Method of and apparatus for temporarily storing a running web

Abstract

A facility for temporary storage of a running web of cigarette paper, tipping paper or the like between a bobbin or another source of web and a web processing or consuming machine employs two polygonal arrays of rollers which can be rotated about their respective axes. Each roller of a first array can be coaxial to and can rotate with a roller of the second array; alternatively, the rollers of the second array can rotate as a unit relative to the rollers of the first array. One or more deflecting rolls are provided to direct the web into and out of the storage facility; alternatively, the deflecting rolls can serve to direct the web from one of the two arrays of rollers to the other array. The web is convoluted about at least one of the two arrays of rollers (preferably about each such array of rollers) when at least one of the arrays of rollers is caused to turn in one direction, and the quantity of the stored web is reduced by rotating at least one of the arrays of rollers in another direction, such as counter to the one direction.

Description

CROSS-REFERENCE TO RELATED CASES

[0001] This application claims the priority of the commonly owned copending German patent application Ser. No. 101 53 961.4 filed Nov. 6, 2001. The disclosure of the above-identified German patent application, as well as that of each US and/or foreign patent and/or patent application identified in the specification of the present application, is incorporated herein by reference.

BACKGROUND OF THE INVENTION

[0002] The invention relates to improvements in methods of and in apparatus for manipulating running webs or strips of paper, lightweight cardboard and other types of wrapping material, especially to apparatus for and to methods of temporarily storing webs of wrapping material which can be utilized with advantage in machines or production lines for the making and/or packing of smokers' products.

[0003] More particularly, the invention relates to improvements in methods of manipulating and in storage facilities for running webs of cigarette paper, co-called tipping paper and other types of running webs or strips which can be utilized to confine and/or interconnect rod-like fillers of smokable material and/or filter material for tobacco smoke.

[0004] It is customary to convey a web of cigarette paper, so-called tipping paper or the like along an elongated path from a source (e.g., a bobbin or reel) to a processing (e.g., wrapping) station along a path which can be lengthened or shortened within a desired range. A lengthening of the path becomes necessary subsequent to splicing of the trailing end of a running expiring web to the leader of a running fresh web. Such mode of manipulation ensures that the splice can be formed between a stationary trailing end of the expiring web and a stationary leader or leading end of the fresh web because the supply of web which is required in a processing machine (e.g., in a cigarette making machine, in a machine for the making of filter mouthpieces or in a so-called tiping machine wherein filter mouthpieces are united with plain cigarettes, cigars or cigarillos) during splicing must be supplied by a storage facility which is installed between the source of web and the consuming machine and defines a variable-length portion of the path for the running web between the source and the consuming machine.

[0005] Any stoppage of the consuming machine (e.g., for the purpose of splicing the trailing end of the web of cigarette paper, artificial cork or the like to the leader of a fresh web) could entail huge losses in output of the consuming machine (e.g., a machine which is designed to turn out around 20,000 plain cigarettes per minute). Therefore, such machines receive a web of wrapping material from a source by way of a storage facility which is activated whenever the running web is about to expire, i.e., when the trailing end of such web is to be attached (e.g., bonded) to the leader of a fresh web. A presently known satisfactory storage facily employs a number of parallel rollers which define for a portion of the ruuning web a meandering path serving to supply the web in the course of a splicing operation. The supply of the (new) web in such storage faciliy is replenished during or subsequent to splicing without necessitating a stoppage or a slowdown of the web consuming machine. Thus, the storage facility must be capable of temporarily or permanently confining therein a length of web which suffices to ensure uninterrupted operation (at normal speed) of the web processing or consuming machine or production line during an interval of time which elapses in the course of a splicing operation. It can be said that there exists a direct relationship between the capacity of the web consuming or processing machine and the interval of time during which the web must be supplied to such machine by a source (i.e., the storage facility) other than a bobbin, a reel or another standard web feeding device.

[0006] As already mentioned hereinbefore, the trailing end of the expiring web is at a standstill during the inteval which elapses for the carrying out of a splicing operation. At the same time, the outlet of the storage facility must or should discharge the web at a speed which matches that in the course of normal operation of the web consuming machine. Such speed can be and normally is very high so that the splicing operation must be completed within a very short interval of time and/or the storage facility must be designed to confine a substantial length of the web. The latter prerequisite can be met if the speed of advancement of the web into the storage facility (upon completion of replacement of an expired bobbin with a fresh bobbin) is much higher than the (normally high or very high) speed of withdrawal of the web from the storage facility into the consuming or processing machine. Once the storage facility is refilled (with the web coming from the fresh reel), the speed of the web at the outlet can again match the speed of the web at the inlet of the storage facility, i.e., the quantity of web in the storage facility can remain constant until a detector or another suitable monitoring device is caused to transmit a signal denoting that the quantity of web remaining on the reel has decreased to that indicating imminent consumption of the convoluted reel, such as a reduction of the diameter of remaining convoluted web to a minimum acceptable value or actual detection of trailing end of the running web.

[0007] A conventional storage facility of the aforedescribed character can be designed to employ a substantial number of parallel rollers which can store flat stretches of web between successive parallel rollers and arcuate stretches each of which overlies approximately one-half of the peripheral (external) surface of a roller. The rollers are confined in a container or housing having an inlet for the running web and an outlet for the advancement of the web toward the processing machine. Such storage facilities are acceptable, particularly as concerns their ability to store a requisite length of the web; however, they also exhibit certain drawbacks which render it desirable to seek improved storage facilities, especially more compact storage facilities which are just as reliable as or even more satisfactory than presently known facilities, not only as concerns their space requirements but also as regards their reliability at web speeds at least matching or exceeding (even greatly exceeding) those of webs in conventional storage facilities.

OBJECTS OF THE INVENTION

[0008] Accordingly, it is an object of the present invention to provide a novel and improved storage facility which can confine a requisite quantity of a running web of flexible material in a portion of its path from a source to a consuming or processing machine in a space which is or which can be a fraction of the space occupied by a standard storage facility without affecting the reliability of the improved facility.

[0009] Another object of the invention is to provide a storage facility wherein the temporarily confined quantity of a web or strip is treated gently and which can be installed in or utilized in conjunction with existing web processing machines or production lines.

[0010] A further object of the invention is to provide the storage facility with novel and improved means for manipulating a running web gently and with novel and improved means for regulating the speed of the running web in dependency upon all variables which must be considered in connection with the feeding of webs into modern high-speed web processing machines and/or production lines.

[0011] An additional object of the invention is to provide a facility for temporary storage of running webs in or in conjunction with machines for the mass production of filter mouthpieces for tobacco smoke, rod-like fillers of natural, artificial or reconstituted tobacco or other smokable material and/or filter cigarettes, cigars, cigarillos or other rod-shaped smokers' products.

[0012] Still another object of the invention is to provide a novel and improved machine or production line which embodies one or more apparatus of the above outlined character.

[0013] A further object of the instant invention is to provide a novel and improved method of manipulating running webs of flexible material (such as cigarette paper, artificial cork or other tipping paper and the like), particularly preparatory to, during and following the splicing of the trailing end of an expiring web to the leader of a fresh web.

[0014] Another object of the present invention is to provide a method which can be practiced by resorting to a fully automatic facility requiring no supervision, a minimum of maintenance and/or a minimum of supervision for extended periods of time.

[0015] An additional object of the present invention is to provide a novel and improved method which can be practiced by resorting to a simple, compact and relatively inexpensive facility for temporary storage of requisite quantities of a running web of cigarette paper, other types of paper, tipping paper including artificial cork and the like.

SUMMARY OF THE INVENTION

[0016] One feature of the present invention resides in the provision of a facility for temporary storage of a running web of flexible material. The facility comprises a web collecting assembly including at least one magazine having means for temporarily gathering the running web, and at least one convoluting unit having means for moving the web in a first direction to thus convolute the web on the gathering means and in a second direction to thus unwind the convoluted web from the gathering means. The gathering means can comprise a set of rollers.

[0017] The web can consist of a wrapping material for smokers' products and the web collecting assembly can be disposed between a bobbin or another suitable source of web and a web processing machine, e.g., a cigarette making or filter cigarette making machine.

[0018] The moving means can include a device (such as a roller) for flexing the running web around the gathering means during movement of the web in the first direction under the action of the moving means. To this end, the moving means can be arranged to move in a predetermined direction (e.g., counterclockwise around the at least one magazine) to thus move the web in the first direction, and the roller of the flexing device can be mounted for rotation about an axis which is inclined relative to the predetermined direction. For example, the axis of such roller can be at least substantially normal to the predetermined direction.

[0019] The at least one magazine is preferably designed in such a way that it includes an inner side and an outer side, and the moving means can be set up to convolute the running web around the outer side of the at least one magazine while the web is being moved in the first direction.

[0020] The at least one magazine can define for the running web a closed (endless) path and the roller of the moving means can be arranged to orbit about the center of such closed path to thus introduce the web into the path in response to orbiting in the first direction. The closed path can be a polygonal (such as a hexagonal or octagonal) or a circular path. In a presently preferred embodiment, the at least one magazine includes a plurality of rollers having parallel axes of rotation; the roller of the moving means is or can be arranged to orbit about an axis which is parallel to the axes of the aforementioned plurality of rollers. The axes of rotation can form a substantially circular array of axes and can be at least substantially equidistant from each other.

[0021] In certain presently preferred embodiments of the improved facility, the web collecting assembly comprises a plurality of magazines, particularly two magazines (i.e., the at least one magazine and a second magazine). The moving means can be arranged to convolute the web around the outer side of the second magazine in response to movement of the moving means in the first direction. The moving means can include means for rotating the second magazine about a predetermined axis and the outer side of the second magazine can define for the moving web an endless path (e.g., a circular path or a polygonal path) having a center located on the predetermined axis. The second magazine can also comprise a plurality of rollers which are rotatable about discrete axes each of which is or can be at least substantially parallel to the predetermined axis. The axes of the just mentioned rollers are or can be at least substantially equidistant from each other. The preferably polygonal or circular outline of the at least one magazine has a center which is preferably located on the predetermined axis.

[0022] The magazines of the web collecting assembly are or can be adjacent each other, and such facility preferably further comprises guide means serving to direct successive increments of the running web from one of plural magazines into another magazine. The guide means can comprise at least one web-deflecting roll. For example, the guide means can comprise a first web deflector at the one magazine and a second web deflector at the other magazine, and each such web deflector can comprise a roll. At least one of the magazines is or can be rotatable and another of the magazines can be set up to rotate with the at least one magazine.

[0023] One of the plural magazines can comprise a plurality of first rollers which are arranged to support a variable length of convoluted web, and another magazine of the plural magazines can comprise a plurality of second rollers, one for each of the first rollers; each second roller can be coaxial with one of the first rollers.

[0024] The moving means can be set up to move the running web relative to the magazine or magazines of the web collecting assembly by moving relative to the magazine or magazines of such assembly.

[0025] The at least one magazine of the web collecting assembly can be designed to have an inner side and an outer side, and the facility embodying such at least one magazine can further comprise means for directing successive increments of the running web from the inner side to the outer side of such magazine. The web directing means can form part of the at least one magazine; such means can comprise a roller. The at least one magazine can comprise a plurality of rollers and one of these rollers can constitute the roller of the web directing means.

[0026] The roller of the aforementioned means for moving the web can be associated with means for moving it along the outer side of the at least one magazine.

[0027] If the web collecting assembly comprises the at least one magazine and a second magazine, the second magaine can be designed to surround the at least one magazine and can be arranged to rotate (when necessary) relative to the at least one magazine. The moving means of such facility can be provided on and then moves with the second magazine to convolute the web around the at least one magazine and, if necessary, around the second magazine in response to rotation of the second magazine in the first direction. The moving means of such facility can be designed to convolute the web around one of the magazines in a clockwise direction and around the other magazine in a counterclockwise direction. The roller of the moving means can form part of the second magazine. The at least one magazine of the just discussed web collecting assembly is or can be a stationary magazine.

[0028] Another feature of the instant invention resides in the provision of a method of temporarily storing a length of a running web of flexible material. The method comprises the steps of advancing the web lengthwise in a predetermined direction along an elongated path, imparting to an elongated portion of the path a configuration which causes the web to form at least a portion of at least one convolution, and altering the configuration to at least partially eliminate the at least one convolution.

[0029] The imparting step can include increasing the length of the elongated portion of the path, and the altering step of such method can include reducing the increased length of the aforementioned path portion.

[0030] The advancing step can include drawing the web from a suitable source, and the method can further include the step of converting the web into a part of a smokers' product downstream of the elongated portion of the path (as seen in the predetermined direction).

[0031] The novel features which are considered as characteristic of the present invention are set forth in particular in the appended claims. The improved storage facility itself, however, both as to its construction and the modes of assembling and operating the same, together with numerous additional important and advantageous features and attributes thereof, will be best understood upon perusal of the following detailed description of certain presently preferred specific embodiments with reference to the acompanying drawwing.

BRIEF DESCRIPTION OF THE DRAWING

[0032] FIG. 1 is a somewhat schematic and partly diagrammatic front elevational view of a storage facility which embodies one form of the present invention and employs a stationary magazine as well as a rotary magazine for temporary storage of a running web of paper or the like;

[0033] FIG. 2 illustrates a portion of the structure of FIG. 1 but with the rotary magazine in a different angular position;

[0034] FIG. 3 shows the structure of FIG. 2 but with the rotary magazine in a third angular position;

[0035] FIG. 4 shows the structure of FIG. 3 but with the rotary magazine in a fourth angular position;

[0036] FIG. 5 is a fragmentary schematic front elevational view of a second storage facility; and

[0037] FIG. 6 is a side elevational view of the second storage facility as seen from the right-hand side of FIG. 5.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0038] FIG. 1 shows a storage facility 2 for a variable length of a running web 10. The latter can constitute a strip of cigarette paper, tipping paper or any other strip of flexible material. A presently preferred use of the storage facility is in or in conjunction with a machine for the making of smokers' products, e.g., in a so-called tipping machine which can be utilized to unite filter mouthpieces of unit length or multiple unit length with plain cigarettes of unit length or multiple unit length to form filter cigarettes of unit length or multiple unit length. Reference may be had, for example, to commonly owned U.S. Pat. No. 5,135,008 (granted Aug. 4, 1992 to Oesterling et al. for “METHOD OF AND APPARATUS FOR MAKING FILTER CIGARETTES”) which discloses a tipping machine for the making of filter cigarettes of double unit length by draping successive patches of adhesive-coated tipping paper around filter mouthpieces of double unit length and around the adjacent ends of pairs of coaxial plain cigarettes of unit length. The thus obtained filter cigarettes of double unit length are severed midway across the convoluted patches to yield pairs of filter cigarettes of unit length.

[0039] A machine which turns out filter mouthpieces, e.g., for use in the tipping machine of U.S. Pat. No. 5,135,008, is disclosed, for example, in U.S. Pat. No. 4,412,505 granted Nov. 1, 1983 to Hüsler et al. for “APPARATUS FOR APPLYING ATOMIZED LIQUID TO A RUNNING LAYER OF FILAMENTARY MATERIAL OR THE LIKE”. A cigarette making machine which can utilize or cooperate with the improved storage facility 2 is disclosed, for example, in U.S. Pat. No. 4,281,670 granted Aug. 4, 1981 to Heitmann et al. for “APPARATUS FOR INCREASING THE PERMEABILITY OF WRAPPING MATERIAL FOR ROD-SHAPED SMOKERS' PRODUCTS”.

[0040] The storage facility 2 which is shown in FIGS. 1 to 4 comprises a web collecting assembly including a first magazine having a stationary disc-shaped first or inner winding element 4 and a second magazine having an annular rotary second or outer winding element 5 which is concentric with and surrounds the inner element 4. Each of FIGS. 1 to 4 shows a constant-width annular clearance between the rotary magazine including the rotary outer winding element 5 and the magazine including the stationary inner winding element 4.

[0041] The winding element 4 carries an annular array of six equidistant rollers including a first roller 6 at the twelve o'clock position and five additional rollers 8 at the two, four, six, eight and ten o'clock positions. These rollers also form part of the first magazine. The axes of the rollers 6, 8 are parallel to the axis of rotation of the winding element 5 and such axes are normal to that side of the winding element 4 which is shown in FIGS. 1 to 4 and are also equidistant from each other. The illustrated rollers 6, 8 have identical diameters and their axes are disposed at the corners of a regular hexagon having its center on the axis of rotation of the winding element 5, i.e., the axes of the rollers 6, 8 are equidistant from the axis of rotation of the rotary winding element 5. It can be said that the rollers 6 and 8 together form a wreath-like array which is concentric with the winding elements 4 and 5.

[0042] Successive increments of the running web 10 advance toward the stationary winding element 4 axially of the rotary winding element 5 and are caused to change the direction of their movement radially outwardly of the element 5 (see the arrow A) by a roller-shaped rotary deflector 12. The path of the web 10 extends about the roller 6 and thereupon about two of the rollers 8 (at the ten and eight o'clock positions) and thereupon tangentially of the next-following roller 8 (at the six o'clock position). Thereafter, the web 10 is deflected by a second deflecting roll 14 on its way toward and into the processing machine (e.g., into a tipping machine of the character disclosed in the aforementioned U.S. Pat. No. 5,135,008 to Oesterling et al.).

[0043] That portion of the path for the web 10 which is defined by the roller 6 and three of the rollers 8, while the rotary winding element 5 dwells in the angular position of FIG. 1, resembles about one-half of a hexagonal path 11. Entry of successive increments of the running web 10 into such hexagonal path (this path is disposed at the outer side of the magazine including the winding element 4 and the rollers 6, 8) is caused by the roller 6. The axis of the rotary deflector 12 is inclined relative to the axis of the winding element 5 and also relative to the plane of each of FIGS. 1 to 4. Such orientation of the deflecting roll 12 entails a certain twisting of the web 10 between the roll 12 and the roller 6.

[0044] The means for supplying the web 10 toward the deflecting roll 12 can comprise a bobbin or any other suitable source, not shown. If the web 10 is made of cigarette paper, the downstream deflector roll 14 can direct it into a cigarette making machine, e.g., into a machine of the type disclosed in the aforementioned U.S. Pat. No. 4,281,670 to Heitmann et al.

[0045] The rotary outer winding element 5 of the rotary second magazine carries eight equidistant rollers including a first roller 16 and seven additional rollers 18. The axes of the rollers 16, 18 are parallel to each other, to the axes of the rollers 6, 8 and to the common axis of the winding elements 4 and 5. Furthermore, the rollers 16, 18 on the illustrated rotary winding element 5 are equidistant from each other and together define an octagonal section 33 (see FIGS. 2 to 4) of the path for the web 10 when the winding element 5 is caused to leave the angular position of FIG. 1 by turning in a counterclockwise direction. That side of the winding element 5 which faces the observer of FIGS. 1 to 4 is assumed to be flat and normal to the axes of the rollers 16, 18; these axes are equidistant from the axis of the winding element 5. The center of the aforementioned octagonal section 33 of the path portion defined by the rollers 16, 18 is located on the axis of the element 5; these rollers can be said to jointly form a wreath-shaped octagonal array which spacedly surrounds and is concentric with the hexagonal array of rollers 6, 8 on the stationary winding element 4. The roller 16 constitutes a means for moving the running web 10 relative to the magazine including the winding element 4 and the rollers 6, 8.

[0046] The means for rotating the winding element 5 clockwise or counterclockwise (see the double-headed arrow B) comprises a (first) drive 20 which is shown only in FIG. 1; this drive can include a reversible electric motor having a rotary output element carrying a pinion 22 mating with a gear 24 affixed to and coaxial with the winding element 5. The illustrated gear 24 is affixed to the radially outermost portion of the winding element 5 so that it surrounds the array of rollers 16, 18.

[0047] The means for rotating the rollers 6, 8 on the stationary winding element 4 about their respective axes comprises a second drive 26 (shown only in FIG. 1). The drive 26 serves to rotate a pulley 28 for an endless belt or band 30 which is trained over six additional pulleys 32 (only one can be seen in FIG. 1) each of which is coaxially affixed to or of one piece with one of the rollers 6 and 8. It is often preferred to select the axial length of each of the rollers 6, 8 in such a way that it suffices to ensure that each such roller can guide the web 10 and can be engaged by the endless belt 30, i.e., the pulleys 32 preferably form integral parts of the respective rollers 6 and 8. The belt 30 is under sufficient tension to be maintained in requisite frictional engagement with the pulleys 32 or directly with the peripheral surfaces of the rollers 6 and 8. It is also possible to employ an internally toothed belt which mates with externally toothed portions of the rollers 6 and 8.

[0048] The character 40 denotes in FIG. 1 a control unit for the drives 20 and 26. This control unit is further operatively connected with a control unit 41 for the bobbin (not shown) which supplies the web 10 to the deflector roll 12, and with a control unit 42 for the machine or production line (not shown) which processes the web 10 advancing beyond the deflector roll 14. The control unit 41 transmits signals denoting several parameters one of which can be indicative of the quantity of convoluted web on the bobbin that supplies the web 10, and the control unit 42 transmit signals denoting the requirements of the web processing machine, the stoppage of the web processing machine, the restarting of such machine and/or other information which enables the control unit 40 to select the length of that portion of the web which is to be stored in the web collecting assembly of the storage facility 2. The latter can serve solely as a means for guiding successive increments of the running web 10 from the deflector roll 12 to the deflector roll 14, as a means for increasing the length of the web between the rolls 12, 14 or as a means for reducing the length of the web between the two deflecting rolls. As shown in FIG. 1, the control unit 40 can receive signals from and transmit signals to the control unit 41 and/or 42.

[0049] When the rotary winding element 5 assumes the angular position of FIG. 1, the web portions or increments advancing beyond the deflecting roll 12 are contacted only by the roller 6 and three of the rollers 8 on their way along (but not in contact with) the roller (moving means) 16 toward the deflecting roll 14. Thus, the web 10 advances along a portion of the outer side of the array of rollers 6, 8 forming part of the first magazine and adjacent to (but spaced apart from) the inner side of the array of rollers 16, 18 forming part of the second magazine. The speed of the web 10 is determined by the control unit 40 in dependency upon the requirements of the consuming or processing machine which receives the web downstream of the deflecting roll 14.

[0050] If the facility 2 is to store a larger quantity of web 10, the control unit 40 causes the drive 20 to turn the winding element 5 in a counterclockwise direction. This causes the roller (moving means) 16 to entrain the web downstream of the roller 8 at the six o'clock position on the stationary winding element 4 and to train the web about two additional rollers 8 (namely those at the four and two o'clock positions of the winding element 4—see FIG. 2) as well as about one of the rolers 18. The web 10 then advances vertically downwardly toward and into contact with the deflecting roll 14. This causes the web to advance along five of six sides of the hexagonal path portion 11 defined by the array of the rollers 6 and 8. In addition, those increments of the web 10 which advance beyond the path portion 11 enter a first facet of the octagonal path portion 33 on their way toward the deflecting roll 14. The path portion 11 begins and ends at the roller 6, and the path portion 33 begins and ends at the roller 16. A comparison of FIGS. 1 and 2, 2 and 3, 2 and 4 and/or 3 and 4 indicates that the web 10 is convoluted clockwise around the rollers 16, 18 but counterclockwise around the rollers 6 and 8.

[0051] As the winding element 5 continues to turn in a counterclockwise direction, the web 10 follows the outline of the octagon 33 by being flexed about successive rollers 18 and the web also begins to form a second hexagonal portion surrounding the first hexagon established by the rollers 6 and 8. A near complete octagonal supply of web 10 around the roller 16 and all seven rollers 18 can be seen in FIG. 3; the only absent part of a complete octagon 33 is that between the roller 16 and the immediately preceding roller 18 (as seen in a counterclockwise direction). As already mentioned above, when the winding element 5 reaches the angular position of FIG. 3, the web 10 is in the process of forming a second hexagon in the path portion 11 around the rollers 6, 8 on the stationary winding element 4, i.e., the supply of web in the storage facility 2 continues to increase partly around the rollers 6, 8 on the stationary winding element 4 and partly about the rolers 16, 18 on the rotary winding element 5.

[0052] The making of two complete hexagons (11) on the element 4 is nearly completed when the outer winding element 5 reaches the angular position of FIG. 4, and the element 5 is then in the process of gathering a second octagon (33) which surrounds the first octagon. Thus, the improved storage facility 2 is capable of gathering a desired number of hexagonal convolutions which surround the rollers 6, 8 on the stationary inner winding element 4 as well as a number of octagonal convolutions which surround the rollers 16, 18 on the rotary outer winding element 5. The overall length of the temporarily stored web in the facility 2 equals or closely approximates the length(s) of the hexagonal supply or supplies surrounding the rollers 6, 8 plus the length(s) of the octagonal supply or supplies surrounding the rollers 16, 18.

[0053] The web 10 continues to move lengthwise in the direction of arrows A and at the speed which is selected by the control unit 40 and is imparted to the winding element 5 by the drive 20; however, the speed of the web at the first deflector roll 12 and at the roller 6 exceeds the speed of the web at the second deflector roll 14. The difference between these speeds (at the rolls 12, 14) determines the length of that portion of the web 10 which is stored in the facility 2 within a selected period of time. Each hexagonal part of the stored web 10 advances in a counterclockwise direction; the web is thereupon deflected by the roller 16 and begins to advance clockwise along the octagonal path defined by the rollers 16, 18 on the rotating winding element 5. In other words, the roller 16 is that constituent of the improved storage facility 2 which enables the latter to ensure that one portion of the stored web 10 moves in a first direction while another portion of the stored web advances in a second direction counter to the first direction; this contributes to compactness of the improved storage facility.

[0054] In order to reduce the quantity of stored web 10 (e.g., during splicing of the trailing end of the running web to the leader of a fresh web, not shown) without affecting the operation of the machine or production line which receives the web 10 downstream of the deflecting roll 14 (as seen in the direction indicated by the arrows A), the control unit 40 causes the reversible drive 20 to rotate the winding element 5 in a clockwise direction. This causes withdrawal of the web from the hexagonal path portion (11) defined by the rollers 6, 8 as well as withdrawal of the web from the octagonal path (33) defined by the rollers 16, 18. Such withdrawal of some of the stored web 10 from the facility 2 can be terminated when the supply of stored web on the rollers 16, 18 is reduced to zero or close to zero (see, for example, FIG. 2 or FIG. 1). Thus, a certain minimum length of the web 10 can remain confined in the facility 2.

[0055] If desired, the deflecting roll 12 can be installed in such a way that it directs successive increments of the web 10 coming from the bobbin or from another source directly to the roller 8 at the six or eight o'clock position in FIG. 1; this renders it possible to reduce the quantity of stored web 10 to zero or nearly to zero when the storage facility 2 is not in use, i.e., when the web can advance from the upstream deflector roll 12 directly to the downstream deflector roll 14. For all practical purposes, the storage facility 2 is empty and not in use when the web 10 is caused advance through this facility in a manner as shown in FIG. 1. On the other hand, the facility 2 can be said to store a maximum length (or maximum required length) of the web 10 when the rotary winding element 5 assumes the angular position of FIG. 4.

[0056] When the annular outer winding element 5 is in motion, the speed of its movement is proportional to the difference between the web processing speed and the speed of the web at the deflector roll 12, i.e., the speed of advancement of the web from the bobbin or another source. The RPM of the array of rollers 16, 18 on the rotary winding element 5 corresponds to the speed differential (in meters per minute) divided by the depth of the storage facility per revolution (in meters).

[0057] Since the rollers 6 and 8 are driven (in the embodiment of FIGS. 1 to 4 by the endless belt 30 and its drive 26), they act as a means for pulling the web 10 along the corresponding portion of the path, i.e., as a means for drawing the web from the bobbin toward and beyond the deflector roll 12. Such arrangement ensures that the pull being exerted by the rollers 6, 8 during filling of the storage facility 2 is relatively small, i.e., that the facility 2 can store a maximum length of web. Furthermore, such mode of operation ensures that, if the facility 2 is to be (rapidly) deactivated (i.e., within a short interval of time), the rollers 6, 8 can be braked within such short interval of time without it being necessary that the web 10 be subjected to the action of a pronounced braking force.

[0058] The reliability of operation of the storage facility 2 can be further enhanced by the provision of elastic decoupling means between this facility and the aforediscussed machine or production line which receives the web 10 advancing along and beyond the downstream deflector roll 14. Such elastic decoupling means can be constituted, at least in part, by the web 10 if the distance between the storage facility 2 and the web processing machine or production line is sufficient to ensure that one can rely upon the innate resiliency of the web in conjunction with an arrangement of the type disclosed, for example, in German patent No. 199 12 867 A1 and/or with a so-called dancer roller. FIG. 1 shows a dancer roller 36 which is an idler roller acted upon by a resilient element 38 and bearing upon successive increments of the running web 10 downstream of the deflector roll 14, preferably between two deflector rolls 34, 35. The resilient element 38 (the resilient element shown in FIG. 1 includes at least one coil spring) tends to move the dancer roller 36 transversely of its axis, i.e., transversely of the adjacent portion of the path for the web 10, so that the web is deflected through 90° by the roll 34, through 180° by the dancer roller 36, and through 90° by the roll 35 before it reaches the web processing machine or production line.

[0059] The roller (moving means) 16 and the rotary winding element 5 form part of a convoluting unit which further includes the drive 20, the pinion 22 and the ring gear 24 and serves to move the web in a first direction (counterclockwise) to convolute the web on the gathering means 6, 8 or in a second direction (clockwise) to thus unwind the convoluted web from the gathering means 6, 8. The roller 16 is set up to flex the running web 10 around the gathering means 6, 8 during counterclockwise movement of the roller 16 about the stationary magazine 4, 6, 8 and to enable the temporarily stored length of the web to leave the stationary magazine during clockwise movement of the roller 16. The axis of the roller 16 is inclined relative to the (predetermined) direction (see the double headed arrow B) of movement of this roller in response to rotation of the winding element 5 of the second magazine 5, 16, 18. In the embodiment of FIGS. 1 to 4, the axis of the roller 16 is at least substantially normal to the directions which are indicated by the double-headed arrow B.

[0060] The hexagonal path or path portion 11 is closed (endless) and receives one or more convolutions of the web 10 when the roller 16 is caused to orbit about the center of such closed path, i.e., about the axis of rotation of the winding element 5.

[0061] FIGS. 5 and 6 illustrate a storage facility 100 which constitutes a modification of the facility 2 of FIGS. 1 to 4. All such parts of the facility 100 which are identical with or analogous to parts of the facility 2 are denoted by similar reference characters plus 100.

[0062] The web collecting assembly of the storage facility 100 comprises a first magazine including a rotary disc-shaped support or carrier 102 for a first roller 106 and seven additional rollers 108. The axis 106a of the roller 106 and the axes 108a of the rollers 108 are parallel to each other and to the axis 102a of the support 102 and are normal to the adjacent plane surface of the support. As can be seen in FIG. 6, each of the (first) rollers 106, 108 is coaxial with and carries one of the (second) rollers 116, 118. The roller 116 is coaxial with one of the rollers 108, the roller 106 is coaxial with one of the rollers 118, and each of the six additional rollers 118 is coaxial with one of the remaining six rollers 108. The rollers 116, 118 form part of or constitute a second magazine of the aforementioned web collecting assembly in the storage facility 100. Each of the rollers 106, 108 is paired with one of the rollers 116, 118 and the two rollers of each such pair can turn independently of each other. The number of pairs of rollers can be reduced to less than or increased above eight without departing from the spirit of the present invention. The rollers 106, 108 are equidistant from each other, as seen in the circumferential direction of the radially outermost portion of the rotary support 102, and the axes 106a, 108a of these rollers are equidistant from the axis 102a of the support 102. Thus, the center of the regular octagon defined by the eight rollers 106, 108 is located on the axis 102a of the support 102, and these rollers together constitute an octagonal array or wreath of rollers spacedly surrounding the axis 102a.

[0063] The support 102 further carries two deflector rolls 112, 113 which are rotatable about parallel axes 112a, 113a and are normal to the axes 102a, 108a and parallel to the adjacent side or surface of the support. The deflector rolls 112, 113 are adjacent the axis 102a and serve to introduce successive increments of the running web 10 into the storage facility 100. Each of the axes 112a, 113a intersects the axis of the rotary support 102.

[0064] Successive increments of the incoming web 10 are deflected by the roller (moving means) 106 radially inwardly of the support 102 which deflects the web toward the roll 113. The latter deflects the web toward the web processing or consuming machine or production line, not shown. The deflecting rolls 112, 113 are rotatable about their respective axes 112a, 113a independently of each other. The web 10 which engages the roller 106 is deflected through 90° on its way toward the roll 112, and the latter deflects the web through approximately 90° (see FIG. 6) toward the roll 113. The roll 113 deflects the web 10 through approximately 90° toward the peripheral surface of the roller 116 which deflects the web, again through about 90°, into the path portion leading to the web processing machine or production line. On its way from the deflector roll 112 to the deflector roll 113, the web 10 moves away from the adjacent surface of the support 102 to thereupon travel along an at least substantially straight path toward the consumer or toward the dancer roller 36 or an equivalent thereof (not shown in FIGS. 5 and 6). The roller 106 is located diametrically opposite the roller 116.

[0065] The support 102 can be rotated about its axis 102a by a first drive 120 having an output shaft for a pulley 122 which drives an endless belt or band 124 trained over the support (see FIG. 5). A second drive 126 serves to rotate the rollers 106, 108 about their respective axes 106a, 108a by way of a pinion 128 on the output shaft of the drive 126 and a combined internal and external gear 130 having an outer annulus of gear teeth mating with the teeth of the pinion 128 and an inner annulus of gear teeth mating with the teeth of the rollers 106, 108. The gear 130 is coaxial with but can rotate independently of the support 102.

[0066] The drive 126 can be modified in that the internal teeth of the annular gear 130 can be replaced with a friction surface engaging the friction surfaces of the rollers 106, 108. All that counts is to ensure that the prime mover (e.g., an electric motor) of the drive 126 can rotate the rollers 106, 108 at a predictable (identical) speed in response to rotation of the output shaft which carries the pinion 128. The control unit (not shown in FIGS. 5 and 6) for the drives 120, 126 can regulate the operation of the drive 126 in such a way that, when the annular gear 130 is caused to turn about the axis 120a, the peripheral speed of each of the rollers 106, 108 matches the speed of the web 10 at the point of entry of the web into the storage facility 100.

[0067] It is possible, and frequently desirable, to rotate the rollers 116, 118 about their respective axes. This can be accomplished by resorting to internal drives (not shown in FIGS. 5 and 6) which are set up to rotate the rollers 116, 118 at peripheral speeds matching the speed of lengthwise movement of the web 10, i.e., the same as described with reference to the peripheral speeds of the rollers 106, 108.

[0068] In order to store a desired or requisite length of the running web 10 in the storage facility 100, the support 102 is caused to rotate in a clockwise direction, as viewed in FIG. 5; this causes the web to form convolutions around the rollers 106, 108 as well as to form convolutions around the rollers 116, 118. At such time, the roller 106 serves as a first guide which directs the web into the octagonal portion or section of the path defined by the rollers 106, 108. The roller 116 also serves as a guide which causes the web (arriving from the deflecting roll 113) to enter the octagonal portion of the path defined by the rollers 116, 118. Successive increments of the running web 10 leaving the path portion defined by the rollers 116, 118 are directed toward the dancer roller (not shown in FIGS. 5 and 6) or directly into the web processing or consuming machine or production line.

[0069] The rollers 106, 108 rotate in a first direction, and the rollers 116, 118 rotate in a second direction (counter to the first direction) while the web 10 advances through the storage facility 100.

[0070] Each stage of storing the web 10 in the facility 100 involves a dual winding or convoluting of the web. Thus, first convolutions develop around the rollers 106, 108 adjacent the support 102, and second convolutions develop simultaneously around the rollers 116, 118, i.e., at a greater distance from the support 102. The deflector rolls 112, 113 cause the web 10 to advance between the two sets of convolutions. In contrast to the mode of operation of the storage facility 2 of FIGS. 1 to 4, the parts of the facility 100 are assembled and cooperate in such a way that the two sets of convolutions are wound in the same direction, namely clockwise as viewed in FIG. 5; however, the web portion(s) forming one set of convolutions advances or advance in a direction counter to that of the web portion(s) forming the other set of convolutions. This is accomplished in that the rollers 106, 108 of one of the two sets or groups of rollers rotate counter to the direction of rotation of the rollers forming the other set or group.

[0071] If the storage facility 100 is to discharge a certain length of the web 10 which is trained over the rollers 106, 108 as well as over the rollers 116, 118, the support 102 is caused to rotate in another direction, namely counterclockwise as viewed in FIG. 5.

[0072] The storage facilities 2 and 100 are susceptible of numerous additional modifications without departing from the spirit and/or scope of the present invention. For example, the roller 106 on the support 102 of the storage facility 100 need not be located diametrically opposite the roller 118. All that is necessary is to mount the deflecting rolls 112, 113 (if necessary with one or more additional deflecting rolls or the like) in a manner to advance the web 10 coming from the roller 106 in a direction other than toward the roller 116, i.e., toward a selected one of the rollers 118 shown in FIG. 5 (e.g., toward a roller 118 next to the roller 106).

[0073] In lieu of directing successive increments of a running web toward a cigarette making machine of the type disclosed in U.S. Pat. No. 4,281,670 to Heitmann et al., or toward a tipping machine of the type disclosed in the U.S. Pat. No. 5,135,008 to Oesterling et al., two storage facilities (e.g., two facilities 2, two facilities 100 or one facility 2 with one facility 100) can be set up to supply webs of cigarette paper and tipping paper to a production line known as PROTOS which is distributed by the assignee of the present application. The PROTOS machine comprises a cigarette maker which can receive a web of cigarette paper from a bobbin by way of a storage facility 2 or 100, and a web of tipping paper (e.g., artificial cork) by way of another storage facility 2 or 100. The web of cigarette paper can be convoluted around a continuous rod-like tobacco filler, and the web of tipping paper is subdivided into discrete uniting bands or patches each of which is convoluted around a group of two or more coaxial rod-shaped components, e.g., a filter mouthpiece of double unit length and two plain cigarettes of unit length in a manner as fully described and shown in the aforementioned U.S. Pat. No. 5,135,008 to Oesterling et al.

[0074] Two identical or different storage facilities 2 and/or 100 are utilized in conjunction with a cigarette making machine if the latter is designed to simultaneously turn out two dscrete cigarette rods each of which is subdivided to yield a discrete file of plain cigarettes of unit length or multiple unit length. Reference may be had, for example, to commonly owned U.S. Pat. No. 4,893,640 to Heitmann et al. granted Jan. 16, 1990 for “MULTIPLE-ROD CIGARETTE MAKING MACHINE”.

[0075] The source which supplies the web to the storage facility 2 or 100 can be of the type known as BOB which is also distributed by the assignee of the present application. Such source can be combined with or embodied into the storage facility 2 or 100, or vice versa, or it can constitute a separate unit. It is also possible to combine the BOB machine with the storage facility 2 or 100 as well as with the machine or production line (such as PROTOS) whis consumes or processes the web.

[0076] An important advantage of the improved storage facility is that it can ensure predictable storage of requisite quantities of a running web as well as that the storing operation can be completed or the facility emptied within short intervals of time. This is attributable, at least in part to the feature that the improved facility is designed to store a desired length of the web in the form of convolutions which are confined in one or more magazines. Since the improved facility can store a desired length of the running web within a short interval of time, it is particularly suitable for use in conjunction with consuming machines which are set up to process (consume) huge quantities of web per unit of time. The control system for the facility 2 or 100 can be readily designed to ensure the delivery of a running web to a consumer at the exact speed which enables the consumer to process the web in an optimum manner.

[0077] As already mentioned hereinbefore, it is often preferred to provide each magazine with a set of equidistant rollers, 6, 8 or 16, 18, or 106, 108 or 116, 118, However, it is possible and under certain circumstances desirable to provide at least one magazine with a set of rollers wherein the distance between at least two neighboring rollers exceeds the distance between the other rollers or vice versa. Such situation can arise if a magazine employs large-diameter rollers so that the gaps or clearances between such large-diameter rollers are relatively narrow or even negligible. For example, and referring again to FIG. 1, if the gap between the roller 6 and the roller 8 at the two o'clock position were narrow or very narrow, this could interfere with advancement of the web 10 from the deflector roll 12 toward and partly around the roller 6. On the other hand, the presence of narrow or very narrow gaps between the roller 6 and the roller 8 at the ten o'clock position or between neighboring rollers 8 is of no consequence because the path 11 surrounds the rollers 6, 8.

[0078] Similar observations apply for the gap between the roller 18 at the twelve o'clock position of the winding element 5 shown in FIG. 2 and the roller 16, i.e., the width of the gap between these rollers should always suffice to ensure unimpeded passage of the running web 10 for winding around the rollers 16, 18 of the second magazine 5, 16, 18.

[0079] A symmetric distribution or arrangement of rollers in the magazines of the storage facility 2 or 100 is desirable and advantageous because this contributes to rapid winding or unwinding of the web. Thus, the polygonal arrays shown in the drawing preferably constitute regular hexagons or octagons. Other polygonal distributions (such as nonagons, septagons and/or others) can be resorted to with equal or similar advantage. It is also possible to employ arrays of rollers which closely approximate circular arrays.

[0080] The storage facility 2 of FIGS. 1 to 4 can also undergo numerous additional modifications without departing from the spirit and scope of the instant invention. By way of example only, the arrangement of rollers in the magazine including the parts 5, 16, 18 can be such that the web can form at least one convolution along the inner side of such magazine simultaneously with the making of convolutions at the exterior of the magazine including the parts 4, 6 and 8. Still further, it is possible to rotate the inner magazine 4, 6, 8 at least during filling or during emptying of the thus modified storage facility 2.

[0081] Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic and specific aspects of the above outlined contribution to the art of manipulating running webs of paper or the like and, therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the appended claims.

Claims

1. A facility for temporary storage of a running web of flexible material, comprising:

a web collecting assembly including at least one magazine having means for temporarily gathering the running web; and

at least one convoluting unit having means for moving the web in a first direction to thus convolute the web on said gathering means and in a second direction to thus unwind the convoluted web from said gathering means.

2. The facility of claim 1, wherein the web consists of a wrapping material for smokers'products and said web collecting assembly is disposed between a source of web and a web processing machine.

3. The facility of claim 1, wherein said moving means includes a device for flexing the running web around said gathering means during movement of the web in said first direction under the action of said moving means.

4. The facility of claim 3, wherein said moving means is movable in a predetermined direction to thus move the web in said first direction and said flexing device includes a roller rotatable about an axis which is inclined relative to said predetermined direction.

5. The facility of claim 4, wherein said axis is at least substantially normal to said predetermined direction.

6. The facility of claim 1, wherein said at least one magazine has an inner side and an outer side, said moving means being arranged to convolute the running web around said outer side while the web is being moved in said first direction.

7. The facility of claim 1, wherein said at least one magazine defines for the running web a closed path and said moving means includes a roller arranged to orbit about a center of said closed path to thus introduce the web into said path in response to orbiting in said first direction.

8. The facility of claim 7, wherein said closed path is one of a polygonal path and a circular path.

9. The facility of claim 8, wherein said axes of rotation together form a substantially circular array of axes.

10. The facility of claim 8, wherein the axes of rollers of said at least one magazine are at least substantially equidistant from each other.

11. The facility of claim 1, wherein said web collecting assembly comprises a plurality of magazines.

12. The facility of claim 11, wherein said plurality of magazines includes said at least one magazine and a second magazine, said second magazine having an inner side and an outer side and said moving means is arranged, to convolute the web around the outer side of said second magazine in response to movement in said first directions.

13. The facility of claim 12, wherein said moving means includes means for rotating said second magazine about a predetermined axis, said outer side of said second magazine defining for the moving web an endless path which is one of a circular path and a polygonal path and has a center on said predetermined axis.

14. The facility of claim 13, wherein said second magazine includes a plurality of rollers rotatable about axes which are at least substantially parallel to said predetermined axis.

15. The facility of claim 14, wherein the axes of said plurality of rollers are at least substantially equidistant from each other.

16. The facility of claim 13, wherein said at least one magazine has an outline which is one of a substantially polygonal and a substantially circular outline with a center on said predetermined axis.

17. The facility of claim 11, wherein said magazines are adjacent each other.

18. The facility of claim 17, further comprising guide means for directing successive increments of the running web from one of said magazines to another of said magazines.

19. The facility of claim 18, wherein said guide means comprises at least one web-deflecting roll.

20. The facility of claim 18, wherein said guide means comprises a first web deflector at said one magazine and a second web deflector at said other magazine.

21. The facility of claim 20, wherein each of said deflectors comprises a roll.

22. The facility of claim 17, wherein one of said magazines is rotatable.

23. The facility of claim 22, wherein another of said magazines is arranged to rotate with said one magazine.

24. The facility of claim 17, wherein one of said magazines comprises a plurality of first rollers arranged to support a variable length of convoluted web and another of said magazines comprises a plurality of second rollers, one for each of said first rollers, each of said second rollers being coaxial with one of said first rollers.

25. The facility of claim 1, wherein said moving means is movable relative to said at least one magazine.

26. The facility of claim 1, wherein said at least one magazine has an inner side and an outer side and further comprising means for directing successive increments of the running web from said inner side to said outer side of said at least one magazine.

27. The facility of claim 26, wherein said means for directing forms part of said at least one magazine.

28. The facility of claim 26, wherein said means for directing comprises a roller.

29. The facility of claim 28, wherein said at least one magazine includes a plurality of rollers and one of said plurality of rollers constitutes said means for directing.

30. The facility of claim 26, wherein said moving means includes a roller and means for moving said roller along an outer side of said at least one magazine.

31. The facility of claim 1, wherein said web collecting assembly further includes a second magazine surrounding and being rotatable relative to said at least one magazine, said moving means being provided on said second magazine and being arranged to convolute the web around said at least one magazine and around said second magazine in response to rotation of said second magazine in said first direction.

32. The facility of claim 31, wherein said moving means is arranged to convolute the web around one of said magazines in a clockwise direction and around the other of said magazines, in a counterclockwise direction.

33. The facility of claim 32, wherein said moving means includes a roller forming part of said second magazine.

34. The facility of claim 32, wherein said at least one magazines is stationary.

35. A method of temporarily storing a length of a running web of flexible material, comprising the steps of:

advancing the web lengthwise in a predetermined direction along an elongated path;

imparting to an elongated portion of said path a configuration which causes the web to form at least a portion of at least one convolution; and

altering said configuration to at least partially eliminate the at least one convolution.

36. The method of claim 35, wherein the said imparting step includes increasing the length of said elongated portion of said path and said altering step includes reducing the increased length of said portion of said path.

37. The method of claim 35, wherein the said advancing step includes drawing, the web from a source, and further comprising the step of converting the web into a part of a smokers' product downstream of said elongated portion of said path, as seen in said predetermined direction.