein the step of producing a composite substrate-web stream comprises the step of:

attaching a plurality of spaced-apart core-forming substrates on a surface of a continuous web.

23. The method of claim 17, wherein the step of producing a composite substrate-web stream comprises the step of:

attaching a plurality of spaced-apart core-forming substrates to a plurality of spaced-apart webs in alternating sequence.

24. The method of claim 17, further comprising the step of:

applying graphics to a core-forming substrate segment.

25. An apparatus for winding a web having a leading edge and a trailing edge, the apparatus comprising:

means for attaching a core-forming substrate to the leading edge of the web;

means for winding the core-forming substrate into an in-line core; and

means for winding the web around the in-line core.

26. The apparatus of claim 25, wherein the means for attaching a core-forming substrate comprises:

means for attaching the core-forming substrate to the leading edge of the web with an adhesive.

27. The apparatus of claim 25, wherein the web comprises an open adhesive disposed on a surface of the web, and wherein the core-forming substrate is a first core-forming substrate, further comprising:

means for attaching a second core-forming substrate to the trailing edge of the web, wherein the second core-forming substrate covers a portion of the open adhesive in the proximity of the trailing edge of the web.

28. The apparatus of claim 25, wherein the web is a non-adhesive web, and wherein the core-forming substrate is a first core-forming substrate, further comprising:

means for attaching a second core-forming substrate to the trailing edge of the web; and

means for attaching the second core-forming substrate to a surface of a portion of the previously wound web.

29. The apparatus of claim 25, further comprising:

means for applying graphics on a surface of the core-forming substrate.

30. An apparatus for winding a web having a leading edge and a trailing edge, the apparatus comprising:

means for attaching a core-forming substrate to the leading edge of the web;

means for slitting the web and the attached core-forming substrate along at least one longitudinal slit line to produce a plurality of substrate-web strips, each substrate-web strip comprising a strip of the core-forming substrate attached to the leading edge of a strip of the web; and

for each substrate-web strip: means for winding the strip of the core-forming substrate into an in-line core; and means for winding the strip of the web around the in-line core.

31. The apparatus of claim 30, further comprising:

means for applying graphics on a surface of the core-forming substrate.

32. A streaming winding system comprising:

a substrate inserter module configured to: receive a web; and produce a composite substrate-web stream comprising an alternating sequence of attached core-forming substrate segments and web segments, wherein each core-forming substrate segment has a leading edge and a trailing edge and wherein each web segment has a leading edge and a trailing edge; and

a winder module configured to: receive the composite substrate-web stream; wind at least a portion of a first core-forming substrate segment into a first in-line core; wind a portion of a first web segment around the first in-line core, wherein the first web segment is disposed between the trailing edge of the first core-forming substrate segment and the leading edge of a second core-forming substrate segment; and cut the composite substrate-web stream along a first cut line.

33. The streaming winding system of claim 32, wherein the winder module is further configured to:

position the first cut line along the leading edge of the second core-forming substrate segment; and

wind the remaining portion of the first web segment around the first in-line core.

34. The streaming winding system of claim 33, wherein the winder module is further configured to:

wind the second core-forming substrate segment into a second in-line core;

wind a portion of a second web segment around the second in-line core, wherein the second web segment is disposed between the trailing edge of the second core-forming substrate segment and the leading edge of a third core-forming substrate segment;

cut the composite substrate-web stream along a second cut line disposed along the leading edge of the third core-forming substrate; and

wind the remaining portion of the second web segment around the second in-line core.

35. The streaming winding system of claim 32, wherein the winder module is further configured to:

position the first cut line between the leading edge and the trailing edge of the second core-forming substrate segment; and

wind the remaining portion of the first web segment and a first portion of the second core-forming substrate segment around the first in-line core, wherein the first portion of the second core-forming substrate segment is disposed between the leading edge of the second core-forming substrate segment and the first cut line.

36. The streaming winding system of claim 35, wherein the winder module is further configured to:

wind a second portion of the second core-forming substrate segment into a second in-line core, wherein the second portion of the second core-forming substrate segment is disposed between the first cut line and the trailing edge of the second core-forming substrate segment;

wind a portion of a second web segment around the second in-line core, wherein the second web segment is disposed between the trailing edge of the second core-forming substrate segment and the leading edge of a third core-forming substrate segment;

cut the substrate-web composite stream along a second cut line disposed between the leading edge and the trailing edge of the third core-forming substrate segment; and

wind the remaining portion of the second web segment and a first portion of the third core-forming substrate segment around the second in-line core, wherein the first portion of the third core-forming substrate segment is disposed between the leading edge of the third core-forming substrate and the second cut line.

37. The streaming winding system of claim 32, wherein the substrate inserter module is further configured to:

attach a plurality of spaced-apart core-forming substrates on a surface of a continuous web.

38. The streaming winding system of claim 32, wherein the substrate inserter module is further configured to:

attach a plurality of spaced-apart core-forming substrates to a plurality of spaced-apart webs in alternating sequence.

39. The streaming winding system of claim 32, wherein the substrate inserter module is further configured to:

apply graphics to a core-forming substrate segment.

40. A streaming winding system comprising:

a substrate inserter module configured to: receive a web; and produce a composite substrate-web stream comprising an alternating sequence of attached core-forming substrate segments and web segments, wherein each core-forming substrate segment has a leading edge and a trailing edge and wherein each web segment has a leading edge and a trailing edge; and

a winder module configured to: receive the composite substrate-web stream; slit the composite substrate-web stream along at least one longitudinal slit line to produce a plurality of composite substrate-web stream strips, each composite substrate-web stream strip comprising an alternating sequence of attached core-forming substrate segment strips and web segment strips, wherein each core-forming substrate segment strip has a leading edge and a trailing edge and wherein each web segment strip has a leading edge and a trailing edge; and for each composite substrate-web stream strip: wind at least a portion of a first core-forming substrate segment strip into a first in-line core; wind a portion of a first web segment strip around the first in-line core, wherein the first web segment strip is disposed between the trailing edge of the first core-forming substrate segment strip and the leading edge of a second core-forming substrate segment strip; and cut the composite substrate-web stream strip along a first cut line.

41. The streaming winding system of claim 40, wherein the winder module is further configured to:

for each composite substrate-web stream strip: position the first cut line along the leading edge of the second core-forming substrate segment strip; and wind the remaining portion of the first web segment strip around the first in-line core.

42. The streaming winding system of claim 41, wherein the winder module is further configured to:

for each composite substrate-web stream strip: wind the second core-forming substrate segment strip into a second in-line core; wind a portion of a second web segment strip around the second in-line core, wherein the second web segment strip is disposed between the trailing edge of the second core-forming substrate segment strip and the leading edge of a third core-forming substrate segment strip; cut the composite substrate-web stream strip along a second cut line disposed along the leading edge of the third core-forming substrate strip; and wind the remaining portion of the second web segment strip around the second in-line core.

43. The streaming winding system of claim 40, wherein the winder module is further configured to:

for each composite substrate-web stream strip: position the first cut line between the leading edge and the trailing edge of the second core-forming substrate segment strip; and wind the remaining portion of the first web segment strip and a first portion of the second core-forming substrate segment strip around the first in-line core, wherein the first portion of the second core-forming substrate segment strip is disposed between the leading edge of the second core-forming substrate segment strip and the first cut line.

44. The streaming winding system of claim 43, wherein the winder module is further configured to:

for each composite substrate-web stream strip: wind a second portion of the second core-forming substrate segment strip into a second in-line core, wherein the second portion of the second core-forming substrate segment strip is disposed between the first cut line and the trailing edge of the second core-forming substrate segment strip; wind a portion of a second web segment strip around the second in-line core, wherein the second web segment strip is disposed between the trailing edge of the second core-forming substrate segment strip and the leading edge of a third core-forming substrate segment strip; cut the substrate-web composite stream strip along a second cut line disposed between the leading edge and the trailing edge of the third core-forming substrate segment strip; and wind the remaining portion of the second web segment strip and a first portion of the third core-forming substrate segment strip around the second in-line core, wherein the first portion of the third core-forming substrate segment strip is disposed between the leading edge of the third core-forming substrate strip and the second cut line.

45. The streaming winding system of claim 40, wherein the substrate inserter module is further configured to:

attach a plurality of spaced-apart core-forming substrates on a surface of a continuous web.

46. The streaming winding system of claim 40, wherein the substrate inserter module is further configured to:

attach a plurality of spaced-apart core-forming substrates to a plurality of spaced-apart webs in alternating sequence.

47. The streaming winding system of claim 40, wherein the substrate inserter module is further configured to:

apply graphics on a surface of a core-forming substrate.

48. A streaming winding system comprising:

means for receiving a web;

means for producing a composite substrate-web stream comprising an alternating sequence of attached core-forming substrate segments and web segments, wherein each core-forming substrate segment has a leading edge and a trailing edge and wherein each web segment has a leading edge and a trailing edge;

means for winding at least a portion of a first core-forming substrate segment into a first in-line core;

means for winding a portion of a first web segment around the first in-line core, wherein the first web segment is disposed between the trailing edge of the first core-forming substrate segment and the leading edge of a second core-forming substrate segment; and

means for cutting the composite substrate-web stream along a first cut line.

49. The streaming winding system of claim 48, further comprising:

means for positioning the first cut line along the leading edge of the second core-forming substrate segment; and

means for winding the remaining portion of the first web segment around the first in-line core.

50. The streaming winding system of claim 49, further comprising:

means for winding the second core-forming substrate segment into a second in-line core;

means for winding a portion of a second web segment around the second in-line core, wherein the second web segment is disposed between the trailing edge of the second core-forming substrate segment and the leading edge of a third core-forming substrate segment;

means for cutting the composite substrate-web stream along a second cut line disposed along the leading edge of the third core-forming substrate; and

means for winding the remaining portion of the second web segment around the second in-line core.

51. The streaming winding system of claim 48, further comprising:

means for positioning the first cut line between the leading edge and the trailing edge of the second core-forming substrate segment; and

means for winding the remaining portion of the first web segment and a first portion of the second core-forming substrate segment around the first in-line core, wherein the first portion of the second core-forming substrate segment is disposed between the leading edge of the second core-forming substrate segment and the first cut line.

52. The streaming winding system of claim 51, further comprising:

means for winding a second portion of the second core-forming substrate segment into a second in-line core, wherein the second portion of the second core-forming substrate segment is disposed between the first cut line and the trailing edge of the second core-forming substrate segment;

means for winding a portion of a second web segment around the second in-line core, wherein the second web segment is disposed between the trailing edge of the second core-forming substrate segment and the leading edge of a third core-forming substrate segment;

means for cutting the substrate-web composite stream along a second cut line disposed between the leading edge and the trailing edge of the third core-forming substrate segment; and

means for winding the remaining portion of the second web segment and a first portion of the third core-forming substrate segment around the second in-line core, wherein the first portion of the third core-forming substrate segment is disposed between the leading edge of the third core-forming substrate and the second cut line.

53. The streaming winding system of claim 48, further comprising:

means for attaching a plurality of spaced-apart core-forming substrates on a surface of a continuous web.

54. The streaming winding system of claim 48, further comprising:

means for attaching a plurality of spaced-apart core-forming substrates to a plurality of spaced-apart webs in alternating sequence.

55. The streaming winding system of claim 48, further comprising:

means for applying graphics on a surface of a core-forming substrate.

56. A streaming winding system comprising:

means for receiving a web;

means for producing a composite substrate-web stream comprising an alternating sequence of attached core-forming substrate segments and web segments, wherein each core-forming substrate segment has a leading edge and a trailing edge and wherein each web segment has a leading edge and a trailing edge;

means for slitting the composite substrate-web stream along at least one longitudinal slit line to produce a plurality of composite substrate-web stream strips, each composite substrate-web stream strip comprising an alternating sequence of attached core-forming substrate segment strips and web segment strips, wherein each core-forming substrate segment strip has a leading edge and a trailing edge and wherein each web segment strip has a leading edge and a trailing edge; and

for each composite substrate-web stream strip: means for winding at least a portion of a first core-forming substrate segment strip into a first in-line core; means for winding a portion of a first web segment strip around the first in-line core, wherein the first web segment strip is disposed between the trailing edge of the first core-forming substrate segment strip and the leading edge of a second core-forming substrate segment strip; and means for cutting the composite substrate-web stream strip along a first cut line.

57. The streaming winding system of claim 56, further comprising:

for each composite substrate-web stream strip: means for positioning the first cut line along the leading edge of the second core-forming substrate segment strip; and means for winding the remaining portion of the first web segment strip around the first in-line core.

58. The streaming winding system of claim 57, further comprising:

for each composite substrate-web stream strip: means for winding the second core-forming substrate segment strip into a second in-line core; means for winding a portion of a second web segment strip around the second in-line core, wherein the second web segment strip is disposed between the trailing edge of the second core-forming substrate segment strip and the leading edge of a third core-forming substrate segment strip; means for cutting the composite substrate-web stream strip along a second cut line disposed along the leading edge of the third core-forming substrate strip; and means for winding the remaining portion of the second web segment strip around the second in-line core.

59. The streaming winding system of claim 56, further comprising:

for each composite substrate-web stream strip: means for positioning the first cut line between the leading edge and the trailing edge of the second core-forming substrate segment strip; and means for winding the remaining portion of the first web segment strip and a first portion of the second core-forming substrate segment strip around the first in-line core, wherein the first portion of the second core-forming substrate segment strip is disposed between the leading edge of the second core-forming substrate segment strip and the first cut line.

60. The streaming winding system of claim 59, further comprising:

for each composite substrate-web stream strip: means for winding a second portion of the second core-forming substrate segment strip into a second in-line core, wherein the second portion of the second core-forming substrate segment strip is disposed between the first cut line and the trailing edge of the second core-forming substrate segment strip; means for winding a portion of a second web segment strip around the second in-line core, wherein the second web segment strip is disposed between the trailing edge of the second core-forming substrate segment strip and the leading edge of a third core-forming substrate segment strip; means for cutting the substrate-web composite stream strip along a second cut line disposed between the leading edge and the trailing edge of the third core-forming substrate segment strip; and means for winding the remaining portion of the second web segment strip and a first portion of the third core-forming substrate segment strip around the second in-line core, wherein the first portion of the third core-forming substrate segment strip is disposed between the leading edge of the third core-forming substrate strip and the second cut line.

61. The streaming winding system of claim 56, further comprising:

means for attaching a plurality of spaced-apart core-forming substrates on a surface of a continuous web.

62. The streaming winding system of claim 56, further comprising:

means for attaching a plurality of spaced-apart core-forming substrates to a plurality of spaced-apart webs in alternating sequence.

63. The streaming winding system of claim 56, further comprising:

means for applying graphics on a surface of a core-forming substrate.

64. A wound web roll comprising:

an in-line core formed from a core-forming substrate; and

a web wound around the in-line core, wherein the web has a leading edge and a trailing edge and the leading edge of the web is attached to the core-forming substrate.

65. The wound web roll of claim 64, wherein the core-forming substrate is a first core-forming substrate, further comprising:

a second core-forming substrate attached to the trailing edge of the web.

66. The wound web roll of claim 64, further comprising:

graphics applied on a surface of the core-forming substrate.

67. A wound web roll produced by the steps of:

attaching a core-forming substrate to a leading edge of a web;

winding the core-forming substrate into an in-line core; and

winding the web around the in-line core.

68. The wound web roll of claim 67, wherein the step of attaching a core-forming substrate to a leading edge of a web comprises the step of:

attaching the core-forming substrate to the leading edge of the web with an adhesive.

69. The wound web roll of claim 67, further produced by the step of:

applying graphics to a surface of the core-forming substrate.