Abstract: Dual sided coating system and method for coating substrates, such as substrates useful as battery electrodes. In certain embodiments, the system includes an inline calender station positioned between the dryer and the rewind of the substrate; i.e., positioned downstream, in the direction of substrate (or web) travel, of the dryer, and upstream of the rewind. In certain embodiments, the calender operation is positioned immediately downstream of the dryer; no intermediate equipment that processes the substrata, such as a vacuum dryer, is positioned between the dryer and the calender. Advantages of such a system and method include twice the throughput compared to single side coating operations, a smaller equipment footprint compared to tandem coating lines, lower capital cost and operating cost compared to tandem coating lines, and fewer issues with wrinkles in the substrate.

Abstract: An interfolding machine includes a first folding roll with a series of the gripper assemblies and a series of tucker assemblies uniformly and alternately spaced to interact with a series of gripper and tucker assemblies of an adjacent second folding roll. The series of alternately spaced gripper and tucker assemblies interact to grip, carry, and release a sheet of material in a manner so as to generate an interfolded stack of sheets. Each tucker assembly includes an outwardly biased tucker element that is operable to self-center in a slot formed in the folding roll. The tucker assembly further includes a roller mounted by a pin to the tucker element such that the tucker element rolls along a surface defined by the slot. Another embodiment of the tucker assembly includes a pivot spring and bumper to self-center the tucker element in the slot.

Abstract: A sheet supply system, for use in supplying overlapped sheets to an interfolder, includes a bed roll on which a web is cut into successive sheets. The sheets are supplied to a sheet supply passage leading to retard rolls, which overlap the sheets within the supply passage. The trailing portion of each downstream sheet bulges outwardly as the sheet is supplied to the supply passage. An air tube directs pressurized air into a volume within which the bulge in the downstream sheet is formed. The pressurized air prevents the leading portion of the upstream sheet from being drawn outwardly along with the trailing area of the downstream sheet, by counteracting a vacuum that results from outward movement of the trailing portion of the downstream sheet after it is released from the bed roll.

Abstract: A packaging system for packaging a compressible article, such as a stack of interfolded paper towels, includes a sleeve supply arrangement for supplying a packaging sleeve to a loading area, a reciprocating article supply arrangement for selectively positioning a compressed article in the loading area, and a sleeve advancing arrangement for advancing the formed sleeve onto the compressed article at the loading area. After a sleeve is advanced onto the compressed article, the article supply arrangement is moved away from the loading area. A movable stripper engages the article and the sleeve during movement away from the loading area, to strip the article and the sleeve from the article supply arrangement. As the article and the sleeve are removed from the article supply arrangement, the article undergoes decompression and establishes contact with the sleeve to maintain the article and the sleeve in frictional engagement, to form a pack.

Abstract: A folding machine includes a first folding roll with a series of the gripper assemblies and a series of tucker assemblies uniformly and alternately spaced to interact with a series of gripper and tucker assemblies of an adjacent second folding roll. The series of alternately spaced gripper and tucker assemblies interact to grip, carry, and release material in a manner so as to generate a folded stack of material, such as sheet material. Each of the gripper assemblies generally includes a rotatable blade, a shaft configured to rotate the blade, a spacer disposed between the blade and the shaft, and a bolt coupling the blade and the spacer to the shaft. A housing is configured with seals to retain lubricated bearings to provide rotation of the shaft of the gripper assembly and to prevent contamination of the bearings.

Abstract: A folding machine includes a first folding roll with a series of the gripper assemblies and a series of tucker assemblies uniformly and alternately spaced to interact with a series of gripper and tucker assemblies of an adjacent second folding roll. The series of alternately spaced gripper and tucker assemblies interact to grip, carry, and release a sheet material in a manner so as to generate an interfolded stack of sheet material. The folding machine further includes a phase adjustment assembly configured adjust the location of the fold in the sheet material, to locate the fold in a proper position on the sheet relative to the leading end of the successive sheet. The phase adjustment assembly generally includes a first helical gear that moves along an axial direction, and an input device configured to cause the axial movement of the first gear so as to cause a change in phasing and a change in location of the fold in the sheet material.

Abstract: A wrapping apparatus for wrapping a continuous elongated article, such as a continuous stack of interfolded paper towels, includes a web supply section that supplies a pair of continuous webs of wrapping material, and a wrapping section for applying the continuous pair of webs about the article. The web supply section includes a pair of web supply stations for each web of wrapping material, and a source of wrapping material, such as a supply roll, is located at each web supply station. The web supply section includes a splicing mechanism for each pair of web supply stations, for splicing together the trailing end of a web from an exhausted supply roll of wrapping material with the leading end of a web from a fresh supply roll of wrapping material, to provide a continuous web of wrapping material to the wrapping section. The web supply section includes a festoon-type web storage mechanism in which the web downstream of the splicing mechanism is trained about a series of rollers in a serpentine path.

Abstract: A continuous wrapping apparatus includes a web supply section that supplies a pair of continuous webs, and a wrapping section for applying the webs about the article. The web supply section includes a pair of web supply stations for each web, and a supply roll is located at each web supply station. Each web supply station includes a splicing mechanism for splicing together the trailing end of a web from an exhausted roll with the leading end of a web from a fresh roll. A storage mechanism is located downstream of each splicing mechanism, and includes rollers that are movable toward and away from each other to continuously supply the web during the splicing operation, which maintains the web ends stationary. The webs are applied to the elongated article such that side areas of the webs overlap each other, and adhesive is applied between the overlapping areas of the webs.

Abstract: A wrapping apparatus for wrapping a continuous elongated article, such as a continuous stack of interfolded paper towels, includes a web supply section that supplies a pair of continuous webs of wrapping material, and a wrapping section for applying the continuous pair of webs about the article. The web supply section includes a pair of web supply stations for each web of wrapping material, and a source of wrapping material, such as a supply roll, is located at each web supply station. The web supply section includes a splicing mechanism for each pair of web supply stations, for splicing together the trailing end of a web from an exhausted supply roll of wrapping material with the leading end of a web from a fresh supply roll of wrapping material, to provide a continuous web of wrapping material to the wrapping section. The web supply section includes a festoon-type web storage mechanism in which the web downstream of the splicing mechanism is trained about a series of rollers in a serpentine path.

Abstract: A wrapping apparatus for wrapping a continuous elongated article, such as a continuous stack of interfolded paper towels, includes a web supply section that supplies a pair of continuous webs of wrapping material, and a wrapping section for applying the continuous pair of webs about the article. The web supply section includes a pair of web supply stations for each web of wrapping material, and a source of wrapping material, such as a supply roll, is located at each web supply station. The web supply section includes a splicing mechanism for each pair of web supply stations, for splicing together the trailing end of a web from an exhausted supply roll of wrapping material with the leading end of a web from a fresh supply roll of wrapping material, to provide a continuous web of wrapping material to the wrapping section. The web supply section includes a festoon-type web storage mechanism in which the web downstream of the splicing mechanism is trained about a series of rollers in a serpentine path.

Abstract: A sleeving system consists of a sleeve forming mechanism for constructing a sleeve from a web of material and a series of pairs of prongs mounted to a pivoting turret mechanism. The prongs are moved to a collapsed position, where a partially opened sleeve is positioned over the collapsed prongs and clamped to one of the prongs. The prongs are pivoted to an inserting station, and are moved apart to open the sleeve at the inserting station. A compressed stack of articles, such as paper towels, is provided to the inserting station, and is inserted by an inserting mechanism into the space between the prongs, and therefore into the opened sleeve. The prongs are then pivoted to a removal station, where a removing mechanism functions to remove the stack from between the prongs and to simultaneously draw the sleeve off of the prongs. The stack undergoes decompression as it emerges from between the prongs, to expand into engagement with the sleeve.