Article, apparatus and method for attachment of a roll of web material to a treated core

Abstract

An article, apparatus and method for attaching a roll of web material to a treated core is disclosed. The article includes a core pre-treated with adhesive and the apparatus includes an adhesive, a conveyor, an applicator unit and roller drums. The method includes activating a treated core with adhesive, aligning the activated area of the treated core with a tail end of the roll of web material, adhering the tail end of the roll of web material with the activated area of the treated core, and winding the roll of web material around the treated core.

Description

CROSS REFERENCE TO RELATED APPLICATION

Not applicable

FIELD OF THE INVENTION

This invention relates generally to an apparatus and method for attaching a roll of web material to a core.

BACKGROUND OF THE INVENTION

Traditionally in the paper industry, roll pulp or heavy board paper was attached to paper cores by the use of tape, most often double-sided tape. Additionally, pulp sheet or heavy weight board papers were frequently attached with double-sided tape that had a split release liner. This enabled bonding more of the tape to the core than to the sheet in the hope that the tape or core material would not travel with the sheet end when the roll runs out feeding into the customer's process, which would contaminate the customers process and product.

There were a number of approaches disclosed in the prior art for attaching a roll of web material to a core. As mentioned above, the use of tape was a common practice. In particular, U.S. Pat. No. 6,547,178 disclosed applying a tape in a single or multiple spiral pattern covering all or most of the length of an empty reel spool (with or without a removable core). The tape had a layer of water-activated adhesive on one side and a layer of pressure-sensitive adhesive on the other side, which may or may not have been protected by a releasable liner. The pressure-sensitive side of the tape was used to adhere to the spool, exposing the water-activated side of the tape. When the water-activated side of the tape was activated, a web of material was attached to the empty reel spool through the water-activated side of the tape and simultaneously the web of material detached from the full roll of web material.

The roll products produced according to U.S. Pat. No. 6,547,178 required the use of tape, which was both expensive and time consuming to use. There remains a continuing need for attaching a roll of web material onto a core with improved features. In addition, the improved apparatus and method should be an efficient and cost effective process and use.

SUMMARY OF THE INVENTION

The present invention is a method of and structure for using adhesive-coated cores in roll products. The inventive structure and process produces a strong core surface that keeps the core material intact and prevents contamination of the customer's process by preventing the core material from travelling with the end of a roll of web material.

The invention also provides a means of reducing the cost of attachment of the roll of web material to the core versus using the expensive tape. It also provides a means of improving the efficiency of the winding process by potentially allowing faster, automatic attachment of the roll of web material to a core that is pre-treated with adhesive and is not activated until the time of use.

One aspect of the present invention is directed to an apparatus for attaching a roll of web material to a treated core. The apparatus includes the treated core that is pre-treated with an adhesive, a conveyor for conveying the treated core into a winder, an applicator unit to activate an area of the adhesive on the treated core and roller drums to align a tail end of the roll of web of material onto the activated area of the treated core. The winder then winds the web of material onto the treated core.

Another aspect of the present invention is directed to a method for attaching a roll of web material to a treated core. The method includes activating the treated core (before attaching the roll of web material) to create an activated area of the treated core, aligning the activated area of the treated core with a tail end of the roll of web material, adhering the tail end of the roll of web material with the activated area of the treated core, and winding the roll of web material around the treated core.

A further aspect of the present invention is directed to a roll product of web material attached around a core by the process of using a core pre-treated with adhesive, activating the treated core (before attaching a tail end of the roll of web material to the treated core) to create an activated area of the treated core, aligning the activated area of the treated core with the tail end of the roll of web material, adhering the tail end of the roll of web material with the activated area of the treated core, and winding the roll of web material around the treated core.

Yet a further aspect of the present invention is directed to a roll product of web material that includes a treated core and a roll of web material, which is wound onto treated core after the treated core is activated.

Another aspect of the present invention is directed to a core that includes an adhesive applied directly (via spraying, rolling, wiping) onto the core. Water, pressure or heat (or a combination of these) activates the adhesive used. An example of a water-activated adhesive is polyvinyl alcohol. Other potential adhesives include polyvinyl acetate, water soluble or water dispersible hot melts, or any other hot melt glues or adhesives which could be activated by heat or pressure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an embodiment of the apparatus for coating a core with adhesive according to the present invention;

FIG. 2 is a perspective view of an embodiment of the winding machine according to the present invention;

FIG. 3 is a perspective view of a rolled product of web material according to the present invention;

FIG. 4 is a perspective view illustrating pulling away of the rolled product of web material according to the present invention;

FIG. 5 is a perspective view illustrating the core after the web material is completely released from the core.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a perspective view of an apparatus 10 used to pre-treat a core 12 with an adhesive. Apparatus 10 includes a base 14 on which the core is placed and can be rotated. The apparatus 10 further includes an applicator 16 for applying adhesive onto the core 12. In an embodiment of the invention, the device 16 used for applying the adhesive around the core 12 is a sprayer (or roller, wiper or other suitable applicator) and may be of any suitable construction. After the adhesive is applied onto the core 12, the adhesive is allowed to dry or cure. In one embodiment of the invention, the apparatus 10 may include a dryer (not shown) to dry the adhesive sprayed onto the core so that the core surface is hard and non-tacky. The adhesive may be applied around the entire core 12 or may be applied on a selected area of the core 12. To apply the adhesive around the core, the core is rotated on the base 14, as depicted by the arrow in FIG. 1. The treated core 18 may be stored until the time of use. When ready to be used, the adhesive is activated. As used herein, “treated core” refers to a core pre-treated with adhesive. The adhesive is inactive until the time of use.

At the time of use, the treated core, 18, is transferred onto a winding machine 20, illustrated in FIG. 2. FIG. 2 shows the winding machine 20 having a roll of web material wound onto the treated core 18. The winding machine 20 includes a conveyor 22, a winder 24 and an applicator unit 26. Conveyor 22 is for conveying the treated core 18, into the winder 24. It should be understood by one of skill in the art that any conventional conveyor might be used such as shuttle, belt, or roller conveyors. Alternatively, the core may be manually transported to the winder.

The treated core 18 is positioned such that a selected area of the treated core 18 is activated. For example, activation may be accomplished either by moisture, pressure, or heat. In an embodiment of the winding machine 20, suction cups (not shown) are used to position treated core(s) 18. In another embodiment, clamps (not shown) are used hold the treated core 18 in position. Another method is to use a traveling applicator (roller, sprayer, wiper) to activate the adhesive after cores are loaded in the winder.

The activator unit 26 of the winding machine 20 is located above or to the side of the treated core(s) 18. The activator unit 26 is configured to spray water on a (selected) area of the treated core 18, which activates the treated core 18.

Rolls of web material (not shown) are also positioned in the winding machine 20 to be cut. The tail end of the cut roll of web material 28 is positioned between two roller drums, a front roller drum 29 and a rear roller drum 30. (Note that the initial set of roll tails from a new reel are manually trimmed and attached to cores that may or may not have the adhesive activated at the time tails are trimmed.) After the treated core 18 is activated, it is positioned between the two roller drums 29 and 30.

In operation, the treated core 18 is transported from the conveyor 22 into the winder 24. Once in position, the applicator unit 26 (traveling or stationary) activates the treated core 18, by spraying water, applying heat or pressure (or any combination thereof) in a selected area of treated core 18 where the roll of web material is to be bonded. Upon activation of the treated core 18, the treated core 18 is positioned between the pair of roller drums 29 and 30. Also between the winder drums 29 and 30 is held the tail end 28 of the cut roll of web material. As the winder drums 29 and 30 are rotated in reverse, this aligns the activated area of the treated core 18 with the tail end 28 of the cut roll of web material. Next, the winder 24 is rotated to wind the roll of web material around the activated core 18.

The treated core 18 is manufactured by applying the adhesive onto a finished core 12, as illustrated in FIG. 1, then drying or curing the adhesive so it is inactive until time of use. In one embodiment, a top-ply web that is pre-treated with adhesive is bonded to the core as the core is produced so the adhesive side is exposed (outside surface), but hard and non-tacky until activated. Yet another method is to apply the wet adhesive as the cores are conveyed into the winder or after they are loaded into the winder.

The adhesive used is an adhesive that is inactive until the time of use (unless it is applied directly at the time of use). Depending on the type of adhesive used, activating the treated core can be accomplished by wetting or moistening the area where the roll of web material is to be attached. Wetting or moistening may be accomplished by water. A water-activated adhesive that may be used is polyvinyl alcohol. After the water-activated adhesive is applied on to the core, the core is dried so that the core surface is hard and non-tacky. Other suitable adhesives used include polyvinyl acetate, water soluble hot melts, water dispersible hot melts, or any other hot melt glues or adhesives which could be activated by heat or pressure.

FIG. 3, illustrates a roll of web material that is completely attached and rolled on to the treated core by the apparatus and method described herein. FIG. 4 shows the roll of web material that has been attached according to the teachings of the present invention, being pulled away or released from the core. FIG. 5 shows small areas of the web of material remaining attached to the core upon completely releasing the web material from the core. It will be appreciated that the above described invention prevents the core from traveling with the ends of the web material when the roll of web material runs out, thereby preventing the contamination of a customer's process and product.

The present invention is applicable to any type of roll of web material including but not limited to, paper, heavy board paper, pulp and any material that lends itself to being bonded and wound around a core.

From the foregoing description, it can be appreciated that the inventive structure and process produces a strong core surface that keeps the core material intact and prevents the core material from travelling with the end of a roll of web material, contaminating the customer's product and process. The invention also provides a means of reducing the cost of attachment of the roll of web material to the core versus by eliminating the use of expensive tape. It also provides a means of improving the efficiency of the winding process by potentially allowing faster, automatic attachment of the roll of web material to a core that is pre-treated with adhesive and is not activated until the time of use.

Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. In addition, the invention is not to be taken as limited to all of the details thereof as modifications, variations, and different combinations thereof may be made without departing from the spirit or scope of the invention

Claims

1. An apparatus for attaching a roll of web material to a core, the apparatus comprising:

a conveyor for conveying a pre-treated core with adhesive into a winder;

an applicator unit to activate an area of the pre-treated core with adhesive; and

roller drums to align a tail end of the roll of web material onto the activated area of the pre-treated core with adhesive;

wherein the winder winds the roll of web of material onto the pre-treated core with adhesive.

2. The apparatus of claim 1, further comprising a clamp to hold the pre-treated core with adhesive in position.

3. The apparatus of claim 1, wherein the applicator unit is a sprayer, roller, brush, wiper, or other suitable applicator.

4. A method for attaching a roll of web material to a core pre-treated with adhesive, the method comprising the steps of:

activating the core pre-treated with adhesive (before attaching the roll of web material) to create an activated area of the core pre-treated with adhesive;

aligning the activated area of the core pre-treated with adhesive with a tail end of the roll of web material;

adhering the tail end of the roll of web material with the activated area of the core pre-treated with adhesive; and

winding the roll of web material around the core pre-treated with adhesive.

5. A roll of web material attached to a core (pre-treated with adhesive) made by the process of:

using a core pre-treated with adhesive;

activating the core pre-treated with adhesive (before attaching a tail end of the roll of web material to the core pre-treated with adhesive) to create an activated area of the core pre-treated with adhesive;

aligning the activated area of the core pre-treated with adhesive with a tail end of the roll of web material;

adhering the tail end of the roll of web material with the activated area of the core pre-treated with adhesive; and

winding the roll of web material around the core pre-treated with adhesive.

6. A roll product of web material comprising:

a core pre-treated with adhesive; and

a roll of web material which is wound onto the core pre-treated with adhesive after the core pre-treated with adhesive is activated.

7. A core comprising:

an adhesive applied onto the core (to adhere a roll of web material).

8. The core of claim 7, wherein the adhesive is sprayed.

9. The core of claim 7, wherein a top-ply web that is pre-treated with adhesive is bonded to the core.

10. The core of claim 7, wherein the adhesive is activated by water.

11. The core of claim 1, wherein the adhesive is sensitive to pressure.

12. The core of claim 7, wherein the adhesive is sensitive to heat.

13. The core of claim 7, wherein the adhesive is polyvinyl alcohol or a polyvinyl acetate.

14. The core of claim 7, wherein the adhesive is selected from the group consisting of water soluble hot melts, water dispersible hot melts, pressure sensitive hot melts, or any hot melt or other adhesive activated by water, heat, or pressure.