Expandable Shaft For Winding/Unwinding Machines

Abstract

An expandable shaft for winding/unwinding machines is provided and includes a shaft body defining a shaft cavity and having a shaft first end, a shaft second end and a shaft body outer surface having a plurality of body openings which communicate the shaft body outer surface with the shaft cavity, a gripping structure, wherein the gripping structure is located within the shaft cavity and aligned with the plurality of body openings and a plunger having a plunger body. The plunger body includes a plunger outer surface having a plurality of peaks and valleys, wherein the plunger is configurable between a first configuration and a second configuration. When in the first configuration the plurality of valleys are aligned with the gripping structure and when in the second configuration the plurality of peaks are aligned with the gripping structure where the gripping structure is protruding from the plurality of body openings.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is related to and claims the benefit of the filing date of U.S. Provisional Patent Application Ser. No. 62/064,643 filed Oct. 16, 2014, the contents of which are incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to an expandable shaft and more particularly to an expandable shaft for retaining material on a winder/unwinder machine.

BACKGROUND OF THE INVENTION

Many different types of industries use rolls of material to store and transport materials used in producing a product. These materials, which include textiles, paper, plastic, metal, string, fabric, etc, are typically wound onto a mandrel, hollow tube or core using a winding machine or winder. When a product is being manufactured, the material is then removed from the tube or core by unwinding the material as needed using an unwinder. In order for the material to be added to or removed from the tube or core, the winder/unwinder machine must be able to hold and rotate the roll of material. This is typically accomplished via a shaft that is removably located within the hollow center portion of the mandrel, tube or core, where the shaft engages the tube or core such that when the shaft rotates, the roll of material rotates. As is required with most mechanical devices, these shafts need to be maintained and repaired periodically.

Unfortunately, however in order to repair the current expandable shafts commonly found in the market place (with the bladder) a fair amount of time would usually be required. The worker typically needs to disassemble the device, replace the bladder (which has a predictable life span) and re-assemble the shaft. Normally this involves the technician removing a steel pin which was driven crosswise in the assembly to hold the shaft together. This is a fairly time consuming and costly operation.

SUMMARY OF THE INVENTION

An expandable shaft for winding/unwinding machines is provided and includes a shaft body, wherein the shaft body defines a shaft cavity and includes a shaft first end, a shaft second end and a shaft body outer surface having a plurality of body openings which communicate the shaft body outer surface with the shaft cavity. The expandable shaft further includes a gripping structure, wherein the gripping structure is located within the shaft cavity to be aligned with the plurality of body openings and a plunger having a plunger body, wherein the plunger body includes a plunger outer surface having a plurality of peaks and valleys, wherein the plunger is configurable between a first configuration and a second configuration, wherein when in the first configuration the plurality of valleys are aligned with the gripping structure and when in the second configuration the plurality of peaks are aligned with the gripping structure such that the gripping structure is protruding from the plurality of body openings.

An expandable shaft for winding/unwinding machines is provided and includes a shaft body, wherein the shaft body defines a shaft cavity and includes a shaft first end, a shaft second end and a shaft body outer surface having a plurality of body openings which communicate the shaft body outer surface with the shaft cavity. The expandable shaft further includes a plurality of gripping pins, wherein the plurality of gripping pins are located within the shaft cavity to be aligned with the plurality of body openings and a plunger having a plunger outer surface with a plurality of peaks and valleys, wherein the plunger is configurable between a first configuration and a second configuration, wherein when in the first configuration, the plunger causes the plurality of gripping pins to protrude from the plurality of body openings and when in the second configuration the plurality of gripping pins are retracted into the plurality of body openings.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages of the present invention will be more fully understood from the following detailed description of illustrative embodiments, taken in conjunction with the accompanying drawings in which like elements are numbered alike in the several Figures:

FIG. 1 is side partially sectional view of an expandable shaft, in accordance with one embodiment of the invention.

FIG. 2 is a collective side view of the components of the expandable shaft in FIG. 1.

FIG. 3 is a side view of the shaft body of the expandable shaft of FIG. 1.

FIG. 4 is a side view of the plunger of the expandable shaft of FIG. 1.

FIG. 5 is side a view of the first shaft handle of the expandable shaft of FIG. 1.

FIG. 6 is side a view of the second shaft handle of the expandable shaft of FIG. 1.

FIG. 7 is a side view of two different types of gripper pins for use with the expandable shaft of FIG. 1.

FIG. 8 is a side perspective view of a gripper pin retainer for use with the expandable shaft of FIG. 1.

FIG. 9 is a side perspective view of a plurality of gripper pins associated with a gripper pin retainer for use with the expandable shaft of FIG. 1.

FIG. 10A is a longitudinal sectional view of peaks of the plunger engaging the gripper pins within the expandable shaft of FIG. 1.

FIG. 10B is a longitudinal sectional view of peaks of the plunger engaging the gripper pins within the expandable shaft of FIG. 1 within a material roll.

FIG. 11A is a longitudinal sectional view of valleys of the plunger engaging the gripper pins within the expandable shaft of FIG. 1.

FIG. 11B is a longitudinal sectional view of valleys of the plunger engaging the gripper pins within the expandable shaft of FIG. 1 within a material roll.

FIG. 12 is a side sectional view of the expandable shaft of FIG. 1 illustrating the air chamber in the collapsed configuration and the plunger in the first configuration, in accordance with one embodiment of the invention.

FIG. 13 is a side sectional view of the expandable shaft of FIG. 1 illustrating the air chamber in the expanded configuration and the plunger in the second configuration, in accordance with one embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

It should be appreciated that an expandable shaft that is easier, more efficient and less costly to use and repair than current expandable shafts is provided in accordance with an embodiment of the invention. As further discussed herein the expandable shaft of the present invention is unique in at least two ways: 1) the cammed plunger, and 2) the gripper pin retainer system. The cammed plunger is the only component which needs to machined to specific machining tolerances. All other manufacturing tolerances are of normal commercial tolerances thus saving on cost. Also, because the cammed plunger comes into direct contact with the gripper pins, a higher level of accuracy than that available with current devices may be achieved. The gripper pin retainer system is very inexpensive and aids in the ease of assembly and disassembly of the device.

Referring to FIG. 1 and FIG. 2, an expandable shaft 100 is provided and includes a substantially cylindrical shaft body 102, a plunger 104, a biasing member (return spring) 106, a gripper pin retainer 108 and a plurality of gripper pins 110, in accordance with one embodiment of the invention. It should be appreciated that although the invention is disclosed herein with regards to a plurality of gripper pins 110, it is contemplated that any gripping structure may be used suitable to the desired end purpose. For example, any gripping structure that is configurable to extend out of (to contact a material roll 111) and retract into the shaft body 102 may be used. Referring to FIG. 3, the shaft body 102 includes a shaft body inner surface 112, a shaft body outer surface 114 and defines a first shaft end opening 116, a second shaft end opening 118 and a shaft cavity 120 communicating the first shaft end opening 116 with the second shaft end opening 118, wherein the shaft cavity 120 includes a shaft cavity diameter DC. Additionally, the shaft body 102 includes a plurality of body openings 122, wherein the plurality of body openings 122 are distributed along the length and circumference of the shaft body 102 to be arranged in a plurality of rows that extend along the longitudinal axis X of the shaft body 102.

Referring to FIG. 4, the plunger 104 is substantially cylindrical in shape and includes a plunger body 124 having a plunger first end 121, a plunger second end 123 and a plunger outer surface 126 that is contoured to include a plurality of peaks 128 and valleys 130 that are distributed along the length of the outer surface 126. Additionally, the plunger body 124 includes a plunger length P_L, a first plunger diameter DP1 and a second plunger diameter DP2, wherein the first plunger diameter DP1 is the diameter of the plunger body 124 with regards to the plurality of peaks 128 and the second plunger diameter DP2 is the diameter of the plunger body 124 with regards to the plurality of valleys 130. Referring to FIG. 5 and FIG. 6, the expandable shaft 100 further includes a first shaft handle 132 and a second shaft handle 134, wherein each of the first shaft handle 132 and the second shaft handle 134 include a handle base 136 and a handle actuator portion 138 and wherein the first shaft handle 132 is non-movably associated with one end of the shaft body 102 such that the handle actuator portion 138 of the first shaft handle 132 is protruding out of the first shaft end opening 116.

The second shaft handle 134 (or actuator handle 134) is non-movably associated with one end of the plunger body 124 such that rotating the second shaft handle 134 causes the plunger body 124 to rotate. Moreover, the second shaft handle 134 is non-movably associated with the other end of the shaft body 102 such that the handle actuator portion 138 of the second shaft handle 134 is protruding out of the second shaft end opening 118 and such that the plunger body 124 is located within the shaft body 102, wherein the return spring 106 is located between the handle base 136 of the first shaft handle 132 and the end of the plunger body 124. It should be appreciated that when the first shaft handle 132 and the second shaft handle 134 are non-movably associated with the shaft body 102, the plunger body 124 is positioned within the shaft cavity 120 such that the plurality of peaks 128 are aligned with the plurality of body openings 122.

Referring to FIG. 7 and FIG. 8, it should be appreciated that each of the plurality of gripper pins 110 includes a pin head 140 and a pin body 142 and the gripper pin retainer 108 includes a plurality of pin openings 144 that are distributed and arranged along the gripper pin retainer 108. Referring to FIG. 9, the plurality of pin openings 144 are sized substantially equal to the pin body 142 of the gripper pins 110 to allow the gripper pins 110 to be located within the pin opening 144. The gripper pins 110 are prevented from passing through the pin openings 144 because the pin heads 140 are larger than the pin openings 144. The gripper pins 110 are located within the pin openings 144 and the gripper pin retainer 108 is located within the shaft cavity 120 such that the pin bodies 142 of the plurality of gripper pins 110 are protruding from the plurality of body openings 122 and such that the pin heads 140 are aligned with the plurality of peaks 128 such that the plurality of peaks 128 push outward on the pin heads 140 to cause the pin bodies 142 of the plurality of gripper pins 110 to protrude from the plurality of body openings 122.

When the expandable shaft 100 is located within the cavity of a material roll mandrel, hollow tube or core 111, the plurality of pin bodies 142 will protrude outwardly (See FIG. 10A and FIG. 10B) to press against the inner wall of the mandrel, hollow tube or core thereby non-movably associating the expandable shaft 100 with the roll of material. Thus, when the expandable shaft 100 rotates, the roll of material will rotate. To remove the expandable shaft 100 from the cavity of the material roll mandrel, hollow tube or core 111, the actuator handle 134 is move along the longitudinal axis of the expandable shaft 100 such that the plurality of valleys 130 are aligned with the plurality of body openings 122, wherein the pin heads are now allowed to move inwardly into the plurality of valleys 130 (See FIG. 11A and FIG. 11B) such that they are no longer pressing against the inner wall of the mandrel, hollow tube or core and the expandable shaft 100 can be removed from the cavity of the material roll mandrel, hollow tube or core 111.

Referring again to FIG. 2 and FIG. 4, the plunger 104 includes a plunger length P_L, wherein the plunger outer surface 126 is configured to have a plurality of peaks 128 and valleys 130 distributed along at least a portion of the plunger outer surface 126 along the plunger length P_L. Referring to FIG. 12 and FIG. 13, it is contemplated that when the plunger 104 is located within the shaft body 102, the plunger 104 is configured to be controllably movable along an axis X that extends along the plunger length P_L between a first configuration 300 and a second configuration 400. This may be accomplished via any method suitable to the desired end purpose and allows the gripper pins 110 to be configurable between being extended out of the plurality of body openings 122 or retracted into the plurality of body openings 122. One embodiment for accomplishing this is by using a pneumatic actuation configuration. In this embodiment, the shaft body 102 includes an air chamber 150 located on the opposing end of the expandable shaft 100 that includes the return spring 106 (i.e. the air chamber 150 is located proximate the second shaft handle 134). The shaft body 102 includes an air intake 152 for introducing air pressure into the air chamber 150, wherein the air intake 152 is sealingly communicated with the air chamber 150. The air chamber 150 is associated with plunger first end 121 such that when the air pressure in the air chamber 150 is at or above a predetermined level, the air chamber 150 pushes against the plunger first end 121 to cause the plunger 104 to move in the direction along the axis X that extends along the plunger length P_L. This causes the plunger 104 to be positioned such that the plurality of peaks are aligned with the gripping pins 110 (pushing the gripping pins 110 outward) and the plunger second end 123 is compressing the biasing member 106. When the air pressure in the air chamber 150 is below a predetermined level, the air chamber 150 ceases to push against the plunger first end 121. Thus, biasing member 106 decompresses causing the plunger 104 to move in the opposite direction along the axis X that extends along the plunger length P_L. This causes the plunger 104 to be positioned such that the plurality of valleys are aligned with the gripping pins 110, thus allowing the gripping pins to retract into the shaft cavity 120.

When the air pressure in the air chamber 150 is low, the air chamber 150 is in a collapsed configuration and the plunger 104 is in a first configuration 300, such that the plurality of gripper pins 110 are aligned with the plurality of valleys 130. This allows the gripper pins 110 to retract into the plurality of body openings 122 to allow the expandable shaft 100 to be disassociated from the material roll mandrel, hollow tube or core 111. When air is introduced into the air chamber 150, the pressure within the air chamber 150 increases such that the air chamber 150 is in an expanded configuration and the plunger 104 is in a second configuration 400, such that the plurality of gripper pins 110 are aligned with the plurality of peaks 128. This causes the plurality of gripper pins 110 to extend outwardly from the plurality of body openings 122 such that the plurality of gripper pins 110 press against the inside wall of the material roll mandrel, hollow tube or core 111 thereby securely associating the expandable shaft 100 with the material roll mandrel, hollow tube or core 111. When the air is released from the air chamber 150, the (return) biasing spring 106 causes the plunger 104 to be reconfigured from the second configuration 400 back into the first configuration 300.

Thus, injecting air into the plunger 104 causes the shaft body 102 to expand axially thereby moving the plunger 104 axially. This causes the peaks 128 of the plunger outer surface 126 to be aligned with the gripper pins 110 and one end of the shaft body 102 to press against the biasing spring 106. This causes the peaks 128 to push against the gripper pins 110 to cause the gripper pins 110 to protrude from the plurality of body openings 122 such that the plurality of gripper pins 110 press against the inside wall of the material roll mandrel, hollow tube or core 111 thus, securing the material roll to the moving components of the machine. Releasing the air causes the plunger 104 to be moved back to its collapsed position (via the biasing spring 106) such that the gripper pins 110 are aligned with the valleys 130 and thus are not protruding. It should be appreciated that the expandable shaft 100 may be either mechanically actuated and/or pneumatically actuated, as desired.

Moreover, the second shaft handle 134 is non-movably associated with the other end of the shaft body 102 such that the handle actuator portion 138 of the second shaft handle 134 is protruding out of the second shaft end opening 118 and such that the plunger body 124 is located within the shaft body 102, wherein the return spring 106 is located between the handle base 136 of the first shaft handle 132 and the end of the plunger body 124. It should be appreciated that when the first shaft handle 132 and the second shaft handle 134 are non-movably associated with the shaft body 102, the plunger body 124 is positioned within the shaft cavity 120 such that the plurality of peaks 128 are aligned with the plurality of body openings 122.

It should be appreciated that other methods for configuring the plunger 104 between the first and second configurations are contemplated. For example, in another embodiment the plunger 104 may move via a mechanical and/or electrical motor. Additionally, in still yet another embodiment, the outer surface 126 of the plunger body 124 may be configured such that all or only portions of the outer surface of the plunger body 124 is configurable to expand and contract. For example, in one embodiment the plunger body 124 may define a hollow portion that includes a bladder, where when air pressure is introduced into the bladder, the outer surface 126 of the plunger body 124 (or only portions of the outer surface 126) expand to compress against the gripper pins 110 thereby causing the gripper pins 110 to extend outwardly from the body openings 122. This may also be accomplished via an electrical and/or mechanical motor.

It should be appreciated that while the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes, omissions and/or additions may be made and equivalents may be substituted for elements thereof without departing from the spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. Moreover, unless specifically stated any use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another.

Claims

1. An expandable shaft for winding/unwinding machines, the expandable comprising:

a shaft body, wherein the shaft body defines a shaft cavity and includes a shaft first end, a shaft second end and a shaft body outer surface having a plurality of body openings which communicate the shaft body outer surface with the shaft cavity;

a gripping structure, wherein the gripping structure is located within the shaft cavity to be aligned with the plurality of body openings; and

a plunger having a plunger body, wherein the plunger body includes a plunger outer surface having a plurality of peaks and valleys, wherein the plunger is configurable between a first configuration and a second configuration, wherein when in the first configuration the plurality of valleys are aligned with the gripping structure and when in the second configuration the plurality of peaks are aligned with the gripping structure such that the gripping structure is protruding from the plurality of body openings.

2. The expandable shaft of claim 1, further comprising a roll of material, wherein the roll of material includes roll inner structure and wherein when the gripping structure is protruding from the plurality of body openings, the gripping structure is contacting the roll inner structure.

3. The expandable shaft of claim 1, wherein the plunger includes a plunger first end, a plunger second end and a plunger axis extending from the plunger first end to the plunger second end, and wherein the plunger is movably associated with the shaft body to be controllably configurable along the plunger axis between the first configuration and the second configuration.

4. The expandable shaft of claim 3, further comprising a first handle and a second handle, wherein the first handle is non-movably associated with one end of the shaft body and wherein the second handle is non-movably associated with plunger second end such that the first and second handle extend out of the shaft first end and shaft second end.

5. The expandable shaft of claim 1, further comprising an air chamber located proximate the plunger first end and associated with the plunger first end, wherein the air chamber is configured to cause the plunger to be configured between the first configuration and the second configuration.

6. The expandable shaft of claim 5, further comprising a biasing member located proximate the shaft second end, wherein when the plunger is in the first configuration, the plunger is located within the shaft cavity such that the plurality of valleys are aligned with the plurality of body openings and the gripping structure.

7. The expandable shaft of claim 6, wherein when the plunger is in the first configuration, the plunger is located within the shaft cavity such that the plurality of valleys are aligned with the plurality of body openings and the gripping structure.

8. The expandable shaft of claim 6, wherein when the plunger is in the second configuration, the plunger is located within the shaft cavity such that the plurality of peaks are aligned with the plurality of body openings and the gripping structure.

9. The expandable shaft of claim 1, wherein the gripping structure is a plurality of gripping pins and wherein the plurality of gripping pins are located to be aligned with the plurality of body openings.

10. The expandable shaft of claim 9, further comprising at least one gripper pin retainer, wherein the at least one gripper pin retainer is configured to associate the plurality of gripping pins together.

11. An expandable shaft for winding/unwinding machines, the expandable comprising:

a shaft body, wherein the shaft body defines a shaft cavity and includes a shaft first end, a shaft second end and a shaft body outer surface having a plurality of body openings which communicate the shaft body outer surface with the shaft cavity;

a plurality of gripping pins, wherein the plurality of gripping pins are located within the shaft cavity to be aligned with the plurality of body openings; and

a plunger having a plunger outer surface with a plurality of peaks and valleys, wherein the plunger is configurable between a first configuration and a second configuration, wherein when in the first configuration, the plunger causes the plurality of gripping pins to protrude from the plurality of body openings and when in the second configuration the plurality of gripping pins are retracted into the plurality of body openings.

12. The expandable shaft of claim 11, wherein when in the first configuration the plurality of valleys are aligned with the plurality of gripping pins such that the plurality of gripping pins are retracted into the plurality of body openings and when in the second configuration the plurality of peaks are aligned with the plurality of gripping pins such that the plurality of gripping pins are protruding from the plurality of body openings.

13. The expandable shaft of claim 11, further comprising a roll of material, wherein the roll of material includes roll inner structure and wherein when the plurality of gripping pins are protruding from the plurality of body openings, the plurality of gripping pins are contacting the roll inner structure.

14. The expandable shaft of claim 11, wherein the plunger includes a plunger first end, a plunger second end and a plunger axis extending from the plunger first end to the plunger second end, and wherein the plunger is movably associated with the shaft body to be controllably configurable along the plunger axis between the first configuration and the second configuration.

15. The expandable shaft of claim 14, further comprising a first handle and a second handle, wherein the first handle is non-movably associated with one end of the shaft body and wherein the second handle is non-movably associated with plunger second end such that the first and second handle extend out of the shaft first end and shaft second end.

16. The expandable shaft of claim 11, further comprising an air chamber located proximate the plunger first end and associated with the plunger first end such that when the air chamber includes a predetermine air pressure, the air chamber is configured to cause the plunger to be configured between the first configuration and the second configuration.

17. The expandable shaft of claim 16, further comprising a biasing member located proximate the shaft second end, wherein when the plunger is in the first configuration, the plunger is located within the shaft cavity such that the plurality of valleys are aligned with the plurality of body openings and the plurality of gripping pins.