EP1747158B1 - Method for making a central unwinding roll and resulting roll - Google Patents

Abstract

This invention relates to a method for the production of a coreless roll (110′) including a sheet (110) of flexible, not moist, material such as a fibrous absorbent material, produced by winding of the sheet in one direction and rolling this sheet about a winding axis perpendicular to such direction, and including a central dispensing leader forming a projection along such axis relative to at least one part of the plane of one of the sides of the roll. The method is characterized in that the leader is produced by displacing a portion of the end of the sheet (110) before winding so that one of the longitudinal edges of the sheet forms an angle (α) other than zero relative to such direction of winding, after which winding of the sheet about the axis is initiated. By preference several sheets are produced by longitudinal cutting of a wide sheet. The solution may be applied for production in particular of general wipe rolls, hand towel rolls, or toilet paper rolls.

Description

The invention relates to the field of rolls of absorbent paper or other similar material such as a nonwoven, for example for wiping. It relates in particular to the field of products for sanitary or domestic use such as wiping rolls or towels or toilet paper.

For these applications, the rolls consist of a continuous sheet which comprises one or more plies. The sheet is optionally precut in consecutive coupons in the direction of the winding, and is wound axially, preferably around an axis that can support or not a mandrel; the roll can thus comprise a central mandrel or not. The sheet may be unwound, either from the outer surface of the roll in the direction of the coil, or from the inside, from the center in the axial direction perpendicular to that of the roll winding. In the latter case, it is said that the roll is centrally rewind.

The present invention relates to the rollers that are used in central unwinding.

When the roll has a mandrel, we must first extract it. In general, it has been designed so that it can be torn by pulling on its edge; most often at one end of the cardboard spiral spiral that forms it. However, practice shows that this solution is not always satisfactory, because the extraction of the mandrel is sometimes difficult if the fracture zone or areas are poorly formed. In addition, this action can cause the first sheets of the roll which become difficult to use. In addition, the first turns of the sheet being most often glued to the mandrel, they are unfit for any use and are a cause of waste.

This mandrel is particularly expensive to produce, since generally consists of two or more layers of cardboard bonded by bonding. It is also associated most often with a glue "hanging" the first turn of the roll. It is no longer useful once removed, and becomes a waste.

To overcome this disadvantage, it also proposes central reels without mandrel. These are in principle easier to implement by the user, because it is no longer necessary to remove a mandrel prior to their commissioning. To achieve these, one can, in manufacture, provide a temporary mandrel on which the sheet is wound. The mandrel is then removed before conditioning the coils. This technique presents constraints on the industrial level because it is necessary to add an extraction station of the mandrels to the winding line. Added to this is the cost of glue and mandrel.

According to a method of manufacture without mandrel, the sheet is cut in line in the direction or longitudinal direction, before winding, from a mother sheet of great width, and in as many bands as individual rolls to obtain.

According to another method of manufacture, the mother sheet is wound directly on a pin, also without the interposition of a mandrel. The initial sheet, which is large in width, is first rolled up to form a single coil with the final diameter of the individual roll, called "log" in the field. After training, the log is extracted from the spindle and cut into individual rolls.

However, the sheet, whether cellulose wadding, creped dry or wet, dry paper or a nonwoven, has some elasticity. Because of the internal stresses of the roll, due for example to the clamping of the sheet on the spindle during the winding and / or the tension of the sheet that generates the unwinding / winding operation by the machine, it can not be avoided normally. reducing the central hole by collapsing or collapsing in the center of the first turns after the pin has been removed. This collapse occurs, for example, after extraction of the spindle and / or at the time of cutting the log, by the pressure exerted by the saw.

In any case, there is a partial or total reduction of the central hole during handling and transport, due to the inevitable vibrations to which the rollers are subjected.

When the central hole is completely reduced, it is difficult to reform at least by hand, and the grip of the first turn is not easy. It inevitably follows waste, especially for the commissioning of the roller in a dispenser, because it is then necessary to grasp several turns at a time.

It is known to produce mandrelless rollers whose central hole remains formed after extraction of the spindle and / or after cutting by a saw. One can use for example a pin whose profile, grooved or polygonal, allows the formation of a hole whose walls are self-supporting. An exemplary embodiment is illustrated by the patent FR 2554799 . The closest state of the art is represented by the manufacturing process disclosed in JP-01308345 .

Nevertheless, the central hole is of small diameter and the first turns remain difficult to access. They come in a tight, helical, low "pitch" torch that is not conducive to easy use. If the diameter of the central hole is larger, it is difficult to avoid associating the first turns between them. For this we use a bonding agent that is deposited directly on the sheet or indirectly via the spindle or one of the winding rolls, by a suitable system, at the time of winding the first turns on the spindle. Any other principle of association of the first turns with each other, by a mechanical process in particular, is applicable. We thus consolidate these first turns which together withstand the efforts of internal constraints.

However, again, the waste can not be avoided during the commissioning of such a roll. Whether in the case of direct use or in the case where this roller is used in a center-fed dispenser in which the end of the sheet must be introduced into a relatively narrow dispensing orifice, one is obliged to to eliminate beforehand the first coils associated with each other.

In this latter type of embodiment also, it can not be avoided that some rollers are shocked during transport, with as consequently the collapse of the central hole as in the cases mentioned above. To avoid this risk, it is also expected to preferentially condition the rolls in cardboard boxes, unlike rollers with mandrel that are sufficient of a flexible envelope of paper or plastic. The cost is considerably increased.

The interest that could be found in these mandrel-free rolls compared to mandrel rollers is thus greatly reduced.

The subject of the invention is therefore a roll without mandrel composed of a sheet of flexible material, such as an absorbent fibrous material with a total grammage of between 15 and 300 g / m ² , preferably between 15 and 100 g / m ² , formed by winding around a winding axis, which does not have the disadvantages reported above.

The absorbent material may be cellulose wadding, dry or wet creped, dry paper or nonwoven. It can be composed of one or more plies, associated or not, possibly pre-cut into coupons.

The material is in the dry state. It is not wet; in particular it is not impregnated with lotion or any other liquid.

The applicant has filed, under number WO2005 / 005295 June 12, 2003 a roll-related patent application comprising a central unwinding primer forming a projection along said winding axis with respect to at least a portion of the plane of one of the sidewalls of the roll.

The invention according to this patent application applies in particular to the rollers whose winding is carried out under conditions of high tension of the sheet and clamping on the winding support, which make it possible to produce rolls with strong footage but which lead to inevitably to the reduction of the central hole.

In particular, the central unwinding primer consists of a portion of the inner end of the sheet, forming the individual roll.

The solution of the invention according to this patent application makes it possible to free itself from all the problems related to the reduction of the central hole since the first sheet is accessed from outside the roll. As a result, it is no longer necessary to tie the first turns together to try to maintain the hole formed. This avoids waste, both at the level of the production machine due to the lack of system of association of the first turns, than during the commissioning of the roll. We can therefore package the rolls in simple flexible packaging, including plastic.

In particular, this primer is formed by transversely folding a portion of the end of the sheet on the winding axis of the roller; it thus has a tapered shape. There is then the additional advantage of facilitating the introduction of the end of the primer into the dispensing device of a center-fed dispenser, for example.

The present application relates to a novel method constituting a variation of the methods described in the Applicant's earlier application.

According to the invention, the manufacturing method contains the technical features of claim 1.

Preferably, the roll of the sheet is carried out on a winding support, such as a spindle. In particular, the end portion is formed by cutting the sheet transversely relative to the direction of travel.

This method has the advantage that it can be applied very simply to an existing industrial installation, with minor modifications.

• on déplace latéralement une portion desdites feuilles,
• on découpe les dites feuilles transversalement par rapport à la direction de défilement pour former des portions d'extrémité,
• on enroule les dites feuilles autour de l'axe et,
• on sépare chacun des rouleaux après leur formation, libérant ainsi chacune des amorces.

More specifically, the method comprising the steps of producing the roll by winding the sheet perpendicularly about a winding axis, according to which:

• laterally moving a portion of said sheets,
• said sheets are cut transversely with respect to the running direction to form end portions,
• these sheets are wrapped around the axis and,
• each of the rolls is separated after their formation, thus releasing each of the primers.

• on arrête la rotation de la ou des feuilles autour du dit axe,
• on déplace le ou les rouleaux par déroulement de feuille sur une première distance déterminée selon à la direction de défilement (MD),
• on entraîne le ou les rouleaux en rotation inverse par rapport au sens de bobinage initial pour dérouler une quantité donnée de feuille,
• on déplace le ou les rouleaux selon la direction (CD) de leur axe sur une deuxième distance prédéterminée,
• on découpe la ou les feuilles entre le ou les rouleaux et les cylindres transversalement à ladite direction de défilement.

According to another characteristic, after winding the roller or rollers,

• the rotation of the leaf (s) around the said axis is stopped,
• the roll or rolls are moved by unwinding the sheet over a first determined distance according to the direction of movement (MD),
• the roller (s) is rotated inversely with respect to the initial winding direction to unroll a given quantity of sheet,
• the roll or rolls are moved in the direction (CD) of their axis over a second predetermined distance,
• the sheet or sheets are cut between the roll or rolls and the rolls transversely to said direction of travel.

More generally, movements and rotation are combined and adapted so as to avoid any breakage of the sheet.

To make the operation safer, movements and rotation are combined to avoid breakage.

According to another characteristic, before cutting the sheet or leaves is applied glue on the portion of the sheets forming the tail of the roll or rolls.

According to another characteristic, after having cut the sheets, the longitudinal edges of the tail portion of the rollers are realigned with the edges of the rollers, in particular by displacement in the opposite direction of the winding support or the tail portion.

Preferably, the primer is made on the side opposite to that by which the support is extracted in order to limit the frictional forces of the sheets in contact with the support and to facilitate its extraction.

The invention also relates to the roll obtained according to the method. The length of the primer is at least 0.3 cm and preferably between 1 and 15 cm. It is in particular of tapered shape and the tail of the rollers. Finally, the glue deposit is parallel to the non-longitudinal edge of the tail portion of the rollers.

• la figure 1 représente un rouleau sans mandrin de l'art antérieur dont le trou central est réduit,
• la figure 2 représente un rouleau de l'invention avec une amorce de dévidage central faisant saillie le long de l'axe par rapport à un des flancs du rouleau,
• les figures 3 à 5 représentent schématiquement, en vue de profil, la progression d'une feuille dans une machine permettant de réaliser les rouleaux sans mandrin avec amorce de dévidage,
• la figure 6 représente la machine selon la figure 4, vue de dessus,
• les figures 7 à 10 représentent schématiquement une machine dans les différentes phases du procédé selon l'invention,
• la figure 11 représente la machine dans la configuration de la figure 9, vue de dessus,
• la figure 12 représente un rouleau obtenu selon le procédé de l'invention.

The invention will now be described in more detail with reference to the appended drawings in which:

• the figure 1 represents a mandrelless roll of the prior art whose central hole is reduced,
• the figure 2 represents a roll of the invention with a central unwinding primer projecting along the axis with respect to one of the sidewalls of the roll,
• the Figures 3 to 5 schematically represent, in profile view, the progression of a sheet in a machine for making rolls without mandrel with unwinding primer,
• the figure 6 represents the machine according to the figure 4 , top view,
• the Figures 7 to 10 schematically represent a machine in the different phases of the process according to the invention,
• the figure 11 represents the machine in the configuration of the figure 9 , top view,
• the figure 12 represents a roll obtained according to the process of the invention.

The roll represented on the figure 1 is, for example, a roll (R) of absorbent paper without mandrel which is used for wiping; either at home or in a workshop. By way of illustration, the paper is, for example, a two-ply cellulose wadding of 20 g / m ² each, preferably associated. The roll was obtained by winding a large sheet of 2600 mm width, on a spindle-shaped winding support for example circular section with a diameter of 10 to 80 mm. After forming a roll, designated "log" in the field, of 20 cm in diameter, for example, the spindle is extracted and led to a sawing station. The rolls thus produced are then packaged for shipping. The roll is shown after the walls of the central hole have collapsed in the central direction. The hole (T) is reduced until it is completely flattened. When commissioning the roller in a center-fed dispenser, the inner end of the sheet must be released and slid into the dispensing orifice. We understand that this operation is difficult in this case, because we must pull on the first turns to clear this end. This inevitably results in waste.

The figure 2 shows a mandrelless roll (10 ') resulting from the process of the invention or as described in the patent application WO2005 / 005295 . The central hole is reduced as in the previous case of the prior art. However, the commissioning of the roll is largely facilitated by the solution of the invention which consisted in forming a central unwinding primer (10B). This primer is, according to the simplest embodiment, constituted by a portion of the inner end of the sheet forming the roller that is beforehand, before any collapse of the walls of the central hole, released, and setting protrusion with respect to one of the flanks of the roll. This primer can be formed, either at the time of formation of the roll just before or during the winding of the sheet, or after making the roll when the hole is still formed, ie just after cutting, in any condition of cause, preferably shortly thereafter, as described in the application WO2005 / 005295 .

Advantageously, this primer (10B), 0.3 to 20 cm long and preferably 1 cm to 15 cm, is formed of a portion of the inner end of the sheet, which is folded into the direction of the winding axis of the roll and is overflowed with respect to the sidewall. This primer thus forms a tip gripping means which is flexible at its end and which can easily be folded against the side of the roll, for packaging said rolls before transport. In addition the tip is handy and can be easily introduced into a dispenser. The length of the primer is chosen in particular for the ease with which it can be grasped and with which it can be introduced into the extraction orifice of a dispenser. The length of the primer corresponds to the distance between the end of the primer and the side of the roll.

The primer can be reinforced by a complementary element, for example staining.

According to an embodiment not shown, the primer can be mechanically reinforced by a tongue, or any appropriate means, or additional element attached to the sheet and arranged to project on the axis of the roller.

The added element is then placed on the end of the sheet before winding or after separation of the rollers, projecting on one of the sides of the roll.

A way of manufacturing rolls according to demand WO2005 / 005295 is described below with reference to Figures 3 to 6 which represent the essential elements of a roll winding machine.

With this machine, is cut in line a large sheet 1 from a mother reel (3), before winding on a spindle (11). The width of the sheet in the field of absorbent paper products is, for example, 2600 mm. The sheet is cut in the longitudinal direction of travel by means of blades 5 arranged in parallel, in a plurality of individual sheets (10) whose width corresponds to the width of the individual rolls that it is desired to obtain. The cutting means may consist of a series of blades arranged vertically or discs cooperating with a support cylinder and cutting the sheet. Other means are known to those skilled in the art.

The sheets (10) are driven to a device comprising two cylinders (7 and 9) parallel and rotated by motor means not shown. The two cylinders are slightly spaced from each other. Once the leaves (10) in the position of the figure 3 a pin (11) forming a winding support is brought into place by appropriate means. The pin pinches the sheet against the cylinders (7 and 9), as seen on the figure 4 . It overlaps the space between these two contiguous drive cylinders. The pin thus delimits on one side an end portion (10A) of the sheets (10). To initiate the winding of the sheets on the spindle, there is provided a means (15) which folds the end portion (10A) on the spindle (11). This means can be constituted by one or more air jets judiciously oriented. Then, a pressure roller (13) is lowered to hold the end (10A) of the sheets against the pin. Once the various members in position, the cylinders (7 and 9) are rotated. These rotate the spindle and the roller 13 on themselves allowing the winding of the sheet as seen on the figure 5 .

When the winding step is completed, the pressure roller is raised and the spindle is moved with its rollers (10 ') to the next station where the individual sheets are cut, parallel to the winding axis, over any the width of the mother sheet, downstream of the rolls (7 and 9). Then, the pin is extracted from the assembly formed by the rollers (10 ').

To achieve a primer at the time of winding the leaves. We see on the figure 6 , which is a top view of the installation corresponding to the view of the figure 4 , the pin (11) placed on the two cylinders (7 and 9) and pinching the sheet. The sheets (10 ₁ , 10 ₂ , ...) are arranged below the pin (11) and their end portions (10A ₁ , 10A ₂ , ...) folded transversely thereto. The means (15), here constituted by air jets, are inclined on the axis of rotation of the spindle so as to print at these end portions a movement movement transverse to the direction of movement of the sheets. These end portions (10A ₁ , 10A ₂ , ...) are thus displaced in the direction of the winding axis. Thus, each end portion, (10A ₁ ) for example, overflows on the side towards the adjacent sheet, (10A ₂ ). Once they are in this position, the pressure roller (13) immobilizes the different end portions (10A ₁ , 10A ₂ , ...) against the pin (11). The winding can begin. During winding, the projecting portion (10B ₁ , 10B ₂ , ...) of the end portion of each of the sheets is pinched between the spindle and the first turn of the adjacent roll.

The overflowing portion is released when the pin is removed. This part (10B ₁ , 10B ₂ , ...), then constitutes the central unwinding primer for the roll.

The process according to the present invention is now described with reference to Figures 7 to 10 which show the successive stages. We use for the same elements, the same references added of 100.

The figure 7 shows here four rollers (110 ') being formed by winding sheets (1101 to 1104). The number of rolls may be different. The leaves are cut in a large sheet (110) according to the scrolling direction (MD) thereof by cutting means schematized by disks (105). They are mounted on a spindle or winding support (111) which is rotated in the direction of the arrow by the two cylinders (107 and 109) on which they rest. The cylinders (107 and 109) are themselves rotated by motor means (not shown). A pressing cylinder (113) ensures the cohesion of the assembly.

On the Figures 8A and 8B the winding of the rollers is finished; the set with the spindle was moved a first distance (L3) determined in the direction of travel (MD) mentioned above, leaving the sheets to unfold. The rollers were laid with the spindle on supports (107 'and 109'). The supports (107 'and 109') are preferably parallel to the cylinders (107 and 109). The spindle is rotated a fraction of a turn, in the opposite direction to the original winding direction, in the direction of the arrow of the Figure 8B to form a loop by unwinding a given amount of sheet.

On the figures 9 and 11 a cylinder (120) is shown which moves the spindle (111) provided with the rollers, preferably parallel in the direction of its axis, over a second determined distance (L2) in the direction of the arrow (CD). The longitudinal edges of the sheets now have an angle (α) with respect to the initial direction of travel (MD). It is observed in the figure that the angular offset occurs from the knives (105) of longitudinal section of the sheet (110) which are upstream of the cylinders (107 and 109). This angular offset is preferentially in the same plane as that of scrolling. However, instead of making the displacement in two perpendicular directions, it can be carried out along a suitable path having at least components in the directions (MD) and (CD)

A new pin (111 ') is deposited on the sheets at the cylinders (107 and 109). The leaves are thus pinched between the pin (111 ') and these cylinders. Then, glue is deposited along a transverse line referenced AA, preferably parallel to the cylinders (107 and 109) which support the winding of the rollers, and transversely cut all the sheets along a line XX by means of a knife which is preferably moved parallel to the winding axis. Line XX is located between the line AA and the cylinders (107 and 109) at a distance L from the cutting members (105).

On the figure 10 after cross section of the sheets, the spindle (111) was moved with its rollers, contrary to the direction of the arrow CD, over a sufficient distance (Sr) in the axis of the rollers to realign the tail portions ( 110B) sheets in the scrolling direction. The winding of the rollers (110) 'is completed in such a way that the end or tail portions (110B) of the glue-coated sheets G are fixed on their respective rolls, so that the longitudinal edges of said portions of tail (110B) are aligned at best with those of their respective roll.

For the tail portion (110B), on the one hand, and the sheet end portion (110A), on the other hand, it is found that the edges generated by the cross section do not form a right angle with the edges longitudinal sheets (110). The end portion (110A) which forms the primer thus has a tapered shape conducive to easy introduction into a dispensing orifice of a reel. The tail portion (110B) is also tapered and is characterized by this method.

The rolls are completed. The spindle is separated from the rollers and the primers are released by moving the rollers apart.

The machine is ready to roll up a new series of rollers. The first step is then to fold the end portions (110A) on the spindle. Because of their inclination with respect to the direction of travel of the sheet (angle α), these portions of sheet (110A) folded on the pin each form a primer and overlap the adjacent roller. The remainder of the sheets that have not undergone this lateral shift is wound while remaining perpendicular to the axis of the spindle to form the rollers.

It is observed that, compared to a known roll winding installation, it was sufficient to include a jack (120) which controls the axial displacement of the spindle over a short distance. The distance of movement of the spindle (111) in the axial direction depends on the length of the unwinding primer.

• Distance L1 entre les organes de coupe (105) et la position sur les appuis (107' et 109') : 700 mm,
• Deuxième distance L2, de déplacement des rouleaux selon l'axe CD : 160 mm
• Distance L de coupe selon XX : 260 mm.

By way of example, products have been produced on an industrial machine. The disposition of the various bodies represented on the figure 11 , which is the top view of the machine, was as follows:

• Distance L1 between the cutting members (105) and the position on the supports (107 'and 109'): 700 mm,
• Second distance L2, displacement of the rollers according to the axis CD: 160 mm
• L cutting distance according to XX: 260 mm.

A primer length C of about 60 mm is obtained. (C = L2xL / L1).

The distance Sr on which the spindle is brought back with the rollers to realign the tail portions is given by the Sr = L2-C relationship, ie here 100 mm.

On the figure 12 there is shown a roller with the last sheet (110B) whose transverse edge is inclined relative to the sides thereof by an angle (β). It is observed that when the section line XX is perpendicular to MD this angle is complementary to the angle (α). In the present example, there is an angle (β) of 77 ° and an angle (α) of 13 °.

Claims (10)

1. Method for manufacturing coreless rolls (110') each consisting of a sheet (110) of not moist flexible material such as an absorbent fibrous material, made by running the sheet in one direction and rolling them around a reeling shaft perpendicular to the said direction, and each comprising a central unwinding start forming a protrusion along the said shaft relative to at least one portion of the plane of one of the edges of the roll, the start being made by offsetting an end portion of the sheet (110) before rolling so that one of the longitudinal edges forms a non-zero angle (α) relative to the said direction of running, characterized in that

   - a wide sheet (110) of flexible material is cut parallel to the direction of running into a plurality of individual sheets (1101, 1102, 1103, 1104) placed side by side,

   - a portion of the said sheets is shifted laterally,

   - the said sheets are cut transversely relative to the direction of running in order to form the end portions (110A),

   - the said sheets are wound around the shaft and,

   - each of the rolls is separated after their formation, thus releasing the start of each of the rolls.
2. Method according to the preceding claim, in which the sheets are placed in rolls on a reeling support (111).
3. Method according to Claim 1 or 2, in which, after winding of the rolls,

   - the rotation of the sheets around the said shaft is stopped,

   - the rolls are moved by unwinding the sheet (110; 1101 to 1104) over a first distance (L3) determined depending on the direction of running (MD),

   - the rolls are rotated in reverse relative to the initial reeling direction in order to unroll a given quantity of sheet,

   - the rolls are moved in the direction (CD) of their shaft over a second predetermined distance (L2),

   - the sheets are cut between the rolls and the cylinders (107 and 109) transversally to the said direction of running (MD).
4. Method according to the preceding claim, in which the movements and the rotation are combined and adapted so as to prevent any breakage of the sheet (110; 1101 to 1104).
5. Method according to Claim 1, in which the movement generating the angle (α) is carried out on a trajectory having at least some components in the directions (MD and CD) .
6. Method according to one of the preceding claims, in which glue is applied to the portion of the sheet forming the tail (110B) of the rolls.
7. Method according to the preceding claim, in which, after the sheets have been cut, the longitudinal edges of the portion of the tail (110B) of the rolls are realigned with the edges of the latter.
8. Method according to the preceding claim, according to which the rolls or the portion of the tail are realigned by movement over a determined distance (Sr).
9. Method according to one of the preceding claims, according to which the start is produced on the side opposite to that by which the support is extracted in order to limit the friction forces of the sheets in contact with the support and to make its extraction easier.
10. Method according to one of the preceding claims, according to which the length of the start obtained is at least 0.3 cm and preferably between 1 and 15 cm.

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