TELESCOPING WEB HANDLING MEMBER

Abstract

Telescoping web handling members which can be adjusted to facilitate processing webs of varying dimensions are presented.

Description

FIELD

The present invention is generally directed to a telescoping web handling member which can be adjusted to facilitate processing webs of varying dimensions.

BACKGROUND

Manufacturing lines for making absorbent articles, such as diapers and adult incontinence products, are typically complex and require significant capital expenditure to develop. In view of this, manufacturers are continually evaluating approaches for imparting flexibility into the manufacturing lines to enable different products to be made on a single line with minimal changeover downtime when switching from the making of one product to another product. Downtime is generally needed to adjust unit operations, settings, equipment, and the like associated with different product sizes and/or configurations.

One item that can change when different absorbent articles are manufactured is the width of component webs (nonwovens, films, laminates, and the like). There can be numerous idler and/or driven rolls employed in a manufacturing line to help manage the position, tension, or other properties of a web. Different width rolls can be used for managing different web widths, but the economics of buying/making multiple rolls and storing the same, and the time and effort to change out rolls to make different products, is generally undesirable. A traditional telescoping roll could be employed in a manufacturing line to permit adjustability, but such traditional telescoping rolls comprise uni-directional diameter steps or changes in sections of the telescoping roll. Web materials in contact with such a roll will tend to “walk” to one side of the roll. Moreover, telescoping rolls with uni-directional diameter changes can induce drag on web materials and/or create additional instability and unwanted wrinkles in the web materials.

What is needed is a web handling member (e.g., a roll) that can be adjusted to manage different web widths, but that comprises similar desirable properties to that of fixed web handling members.

SUMMARY

The present invention is generally directed to telescoping web handling members which can be adjusted to facilitate processing webs of varying dimensions. In accordance with one embodiment, there has now been provided a telescoping web handling member comprising a first section comprising a first outer web contacting surface, a second section comprising a second outer web contacting surface, and a third section disposed between the first section and the second section and comprising a third outer web contacting surface. At least two of the first section, the second section, and the third section are slidably engaged with one another. And at least two of the first outer web contacting surface, the second outer web contacting surface, and the third outer web contacting surface are on a same plane.

In accordance with another embodiment, there has now been provided a telescoping web handling member comprising a first section, a second section, and a third section disposed between the first section and the second section. At least two of the first section, the second section, and the third section are slidably engaged with one another. There are multiple outer diameter changes between the sections that are both symmetric and centered among the first section, the second section, and the third section.

In accordance with yet another embodiment, there has now been provided a telescoping web handling member comprising a first section, a second section, and a third section disposed between the first section and the second section. The third section comprises a different effective outer diameter from that of the first second and the second section. The third section is slidably engaged with the first section, and rigidly fixed to the second section.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description of specific embodiments of the present invention can be best understood when read in conjunction with the drawings enclosed herewith.

FIG. 1 is a plan view of an exemplary web handling member working in concert with a pair of opposing web folding boards.

FIG. 2 is a partial side view of the exemplary web handling member shown in FIG. 1.

FIGS. 3A-3C are plan views of an exemplary web handling member in three different configurations having three different overall lengths.

FIG. 4 is a cross-sectional view of an exemplary web handling member of the present invention.

FIG. 5 is partial cross-sectional view of one section of the web handling member of FIG. 4 and connective structural elements of the same.

The embodiments set forth in the drawings are illustrative in nature and not intended to be limiting of the invention defined by the claims. Moreover, individual features of the drawings and invention will be more fully apparent and understood in view of the detailed description.

DETAILED DESCRIPTION

The following text sets forth a broad description of numerous different embodiments of the present invention. The description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. And it will be understood that any feature, characteristic, component, composition, ingredient, product, step or methodology described herein can be deleted, combined with or substituted for, in whole or part, any other feature, characteristic, component, composition, ingredient, product, step or methodology described herein. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims. All publications and patents cited herein are incorporated herein by reference.

It should also be understood that, unless a term is expressly defined in this specification using the sentence “As used herein, the term ‘______’ is hereby defined to mean . . . ” or a similar sentence, there is no intent to limit the meaning of that term, either expressly or by implication, beyond its plain or ordinary meaning, and such term should not be interpreted to be limited in scope based on any statement made in any section of this patent (other than the language of the claims). No term is intended to be essential to the present invention unless so stated. To the extent that any term recited in the claims at the end of this patent is referred to in this patent in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such a claim term be limited, by implication or otherwise, to that single meaning. Finally, unless a claim element is defined by reciting the word “means” and a function without the recital of any structure, it is not intended that the scope of any claim element be interpreted based on the application of 35 U.S.C. §112, sixth paragraph.

The present invention is generally directed to telescoping web handling members which can be adjusted to facilitate processing webs of varying dimensions. The web handling members can be stationary, rotate, oscillate, be in the form of an idler roll, be in the form of a driven roll, have a circular cross-sectional geometry, and/or have a non-circular cross sectional geometry, for example. The web handling members can be an independent structure or be associated with another manufacturing component. By way of example only, an exemplary web handling member will be described below as an associated component to a web folding apparatus 10 shown in FIG. 1.

Folding apparatus 10 includes a pair of opposing folding boards 12, and an adjacent web handling member that is in the form of an exemplary telescoping idler roll 22. The telescoping idler roll 22 can support a full width of the web. Additional features of telescoping idler roll 22 is shown in FIG. 2, which is an enlarged view of the section shown in broken lines in FIG. 1 and labeled 2.

Telescoping idler roll 22 includes three sections: first section 30, second section 33, and third section 36 disposed intermediate first section 30 and second section 33 when idler roll 22 is in an extended configuration. Web handling members of the present invention will typically have at least three sections. While telescoping idler roll 22 is shown with just three sections, variations including four sections, five sections, and more are contemplated herein.

Each of first section 30, second section 33, and third section 36 comprises an outer web contacting surface 31, 34, and 37, respectively. As can be seen in FIG. 2, outer web contacting surface 31 of section 30 and outer web contacting surface 34 of section 33 are on the same plane P. In alternative arrangements, outer web contacting surfaces of multiple sections can be located slightly out-of-plane from one another—for example, a gap of 5 mm (millimeter) or less, or 1 mm or less.

Each of first section 30, second section 33, and third section 36 also comprises an outer diameter 32, 35, and 38, respectively. The outer diameter changes among the sections permit a section to be slidably engaged with an adjacent section—the telescoping nature of at least some of the idler roll sections enable the overall length 24 (see FIG. 1) of idler roll 22 to be adjustable for processing and handling webs of varying widths. FIGS. 3A-3B illustrate telescoping idler 22 in three different configurations to process webs having three different widths, wherein the overall length 24 of idler 22 is varied. In one embodiment, the overall length can vary from about 600 mm in a closed configuration such as shown in FIG. 3A to about 850 mm in an open configuration such as shown in FIG. 3B.

Referring again to FIG. 2, outer diameter 38 of third section 36 is smaller than outer diameter 32 of first section 30 and outer diameter 35 of second section 35 to define a step or outer diameter change 40, 42 between adjacent sections. It can be advantageous to limit the step amount or outer diameter change between adjacent sections. Thus, preferred step amounts include no more than 10, 9, 8, 7, 6, 5, 4, 3, and 2 mm. In one execution the step amount is between about 1.5 mm and about 3 mm.

It can also be advantageous to manage the length of the stepped portion. For example, the length 50 of the exposed portion of third section 36. In some arrangements, the stepped portion length 50 can range from about 1 mm to about 500 mm, and from about 10 mm to about 350 mm.

In exemplary idler roll 22, outer diameter change 40 is the same (symmetric) as outer diameter change 42. Furthermore, the diameter changes 40, 42 in exemplary idler roll 22 are centered among first section 30, second section 33, and third section 36. In alternative arrangements, outer diameter changes may be off-centered among the plurality of sections. And multiple outer diameter changes can be different where there is end-to-end symmetry along the length of the web handling member. For example, the web handling member may have five sections with two different diameter or step changes among the five sections.

As shown in FIG. 2, a central axis CA of first section 30, second section 33, and third section 36 are aligned with one another. Alternatively, the central axis of at least one of the sections can be offset from that of other sections.

In some arrangements, less than all of the adjacent sections are slidably engaged with one another. For example, and as shown in FIG. 4, third section 36 can be slidably engaged with first section 30, but has a fixed engagement with second section 33. Here, third section 36 and second section 33 can be manufactured individually as distinct components and thereafter joined to one another, or they can be manufactured together where a step or outer diameter change exists between the adjacent sections. A bushing 55 can be employed to facilitate an appropriate balance of fit and slidability between third section 36 and first section 30. For example, a polymer bushing made from PEEK, PTFE, Nylon, or UHMW PE can be disposed within first section 30 so that third section 36 can travel within first section 30 for adjusting overall length 24. The fixed engagement between third section 36 and second section 33 can be accomplished via a press fit and/or additional affixment materials and techniques.

The sections of the telescoping web handling member can have similar or varying properties and/or configurations. For example, the sections can be made out of different material, wherein one of the sections comprises metallic materials and another of the sections comprises plastic or polymeric materials. In one arrangement, first section 30 and second section 33 are made out of aluminum, while section 36 is made out of plastic. In another example, the sections can be made of out of the same material, wherein each of the sections comprise metallic materials or each of the sections comprise plastic or polymeric materials. In one arrangement, the first section 30, the second section 33, and section 36 may be made out of aluminum. In yet another arrangement, for example, the first section 30, the second section 33, and section 36 may be made out of steel. The materials may be selected based on durability, strength, weight considerations, and the properties of the material that is to interact with the telescoping web handling member. Further, the various sections can also exhibit different levels of solidness and hollowness. For example, third section 36 can be substantially solid, while first section 30 and second section 33 are hollow (or comprise both hollow and solid sections). The connectivity approach of the sections of exemplary idler 22 shown in FIG. 4, provides a difference in wall thickness between hollow first section 30 and hollow second section 33—that is, first section 30 comprises a wall thickness that is less than that of second section 33 because third section 36 travels within first section 30 (for adjusting the overall length of the idler) and is press fit into second section 33.

One or more of the sections of the telescoping web handling member can employ a surface coating material. Coating materials can be used for a variety of purposes, including, for example, improved wear properties, controlling coefficient of friction, and complying with regulations such as those issued by the U.S. Food and Drug Administration.

FIG. 5 shows a cross-sectional enlarged portion of section 30 shown in broken lines in FIG. 1 and labeled 5. An exemplary connection of section 30 to a shaft 60 via bushing 62, bearing 64, and retaining ring 66 is shown. The stepped configuration of shaft 60 ensures that when the telescoping idler 22 is extended, shaft 60 pulls the bearing 64 and section 30 assembly with it. Alternative features and connectivity can also be employed within the spirit of the invention.

This application claims the benefit of U.S. Provisional Application No. 62/419,572 filed on Nov. 9, 2016, the entirety of which is incorporated by reference herein.

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”

Every document cited herein, including any cross referenced or related patent or application and any patent application or patent to which this application claims priority or benefit thereof, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims

1. A telescoping web handling member, comprising:

a. a first section comprising a first outer web contacting surface;

b. a second section comprising a second outer web contacting surface; and

c. a third section disposed between the first section and the second section, the third section comprising a third outer web contacting surface;

d. wherein at least two of the first section, the second section, and the third section are slidably engaged with one another; and

e. wherein at least two of the first outer web contacting surface, the second outer web contacting surface, and the third outer web contacting surface are on a same plane.

2. The telescoping web handling member of claim 1, wherein the first section, the second section, and the third section are configured to rotate.

3. The telescoping web handling member of claim 1, wherein the first section, the second section, and the third section define an idler roll.

4. The telescoping web handling member of claim 1, wherein the first section and the second section comprise a metallic material; and wherein the third section comprises a polymeric material.

5. The telescoping web handling member of claim 1, wherein the first section and the second section are aluminum; and wherein the third section is plastic.

6. The telescoping web handling member of claim 1, wherein the first section and the second section are hollow; and wherein the third section is solid.

7. The telescoping web handling member of claim 1, wherein the first section comprises a first wall thickness and the second section comprises a second wall thickness; and wherein the first wall thickness is different than the second wall thickness.

8. The telescoping web handling member of claim 1, wherein the third section has a smaller outer diameter than that of the first section and the second section.

9. The telescoping web handling member of claim 1, wherein third section is slidably engaged with the first section; and wherein the third section is rigidly fixed to the second section.

10. A telescoping web handling member, comprising:

a. a first section;

b. a second section; and

c. a third section disposed between the first section and the second section;

d. wherein at least two of the first section, the second section, and the third section are slidably engaged with one another;

e. wherein there are multiple outer diameter changes between the sections; and

f. wherein the multiple outer diameter changes are both symmetric and centered among the first section, the second section, and the third section.

11. The telescoping web handling member of claim 10, wherein the first section, the second section, and the third section are configured to rotate.

12. The telescoping web handling member of claim 10, wherein the first section, the second section, and the third section define an idler roll.

13. The telescoping web handling member of claim 10, wherein the first section and the second section comprise a metallic material; and wherein the third section comprises a polymeric material.

14. The telescoping web handling member of claim 10, wherein the first section and the second section are aluminum; and wherein the third section is plastic.

15. The telescoping web handling member of claim 10, wherein the first section and the second section are hollow; and wherein the third section is solid.

16. The telescoping web handling member of claim 10, wherein the first section comprises a first wall thickness and the second section comprises a second wall thickness; and wherein the first wall thickness is different than the second wall thickness.

17. The telescoping web handling member of claim 10, wherein the third section has a smaller outer diameter than that of the first section and the second section.

18. The telescoping web handling member of claim 10, wherein third section is slidably engaged with the first section; and wherein the third section is rigidly fixed to the second section.

19. A telescoping web handling member, comprising:

a. a first section;

b. a second section; and

c. a third section disposed between the first section and the second section;

d. wherein the third section comprises a different effective outer diameter from that of the first second and the second section;

e. wherein the third section is slidably engaged with the first section; and

f. wherein the third section is rigidly fixed to the second section.

20. The telescoping web handling member of claim 19, wherein the first section, the second section, and the third section define an idler roll.