Web winding and conveying system for web processing system

Abstract

A reel transfer assembly (20) for a web processing system (200) includes a support beam (22) configured to be movably mounted to a frame (100F) of the web processing system (100). The reel transfer assembly (20) includes a segmented reel assembly (24) rotatably mounted to a support beam (22). The segmented roll assembly (24) includes a first end section (24A), a second end section (24B), a central section (24C) positioned between the first end section (24A) and the second end section (24B). The reel transfer assembly (20) includes a first transfer reel (26A) positioned between the first end section (24A) and the central section (24C) and a second transfer reel (26B) positioned between the second section (24B) and the central section (24A). The reel transfer assembly (20) includes an actuation assembly (28) connected to the support beam (22), the first transfer reel (26A), and the second transfer reel (26B). The actuation assembly (20) includes a first drive system configured to translatably move the first transfer drum (26A) and the second transfer drum (26B) relative to the support beam (22) between a stowed position and an extended position. A second drive system is connected to the frame (100F) and the support beam (22) and is configured to move the reel transfer assembly (20) in translation relative to the frame.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application is a PCT application of and claims priority to U.S. Provisional Application No. 63 / 467,614 filed on May 19, 2023, which is incorporated herein by reference in its entirety. Technical Field

[0003] The present invention relates to a web winding and transfer system for a web handling system. Background Art

[0004] Polymer film is made by melting polymer pellets in an extruder device and forcing the molten polymer to leave the gap (e.g., die slot, die lip) in a die connected to the extruder device. The molten polymer film is extruded from the die in the form of a web or tubular. The web is cooled and processed on a cooling cylinder to form a single-layer web. The tubular is processed in a blown film device, where it is discharged in the form of a flat two-layer web. The web is further processed by a roller configuration to impart desired physical properties in the web. The web is discharged from the roller configuration to a downstream winding system such as a turret winder, where the web is wound onto a core.

[0005] Problems may arise when operating these systems that may cause the winding or other process to be interrupted and / or have web quality problems or other defects in the process. In some cases, the winding or other process will need to be interrupted to correct or clear these problems (e.g., web quality defects, trim loss, bad roll changes at the spindle, etc.). These will require slowing down of upstream processes or machine shutdowns. Operator intervention to correct these situations may place them in hazardous areas. Slowing down or stopping the entire machine line may also cost time and material costs, especially during the speed-up period when the line returns to normal operating conditions.

[0006] Therefore, there is a need for an improved system that solves the above problems. Summary of the invention

[0007] According to aspects presented herein, a roll conveyor assembly for a web handling system is disclosed, the roll conveyor assembly comprising a support beam that is movably mounted (e.g., mounted for vertical or horizontal travel or a combination thereof) to a frame of the web handling system. The roll conveyor assembly comprises a segmented roll assembly rotatably mounted to the support beam. The segmented roll assembly comprises a first end segment, a second end segment, and a central segment positioned between the first end segment and the second end segment. The roll conveyor assembly comprises a first conveyor roll positioned between the first end segment and the central segment and a second conveyor roll positioned between the second segment and the central segment. The roll conveyor assembly comprises an actuation assembly connected to the support beam, the first conveyor roll, and the second conveyor roll. The actuation assembly comprises a first drive system that is configured to move the first conveyor roll and the second conveyor roll in translation relative to the support beam between a storage position and an extended position. The second drive system is connected to the frame and the support beam and is configured to move the roll conveyor assembly in translation relative to the frame.

[0008] In some embodiments, the spool transfer assembly includes a belt-type auxiliary conveyor assembly movably connected to the frame between a retracted position and an engaged position.

[0009] In some embodiments, the belt auxiliary conveyor assembly includes a first continuous conveyor belt mounted and driven about a first pair of conveyor rollers and a second continuous conveyor belt mounted and driven about a second pair of conveyor rollers.

[0010] In some embodiments, a first transfer drum is movably positioned opposite the first continuous conveyor belt and a second transfer drum is movably positioned opposite the second continuous conveyor belt to urge the web strip to attach to the leader strip.

[0011] In some embodiments, the web transport assembly includes a transport web slitter movably mounted relative to the frame and including a movable cutting device configured to translationally slit the web strip.

[0012] A rotary hopper system for a web handling system is disclosed, the web handling system comprising a track assembly mounted to a frame and a core drum rotatably mounted and translatably movable along the track between an operating position, a winding position, and an unloading position. The core drum is rotatable relative to the track and is configured to wind a web thereon.

[0013] In some embodiments, the rotary hopper system includes a knife slitter that is movably mounted (eg, translational linear movement) relative to the frame and configured to cut the web and separate the web from normal downstream processes.

[0014] In some embodiments, the rotary hopper system includes an adhesive application system configured to apply adhesive to an outer surface of the core roll.

[0015] In some embodiments, the rotary hopper system includes a paster drum that is rotatably mounted to a frame and can move toward and away from a core drum (e.g., a translational linear movement, e.g., a substantially horizontal movement or an angular movement). The paster drum is movable to contact the web and urge the cut web against the core drum so that the cut web is adhered to the core drum due to the adhesive.

[0016] In some embodiments, the rotary hopper system includes a backup idler roll that is located below and laterally offset from the core roll. The backup idler roll is configured to guide the web between the transfer roll assembly and the core roll during the transition step from the rotary hopper to the winder spindle winding process to allow for proper cutting geometry between the web and the transfer slitter.

[0017] In some embodiments, the normal downstream process includes the web traveling to a dual turret winding system, and the separation of the web from the normal downstream process includes preventing the web from traveling to the dual turret winding system.

[0018] In some embodiments, the rotary stocker system includes a drive unit configured to rotate the core reel such that the web is wound around the core reel.

[0019] The present invention discloses a web handling system, which comprises: (a) a web winding system; (b) a roll transfer assembly located upstream of the web winding system, the roll transfer assembly comprising: a support beam, which is movably mounted to a frame of the web handling system; a segmented roll assembly rotatably mounted to the support beam, the segmented roll assembly comprising a first end segment, a second end segment, a central segment positioned between the first end segment and the second end segment, a first transfer roll positioned between the first end segment and the central segment, and a second transfer roll positioned between the second segment and the central segment; an actuation assembly connected to the support beam, A web material winding system is provided in the embodiment of the present invention, wherein the web material winding system comprises a web material winding system, a web material winding system and a web material winding system. The ...

[0020] In some embodiments, the web handling system includes a first slitter system located upstream of the web winding system and configured to sever the web from the web winding system.

[0021] In some embodiments, the web handling system includes a paster reel movably mounted to the frame and movable toward and away from the core reel. The paster reel is configured to transfer the web to the core reel.

[0022] In some embodiments, the web handling system includes a leader supply system located downstream of the first slitter system. The leader supply system includes one or more supplies of leader webs stored therein. The roll transfer system is configured to cut the web from the core roll and transfer the web to the leader web. The leader web is threaded into the web winding system.

[0023] In some embodiments, the first end segment, the second end segment, and / or the central segment include nozzles configured to discharge gas therefrom.

[0024] A method for conveying webs from and to a continuous process flow leading to a winding system is disclosed herein. The method comprises the following steps: providing a web handling system for feeding webs to a winding system; providing a rotary hopper system located upstream of the web handling system and having a core roll therein; providing a paster roll mounted to a frame movably toward and away from the core roll; providing a first web slitter located upstream of the web handling system; providing a transfer roll assembly located upstream of the web handling system, the transfer roll assembly including a second web slitter; providing a belt-type auxiliary conveyor assembly located upstream of the web handling system; providing a leader supply system located downstream of the first slitter system, the leader supply system including a supply of leader webs stored therein and fed to the web handling system. The method further includes the steps of cutting the web via a first web slitter so that the web is not fed into a web handling system; transferring the web via a paster reel to a rotary hopper system; cutting the web from a core reel via at least a second web slitter; and transferring the web to a leader web via a transfer reel assembly and a belt-type auxiliary conveyor assembly.

[0025] In some embodiments, the method includes a web having a first layer and a second layer. The method also includes supplying a first leader web of the leader webs and a second leader web of the leader webs via a leader supply system. The method also includes transferring the first layer to the first leader web and transferring the second layer to the second leader web.

[0026] Any of the aforementioned embodiments may be combined. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Referring now to the drawings, which are exemplary embodiments and in which like elements have like reference numerals:

[0028] Figure 1 is a schematic top view of the structure of a turret winding system of a web conveying and winding system according to an embodiment of the present disclosure;

[0029] Figure 2 is another schematic top view of the structure of the turret winding system of the web transport and winding system;

[0030] Figure 3 is a schematic side view of the structure of the web conveying and winding system and the turret winding system;

[0031] Figure 4A is a schematic side view showing the normal operating position of the web and web components of the web transfer and winding system;

[0032] Figure 4B yes Figure 4A Detail 4B is an enlarged view of a portion of the web;

[0033] Figure 5A is a schematic side view showing the web and web components of the web transport and winding system switched to a rotary hopper position;

[0034] Figure 5B is a simplified schematic side view showing the web and web components of the web transport and winding system switching to a rotary hopper position;

[0035] Figure 6 is a schematic side view of a web and web components of a web transfer and winding system showing preparation for rethreading the web back to a winder;

[0036] Fig. 7A is a schematic side view showing the beginning of the transition of the web and web components of the web transport and winding system from a rotary stocker back to a winder position;

[0037] Figure 7B yes Fig. 7A A simplified side view of a portion of a web and web components of a web transport and winding system;

[0038] Figure 7C yes Fig. 7A A simplified side view of a portion of a web and web components of a web transport and winding system;

[0039] Fig. 8A is a schematic side view of a web and web components of a web transfer and take-up system, showing a transfer reel assembly in a transfer position;

[0040] Figure 8B yes Fig. 8A A simplified schematic side view of a web and web components of a web transport and winding system of FIG. 1 showing an edge trim slitter in position for slitting a leading width into the web;

[0041] Fig.8C1 yes Figure 8B A perspective view of a web and components of a web transport and take-up system of FIG. 1 showing a full width guide reel and showing an edge trim slitter in position for slitting a leader width into the web;

[0042] Figure 8C2 yes Figure 8B A perspective view of a web and components of a web transport and take-up system of FIG. 1 showing two reduced width guide reels and showing an edge trim slitter in position for slitting a leading width of the web;

[0043] Fig.8D yes Figure 8B A simplified schematic side view of a web and web components of a web transfer and take-up system of FIG. 1 showing the take-off reel of the transfer reel assembly in position with a conveyor belt system with a leading web disposed between the conveyor belt system and the take-off reels;

[0044] Figure 8E1 yes Figure 8B A simplified schematic side view of the web and web components of the web transfer and winding system of FIG. 1 showing the transfer knife assembly severing the center leader strip and the outer web sections still being wound on the rotary hopper;

[0045] Figure 8E2 yes Figure 8E1 Detail 8E2 is an enlarged view;

[0046] Figure 8F yes Figure 8E1 A simplified schematic side view of a web and web components of a web transport and winding system of FIG. 1 , showing a traction roller moving downward;

[0047] Figure 8G is a perspective view of the divider and track assembly;

[0048] Figure 8H is a side view of the slitter, shown with the blade in a retracted position;

[0049] Fig.8I is a side elevation view of the slitter with the blade in an extended position;

[0050] Fig.9Ais a schematic side view of a web and web components of a web transfer and take-up system showing a transfer reel assembly and a retracted belt conveyor system;

[0051] Fig.9B1 yes Fig.9A A simplified schematic side view of a web and web components of a web transport and winding system;

[0052] Figure 9B2 yes Figure 2 B1 details Figure 2 Enlarged view of B2;

[0053] Fig. 9C is a simplified schematic side view of a web and web components of a web transfer and reel system showing a transfer reel assembly in a storage position;

[0054] Fig. 10A is a schematic side view of a web and web components of a web transport and winding system showing a rotary stocker in an unloading position and a stocker reel unloaded onto a cart;

[0055] Fig. 10B yes Fig. 10A A simplified side view of a portion of a web and web components of a web transport and winding system;

[0056] Fig.11A and Fig. 11B is a flow chart of a method of using a web transfer and winding system;

[0057] Fig. 12A is a front perspective schematic diagram of a web and web components of a web transport and rewinding system showing an edge trim slitter in an outward trimming position;

[0058] Fig. 12B is a front perspective schematic diagram of a web and web components of a web transport and winding system showing two reduced width guide reels and showing an edge trim slitter in an outward trimming position;

[0059] Fig.13 is a rear perspective schematic diagram of a web and web components of a web transport and winding system shown from the rotary hopper side;

[0060] Fig.14A yes Fig. 14B A front schematic diagram of a portion of a web transport and winding system;

[0061] Fig. 14B is a side view of a portion of a web transfer and reel system, wherein a transfer roll assembly is shown in a storage position;

[0062] Fig. 14C yes Fig. 14BA rear schematic diagram of a portion of a web conveying and winding system;

[0063] Fig.15A yes Fig. 15B A front schematic diagram of a portion of a web transport and winding system;

[0064] Fig. 15B is a side view of a portion of a web transfer and reel system, wherein the transfer reel assembly is shown in an extended position;

[0065] Fig. 15C yes Fig. 15B A rear schematic diagram of a portion of a web conveying and winding system;

[0066] Fig.16 yes Fig. 14B A front schematic diagram of a conveyor reel assembly;

[0067] Fig.17 yes Fig. 15B A front schematic diagram of a conveyor reel assembly;

[0068] Fig.18 is a front view of a roll transport assembly with a support beam movably mounted to a frame and showing the support beam and a transport roll in a stored or raised position;

[0069] Fig.19 is a front view of a roll transport assembly with a support beam movably mounted to a frame and shown with the support beam in a lowered position and a transport roll in a stored or raised position;

[0070] Fig. 20A is a front view of a roll transport assembly with a support beam movably mounted to a frame and showing the support beam and a transport roll in a transport or lowered position;

[0071] Fig. 20B yes Fig. 20A A side view of a roll conveying assembly;

[0072] Fig.21 yes Fig.18 A perspective view of a roll transport assembly;

[0073] Fig.22A is a side view of the roll transport assembly shown with the transport slitter shown in a retracted position;

[0074] Fig. 22B is a side view of a roll transport assembly showing a transport slitter shown in an extended position;

[0075] Fig.23A is a front view of the roll conveying assembly of the present invention;

[0076] Fig. 23B yes Fig.23A an enlarged view of detail 23B;

[0077] Fig.23C yes Fig.23A A cross-sectional view of the roll conveying assembly taken along section CC;

[0078] Fig.24 yes Figure 4A , Fig.8C1 and Figure 8C2 A perspective view of a belt auxiliary conveyor assembly;

[0079] Fig.25 yes Fig.24 a side view of a portion of a belt auxiliary conveyor assembly; and

[0080] Fig.26 yes Figure 4A A perspective view of a web transport and winding system showing details of the lead-in system. DETAILED DESCRIPTION

[0081] like Figure 4A As shown, a web handling system (e.g., a web transport and rewind system) according to an embodiment of the present disclosure is generally indicated by the numeral 100. The web transport and rewind system 100 includes a linear hopper 10 positioned to receive a web W from an upstream portion (not shown) of a machine that includes a web handling system, such as a blown film processing system in which a double-sheet web is produced or another type of system in which a single-sheet web is produced. FIG. 4A to FIG. 10B , Fig. 12A , Fig. 12B and Fig.13 The web W shown is as follows Figure 4BDetailed description of the double sheet web. The web transport and winding system 100 is configured to handle the double sheet web W by including repeating components as described herein. The web transport and winding system 100 includes a plurality of guide rollers 80A, 80B, 80C, 80D, 80E, 80F and 80K, which guide the web W through the web transport and winding system 100. The guide reels 80A, 80C, 80D, 80E, 80F and 80K have a uniform cylindrical shape. The guide reel 80K is an unwinding reel having a uniform cross-sectional diameter over its entire width, but is formed into a curved or arched shape for guiding the web to the opposite ends of the reel while generating an unwinding action. Both the amount of bending and the direction of rotation can be adjusted to increase or decrease the amount of unwinding action across the guide reel 80K. However, the present disclosure is not limited in this regard, as other styles of unwinder rolls having non-uniform shapes may be employed, i.e., an inverted crown shape having a thicker (i.e., larger outer diameter) central portion that tapers to a thinner (i.e., smaller outer diameter) central portion toward the ends of the guide rolls. Guide rolls 80C and 80D form a nip through which the web W is pulled with the assistance of guide roll 80C, which is a driven pull roll. Guide rolls 80E and 80F selectively form a leading guide nip operable during web transport and through which the web W is pulled with the assistance of guide roll 80E, which is a driven pull roll that is mounted on an axle that is fixed in position relative to frame 100F and therefore does not have any linear movement. Guide rolls 80E and 80F are Figure 5B For example, guide roller 80F may be moved toward guide roller 80E (eg, may be laterally translated relative to frame 100F) to form a roller gap (eg, Figure 6 , Fig. 7A , Fig. 8A , Figure 8F , Fig.9B1 , Fig. 12A , Fig. 12B , Fig.13 ) and are far away from each other, such as Figure 5B As shown. The guide reels 80E and 80F are vertically adjacent to the belt auxiliary conveyor assembly 60, as further described herein. Fig.8C1 , Figure 8C2 , Figure 8G , Figure 8H , Fig.8I , Fig. 12A and Fig. 12BAs shown, the web conveying and winding system 100 includes two edge trimming slitter 70, which are mounted adjacent to the web W and positioned between the idler rollers 80A and 80B. The edge trimming slitter 70 is movably mounted to a linear track 70R, which is fastened to a beam 70B, which is fastened to a frame 100F. The edge trimming slitter 70 includes a linear bearing 70L that rides along the linear track 70R. Each edge slitter 70 includes a band clamp 70C that engages a drive belt 70BB. The drive belt 70BB is wrapped around a drive sprocket 70X attached to a gear box 70Y. A motor 70M is drivingly engaged with the gear box 70Y and is fastened to the beam 70B via a mounting bracket 70G. Each edge slitter 70 includes a retractable and extendable cutting knife 70Z, as shown in FIG. Fig.8I , wherein the cutting knife 70Z is shown in an extended position. Figure 8H The edge slitter 70 is shown with the cutting blade hidden and in a retracted position. The edge slitter 70 can be cut across the web W from the edge of the web (see Fig. 12A and Fig. 12B ) is laterally translated to a central position for forming by cutting a narrow web strip WN, such as Fig.8C1 and Figure 8C2 As shown and marked by arrow LL.

[0082] The web transport and winding system 100 includes a transport section 90 including components that cooperate to transport the web W to a downstream winding system (eg, Figures 1 to 3 The dual turret winding system 200 includes a finished product roll cart 201, a finished roll overhead hanger 202, a winder mandrel 203, a winder web guide rod 204, a winder-roll changer carriage 205, a winder-winder changer lead-in roll 206, a static neutralization rod 207, a winder lead-in roll including a separator nip 208 and an edge trim slitter 70.

[0083] Reference again Figure 4A The web transport and winding system 100 includes a roll transport assembly 20 mounted in a movable relationship (e.g., translational movement, vertical movement, tilting movement) relative to a frame 100F (e.g., a stationary frame) in which the web transport and winding system 100 is mounted. As further described herein, the roll transport assembly 20 can be moved from a storage position (e.g., Figure 4A ) to the transfer location (e.g. Fig. 8A , Figure 8B , Fig.8D , Figure 8E and Figure 8F), in which transfer position, portions of the roll transfer assembly 20 are deployed to assist in transferring the web W to the leader during the rethreading of the web through the web transfer and rewinding system 100. As further described herein, the roll transfer assembly 20 cooperates with the belt auxiliary conveyor assembly 60 to push a pair of narrow web strips WN of the double-layer web W (see Fig.8C1 and Figure 8C2 ) are attached to (eg, adhered to) the upper leader strip 52U and the lower leader strip 52L.

[0084] The web transport and winding system 100 includes an upper leader supply system 50U and a lower leader supply system 50L. The upper leader system 50U includes an upper leader supply spindle reel 51U that is rotatably mounted to the frame 100F and has a supply of an upper leader strip 52U (e.g., a polymer film web) rolled thereon, and the lower leader system 50L includes a lower leader supply spindle reel 51L that is rotatably mounted to the frame 100F and has a supply of a lower leader strip 52L (e.g., a polymer film web) rolled thereon. Although the web conveying and winding system 100 is shown and described as including an "upper" leader supply system 50U and a "lower" leader supply system 50L, the present invention is not limited to this, as other relative positions of the leader supply systems 50U and 50L can be adopted, including but not limited to the left leader supply system and the right leader supply system of the two leader supply systems can be positioned substantially along the same horizontal line.

[0085] The upper leader system 50U comprises an upper adhesive application system 54U positioned at the upper leader spindle reel 51U downstream. The upper adhesive application system 54U is configured to be applied to the upper leader strip 52U such as adhesives such as double-sided tape. An idler roll 55U is relatively positioned with the upper adhesive application system 54U to prevent the upper leader strip 52U from deflecting in the application process of adhesive. An upper leader slitter 56U is positioned at the downstream of the upper adhesive application system 54U, and is configured to cut the upper leader strip 52U transversely, so that this upper leader strip is separated from the upper leader spindle reel 51U thus. Another idler roll 57U is positioned at the downstream of the upper leader slitter 56U, and is configured to guide the upper leader strip 52U to cross the idler roll 57U and towards the leader roll gap formed by the idler roll 80E and 80F.

[0086] The lower leader system 50L comprises the lower adhesive application system 54L positioned at the lower leader spindle reel 51L downstream.The lower adhesive application system 54L is configured to apply adhesives such as double-sided tape to the lower leader strip 52L.The idler roll 55L is relatively positioned with the lower adhesive application system 54L to prevent the lower leader strip 52L from deflecting in the application process of adhesive.The lower leader slitter 56L is positioned at the downstream of the lower adhesive application system 54L, and is configured to cut the lower leader strip 52L transversely, so that this lower leader strip is separated from the lower leader spindle reel 51L thus.Another idler roll 57L is positioned at the downstream of the lower leader slitter 56L, and is configured to guide the lower leader strip 52L to cross the idler roll 57L and towards the leader roll gap formed by the idler roll 80E and 80F.

[0087] like Fig. 12B As shown, idler rolls 57U and 57L and upper and lower leader strips 52U and 52L each have a width W57. Idler rolls 80E and 80F each have a width W80 approximately equal to width W57. Although idler rolls 80E and 80F are shown and described as each having a width W80 approximately equal to width W57, the present invention is not limited thereto, as idler rolls 80E and 80F may have a greater width, approximately equal to the width of the entire segment roll 24, such as Fig. 12A As shown. Figure 8C2 As shown, the narrow web strip WN has a width WWN that is less than the total width WF of the web W and slightly greater than the width W57 of the idler roller reels 57U and 57L and the upper and lower leader strips 52U and 52L. The first and second continuous conveyor belts 60B and 60B are laterally spaced apart from each other by a width W60 that is slightly greater than the width W57 of the idler roller reels 57U and 57L and the upper and lower leader strips 52U and 52L and slightly greater than the width W80 of each of the idler roller reels 80E and 80F. Making the narrow web strip width WNN slightly greater than width W57 allows the first and second continuous conveyor belts 60B, 60B to grip the narrow web strip WN and the upper and lower leader strips 52U, 52L to pass between the first and second continuous conveyor belts 60B, 60B and guide rollers 80E and 80F.

[0088] like Fig.26As shown, each of the upper leader system 50U and the lower leader system 50L includes a column 100FX fastened to the frame 100F and an expandable mandrel 51X attached to the column 100FX. The upper leader mandrel reel 51U and the lower leader mandrel reel 51L are fastened to a corresponding one of the expandable mandrels 51X. The brake or motor system 51B is communicated with a corresponding one of the expandable mandrels 51X to generate tension in the upper leader strip 52U and the lower leader strip 52L. The upper leader strip 52U and the lower leader strip 52L are wound around, stored on and dispensed from a corresponding one of the upper leader mandrel reel 51U and the lower leader mandrel reel 51L. The upper and lower leading member slitter 56U, 56L are located between the respective idler roller reels 57U, 57L and the guide reel 58. The mounting frame 100F1 is secured to the frame 100F and supports the idler roller reels 57U, 57L and the guide reel 58. The cylinder 81 is mounted to the mounting frame 100F1 and has a rod end 82 movably extending therefrom. The rod end 82 is pivotally attached to a link arm 83 having an opposite end attached to a pivot pin 81P that engages the guide reel 80F. The cylinder 81, rod end 82, link arm 83 and pivot pin 81P cooperate to move the guide reel 80F toward and away from the guide reel 80E. As shown in FIG. Figure 4A As shown, the web conveying and winding system 100 includes a rotary hopper assembly 30, which is located downstream of the guide reels 80C and 80D. The rotary hopper assembly 30 includes a track assembly 30A (e.g., two parallel guide rails) that is mounted to the frame 100F or to a structure adjacent thereto. The core reel 30R is rotatably mounted on an axle (not shown) that is movably fastened to the track 30A, for example, at the opposite ends of the axle. The axle is movably mounted (e.g., slidably, linearly actuator movably, or movably guided by a rack and pinion) to the track assembly to facilitate the axle and the core reel 30R from an operating position (see Figure 4A ) to the winding or building position (see Figure 6 ), to the teleport location (see Fig. 7A ) and to the unload position (see Fig. 10A ) linear movement (eg, horizontal travel). Before the cut web W is wound onto the core roll 30R, the adhesive AD (see Figure 5B ) is applied to the outer surface of the core roll. The rotary hopper assembly 30 includes a knife slitter 40 that is movable relative to the frame and is configured to cut the web W and separate the web W from the normal downstream process (i.e., disconnect the web W from traveling to the dual turret winding system 200).

[0089] The rotating hopper assembly 30 includes an applicator drum 30P that is rotatably mounted to the frame 100F and is movable toward and away from the core drum 30R (e.g., a horizontal rail-guided movement). The applicator drum 30P contacts the web W and is configured to push the cut web W against the core drum 30R so that the cut web W is formed due to the adhesive AD thereon (see FIG. Figure 5B ) and pasted to the core reel 30R. The paster reel 30P continues to push the cut web W against the core reel 30R so that the web W is evenly wound onto the core reel 30R. When the core reel 30R is full, the paster reel 30P is retracted away from the core reel 30R.

[0090] The core roll 30R is in communication with a drive unit (not shown) that rotates the core roll 30R to facilitate winding of the web W onto the core roll after it is severed from the normal path of travel and during the final stages of the transfer process. The rotary hopper system 30 includes a loader / unloader assembly 30H (e.g., an integrated lift) having a pair of lifting features 30H1 and 30H2 (e.g., hooks, chains, cables, etc.) adapted therefor. The lifting features 30H1 and 30H2 are configured to receive opposite ends of a shaft, lift the shaft and the loaded core roll 30R off the track assembly 30A, and lower the loaded core roll 30R onto the cart 30C. The lifting features 30H1 and 30H2 are configured to receive opposite ends of a shaft, lift the shaft and a new empty core roll 30R, and position the core roll onto the track assembly 30A. As Figure 7C As shown, the rotary stocker system 30 includes a backup idler roll 33 located below the core roll 30R and above the idler roll 57L. Fig.8C1 and Figure 8C2 As shown, the backup idler roll 33 guides the web W between the transfer roll assembly 20 and the core roll 30R during the transition step from the rotary stocker to the winder mandrel wind-up process to allow for proper cutting geometry between the web W and the transfer slitter 21 .

[0091] like Figure 5B , Fig.8C1 , Figure 8C2 , Fig. 12A and Fig. 12BAs shown, the belt-type auxiliary conveyor assembly 60 includes a first continuous conveyor belt 60B mounted and driven around a pair of first conveyor rollers 60R1 and 60R2 and a second continuous conveyor belt 60B mounted and driven around a pair of second conveyor rollers 60R1 and 60R2. The first transfer reel 26A can be positioned opposite and adjacent to the first continuous conveyor belt 60B, and the second transfer reel 26B can be positioned opposite and adjacent to the second continuous conveyor belt 60B to urge the web strip WN to be attached to the leader strip. The belt-type auxiliary conveyor 60 is movably mounted to the frame 100F (see Figure 3 and FIG. 4 ), for: when the roll conveying assembly 20 is in the conveying position, toward (see Fig.8D , Figure 8E and Figure 8F ) the roll conveying assembly 20 moves (eg, linearly moves); and when the pair of narrow web strips WN (see Fig.8C1 and Figure 8C2 ) are transferred to the front and rear of the upper leading strip 52U and the lower leading strip 52L, away from (see Fig.9A , Fig.9B1 and Fig. 9C ) The roll conveying assembly 20 moves. For the sake of clarity, Figure 9B2 In FIG. 1 , the pair of narrow web strips WN are denoted as WNU and WNL. Figure 9B2 As shown, the upper leader strip 52U is adhered to the narrow web strip WNU by adhesive AD; and the lower leader strip 52L is adhered to the narrow web strip WNL by adhesive AD.

[0092] like Fig.24 As shown, the belt auxiliary conveyor assembly 60 includes two spaced apart mechanisms, each of which is also indicated by the number 60. Each mechanism of the belt auxiliary conveyor assembly 60 includes a linear track 67R mounted to the plate frame 66 and a linear bearing 67 that is slidably engaged with the linear track 67R and mounted to the frame 100F. Each mechanism of the belt auxiliary conveyor assembly 60 includes a gear box 65 mounted to the plate frame 66 and a motor 60M connected to the gear box 65. The gear box 65 is connected to the first conveyor roller 60R1 via a shaft and a one-way (i.e., clutched) radial bearing 64. Therefore, the first conveyor roller 60R1 is driven in one rotational direction by the motor 60M and the gear box 65. Each mechanism of the belt auxiliary conveyor assembly 60 includes a second conveyor roller 60R2, which is an idle roller and is rotatably mounted to the plate frame 66 via a shaft 69 and supported by a radial bearing 62. The continuous conveyor belt 60B sits in and is wound around the outer circumferential portions of the first conveyor roller 60R1 and the second conveyor roller 60R2 , and is driven by the first conveyor roller 60R1 .

[0093] like Fig.24 and Fig.25 As shown, each mechanism of the belt auxiliary conveyor assembly 60 includes a cylinder 61 having an actuating rod 61A movably extending therefrom. The distal end of the actuating rod 61A is fastened to the plate frame 66. The cylinder 61 is mounted to the frame 100F via a bracket 61B. The actuating rod 61A can extend and retract from the cylinder 61 in response to fluid (e.g., hydraulic, pneumatic) pressure applied to and released from the cylinder 61 to move the plate frame 66 and the components attached thereto (e.g., the first conveyor roller 60R1, the second conveyor roller 60R2, and the continuous belt 60B) toward and away from the web W in the direction L60, as shown in FIG. Figure 4A shown.

[0094] like Fig.25 As best shown, each mechanism of the belt auxiliary conveyor assembly 60 includes a guide plate 60G that is secured to a plate frame 66. The guide plate 60G has a guide surface 60G1 that is in sliding engagement with the underside 60B1 of the continuous conveyor belt 60B. The guide plate 60G ensures that the continuous conveyor belt 60B is held tight (i.e., prevented from sagging) against the rollers 26A and 26B that hold the web WN.

[0095] refer to Fig.16 , the roll transport assembly 20 includes a support beam 22 and a segmented roll 24 rotatably mounted to the support beam, the support beam being movably mounted to the frame 100F via a support beam actuator system 22A. The segmented roll assembly 24 includes a first end segment 24A and a second end segment 24B, wherein a central segment 24C is axially positioned between the first end segment 24A and the second end segment 24B. A first transport roll 26A is positioned between the first end segment 24A and the central segment 24C; a second transport roll 26B is positioned between the second segment 24B and the central segment 24C. Fig.23A , Fig. 23B and Fig.23C As shown, the first end section 24A, the second end section 24B and the central section 24C are fixedly fastened to the support beam 22 via fasteners such as bolts 24Q. The web W is stationarily straddling the first end section 24A, the second end section 24B and the central section 24C. In some embodiments, the first end section 24A, the second end section 24B and / or the central section 24C include nozzles formed therein for discharging a gas such as air therefrom to reduce friction between the web W and the first end section 24A, the second end section 24B and the central section 24C and to help the web W float or glide on the first end section 24A, the second end section 24B and the central section 24C. In some embodiments, the first end section 24A, the second end section 24B and the central section 24C are rotatably mounted to the support beam 22. In some embodiments, as Figure 8E1 , Figure 8E2 and Fig.18 As shown, a nozzle 24N (e.g., a hole or orifice) is formed in or attached to the central section 24C. The nozzle 24N communicates with an interior area of ​​the central section 24C, in which an air supply is disposed and connected to the nozzle 24N (e.g., via a manifold). The nozzle 24N discharges a gas, such as air, from the nozzle and pushes the narrow web WN (see Figure 8E1 and Figure 8E2 ) downward along the belt auxiliary conveyor assembly 60, guiding the narrow web strip WN into the web leading member roller gap between the guide reels 80E and 80F. Fig.16 ) and the travel position (i.e., in the raised position shown in FIG. Fig.16 The storage locations shown are Fig.17 In the embodiment of the present invention, the first end section 24A, the second end section 24B, the central section 24C, the first conveying roll 26A and the second conveying roll 26B are coaxial with each other (in a position between the conveying position or the lowered position shown). The first end section 24A, the second end section 24B, the central section 24C, the first conveying roll 26A and the second conveying roll 26B are coaxial with each other. The lengths of the first end section 24A and the second end section 24B are approximately equal. The length of the first end section 24A and the length of the second end section 24B are each greater than the length of the central section 24C. The first conveying roll 26A and the second conveying roll 26B each have a length less than the length of the central section 24C. The roll conveying assembly 20 includes an actuating assembly 28, which is movably mounted to the support beam 22. As shown in FIG. Fig.18 , Fig.19 and Fig. 20A As shown, the roll transport assembly 20 is fastened to the support beam 22 via the spaced support 31. The motor 28M is fastened to the top portion of the spaced support 31 via the coupling 31C. The actuation assembly 28 includes a first actuation rod 28A (e.g., a linear track) and a second actuation rod 28B (e.g., a linear track) coupled to each other by a cross member 28C. The first transport roll 26A is actuated by a first bracket 29A (see Fig.17 ) is rotatably coupled to the first actuating rod 28A; and the second conveying reel 26B is driven by a second bracket 29B (see Fig.17 ) is rotationally coupled to the second actuating rod 28B. The actuating assembly 28 includes a first drive system 28A that moves the first and second transport spools 26A, 26B translationally relative to the beam 22 (e.g., downward and away from the beam 22). The first drive system 28A includes a lead screw 28Q coupled to a motor 28M and coupled to a cross member 28C. The motor 28M rotates the lead screw 28Q, which causes the cross member 28C, the first actuating rod 28A, and the second actuating rod 28B to move upward in the direction of arrow Y and downward in the direction of arrow X. The first actuating rod 28A and the second actuating rod 28B slide in corresponding pairs of linear bearings 31B that are secured to the spacing supports 31 and to the lower portion of the support beam 22.

[0096] like Fig.18 , Fig.19 and Fig. 20A As shown, the roll transport assembly 20 includes a second drive system 22A, which is configured to move the roll transport assembly 20 relative to the frame 100F (see Figure 4A The frame 100F of the present invention is provided with a first drive system 22A, which is provided to move translationally (e.g., upward in the direction of arrow Y, downward in the direction of arrow X, horizontally and angularly). The second drive system 22A includes a first actuator system 22K arranged on a first end of the support beam 22 and a second actuator system 22K' arranged on a second end of the support beam 22. The first actuator system 22K includes a motor 22M fastened to the frame 100F via a mounting bracket 22J. A lead nut 22B is fastened to the support beam 22, near the first end of the support beam 22. A lead screw 22D is connected to the motor, which is configured to rotate the lead screw 22D in the lead nut 22B, so that the support beam 22 moves downward in the direction of arrow X and upward in the direction of arrow Y. A linear rail 22R is fastened to the frame 100F. A linear bearing system 22C is fastened to the first end of the support beam 22. The linear bearing system 22C is arranged to slide on the linear rail 22R in response to the movement of the support beam 22. The second actuator system 22K' is configured identically to the first actuator system 22K. In some embodiments, the first actuator system 22K and the second actuator system 22K' operate synchronously.

[0097] like Figure 7C and Fig.17 As shown, the roll transport assembly 20 includes a transport web slitter 21, which is pivotally fastened to a support beam 22 and is mounted for translationally slitting a narrow web strip WN (i.e., in an axial direction transverse to the direction of travel of the web W (e.g., Fig. 12A , Fig. 12B and Fig.17 As shown by the arrow TT in the figure, the Fig.22A and Fig. 22B As shown, the transfer web slitter 21 mounted to the roll transfer assembly 20 can pivot about the pivot pin 21P along the arc path shown by the arrow 21A. The actuating cylinder 21F is mounted to the support beam 22 via the mounting bracket 21N. The actuating cylinder 21F has a rod end 21R that movably extends from the actuating cylinder 21F. The rod end 21R is linked to the pivot pin 21P so that the movement of the rod end 21R causes the pivot pin 21P and the transfer web slitter 21 to rotate in the direction of the arrow 21A. The transfer web slitter 21 is Figure 7C and Fig.22A 8E and 8B are shown in a storage position adjacent to the beam 22. The transfer web slitter 21 is shown in FIG. Fig. 22B2 is shown in an extended position pivoted away from the beam 22 in the direction of arrow 21A to separate the narrow web strip WN from the core reel 30R.

[0098] like Fig.11A and Fig. 11B 4 , a method 400 for winding a web W and a conveyor system for a web handling system 100 is provided. The method includes providing a web W to the web handling system 100, which is initially in normal operation 401. The method 400 includes a switching step 402 from a path to a turret winding system 200 to a rotating hopper assembly 30. The switching step 402 includes engaging an applicator roll 30P with a core roll 30R having an adhesive thereon (see Figure 5A ); The knife slitter 40 passes the web W from the turntable winding system 200 (see Figure 5A ) is cut off, and the web W is transferred to the rotary hopper assembly 30, and the roll of web W is started to be wound on the core roll 30R; and the turret winding system 200 and other equipment downstream of the rotary hopper assembly 30 are powered off so that the operator can clear any problems in the turret winding assembly 200 and the path leading to it.

[0099] The method 400 further includes preparing the machine including the web handling system 100 for a rethreading step 403 in which the operator inserts the prethreaded leader strip WP (together with the leader strips 52U and 52L) (see Figure 5A ) is fed back to the turret winding assembly 200. This can be done by manual threading through the machine or by an automated threading system which can be provided to safely transport and attach the pre-threaded leader strip WP to the spindle on the turret winding system 200 without requiring an operator to enter the internal machine area. The trailing end of the pre-threaded leader strip WP is transferred to the spindle by means of a transfer aid 91 (see Figure 6 ) is positioned between the guide rolls 80E and 80F. Adhesive such as tape is applied to the upper and lower leader strips 52U and 52L by the upper and lower adhesive application systems 54U and 54L, respectively. The machine is now ready to switch back to normal winding operation.

[0100] The method 400 further includes the start 404 of the transition step from the rotating stocker assembly 30 back to the mandrel on the turret winding system 200. The start 404 of the transition step includes: retracting the core roll 30R to the transfer position; moving the roll transfer assembly 20 at arrow X (see Figures 8E and Figure 8F ) moves downwardly to the upper leading member strip 52U and the lower leading member strip 52L (see Fig. 7A) between the upper and lower leader strips 52U and 52L (see FIG. 1 ); the belt auxiliary conveyor assembly 60 is accelerated to the web production line speed and moved into contact with the first transfer reel 26A (i.e., a reel with a clutch that can only rotate in one direction) and the second transfer reel 26B (i.e., a reel with a clutch that can only rotate in one direction); the edge trimming slitter 70 is moved to the transfer position and cuts, thereby producing a smaller web than the upper leader strip 52U and the lower leader strip 52L (see FIG. 1 ). Fig.8C1 and Figure 8C2 ) a slightly wider narrow web strip WN; a linear hopper 10 engages with the temporarily accumulated web to allow the downstream web to be slightly slowed down for transfer; and the spindle on the turret winding system 200 is accelerated to the transfer speed, which in turn pulls the pre-inserted leader WP, the upper leader strip 52U and the lower leader strip 52L through the machine.

[0101] The method 400 further includes a transport roll assembly severing step 405 in which the transport web slitter 21 severing the narrow web strip WN (see Figure 8E1 ); the first transfer reel 26A and the second transfer reel 26B extend downwardly along the belt auxiliary conveyor assembly 60, thereby guiding the narrow web strip WN into the web leader roller gap between the guide reels 80E and 80F; the leader transfer system performs tape transfer, and the upper adhesive application system 54U and the lower adhesive application system 54L apply adhesive such as side tape to the upper leader strip 52U and the lower leader strip 52L. Since the narrow web strip WN is connected to the upper leader strip 52U and the lower leader strip 52L with tape, it can now be guided to the winder spindle through the pre-inserted leader strip WP (which now has tape on each side). Figure 8E1 As shown, the web W' (see Fig.8C1 , Figure 8C2 and Fig.13 ) is still being wound onto the core reel 30R at this time.

[0102] The method 400 further includes a retracting step 406 in which the roll transport assembly 20 is retracted. Fig.9B1 The belt auxiliary conveyor assembly 60 is retracted upward in the direction indicated by the arrow Y in FIG. Fig.9B1 The edge trimming slitter 70 is retracted horizontally in the direction indicated by the arrow X in FIG. 1 , and the edge trimming slitter 70 is moved outward into the operating position and cuts the narrow edge trimming strip WNT (see FIG. 1 ). Fig. 12A and Fig. 12B), these narrow edge trimming strips are still wound onto the core reel 30R, the production line speed is accelerated to the normal operating speed, the linear accumulator 10 begins to return to the running position, the upper leading member slitter 56U and the lower leading member slitter 56L cut the upper leading member strip 52U and the lower leading member strip 52L from the production line, and the leading member clamps are engaged to stop the feeding of the upper leading member strip 52U and the lower leading member strip 52L from the upper leading member spindle reel 51U and the lower leading member spindle reel 52L, and the edge trimming material WNT is guided to the trimming material chute 93 (see Fig. 10B ) and a roll change is initiated at the turret winding system 200 to transfer to a new core. With the edge trim strip WNT now directed into the trim chute 93, the web W' no longer travels to the core roll 30R and the roll rotation can be stopped.

[0103] The method 400 further comprises an unloading step 407, in which the core reel 30R with the web W accumulated thereon is retracted to an unloading position, such as Fig. 10A The loader / unloader assembly 30H (e.g., an integrated lifter) grabs the core roll 30R with the web W rolled thereon, the stocker arm assembly (i.e., the track assembly 30A) unlocks from the core roll 30R, and the loader / unloader assembly 30H drops the core roll 30R downward onto a cart 30C or the floor so that it can be removed from the machine area (see Fig. 10A ), a new core roll 30A is ready with tape for use in the rotating hopper assembly 30 and is loaded back into the track assembly 30A by the loader / unloader assembly 30H, and the core roll 30R moves to the ready transfer position. In the event of another web material run abnormality, the operator can start the transfer.

[0104] As will be clear to those skilled in the art, various modifications, adjustments and variations may be made to the aforementioned specific disclosures without departing from the scope of the invention claimed herein. Without departing from the scope of the invention, the various features and elements of the invention described herein may be combined in a manner different from the specific examples described or claimed herein. In other words, any element or feature may be combined with any other element or feature in different embodiments, unless there is an obvious or inherent incompatibility between the two, or is specifically excluded.

[0105] References in the specification to "one embodiment", "an embodiment", "some embodiments", etc. indicate that the embodiment may include a particular aspect, feature, structure, or characteristic, but not every embodiment must include the aspect, feature, structure, or characteristic. In addition, such phrases may, but do not necessarily, refer to the same embodiment mentioned in other parts of the specification.

[0106] Unless the context clearly dictates otherwise, the singular forms "a," "an," and "the" include plural referents. Thus, for example, reference to "a plant" includes a plurality of such plants. It is further noted that the claims may be drafted to exclude any optional elements. As such, this statement is intended to serve as an antecedent basis for the use of exclusive terminology (such as "solely," "only," and the like) in conjunction with the recitation of claim elements or the use of a "negative" limitation. The terms "preferably," "preferred," "preferred," "optionally," "may," and similar terms are used to indicate that the referenced items, conditions, or steps are optional (non-essential) features of the present invention.

[0107] The term "and / or" means any one, any combination of items, or all of the items associated with this term. The phrase "one or more" is readily understood by those skilled in the art, especially when read in the context of its use.

[0108] As will be understood by those skilled in the art, all numbers (including those representing the amounts of reagents or ingredients, properties such as molecular weight, reaction conditions, etc.) are approximate and should be understood to be optionally modified in all cases by the term "about". These values ​​can vary depending on the desired properties sought to be obtained by those skilled in the art utilizing the teachings described herein. It should also be understood that such values ​​inherently contain variability necessarily resulting from the standard deviation found in their respective testing measurements.

[0109] As will be appreciated by those skilled in the art, for any and all purposes, particularly with regard to providing a written description, all ranges listed herein also encompass any and all possible subranges and combinations of subranges thereof, and individual values, particularly integer values, constituting the range. The ranges listed include each specific value, integer, decimal, or unit within the range. Any listed range can be easily identified as fully describing and enabling the same range to be decomposed into at least equal half, one-third, one-quarter, one-fifth, or one-tenth. As a non-limiting example, each range discussed herein can be easily decomposed into lower one-third, middle one-third, and upper one-third, etc.

[0110] As will also be understood by those skilled in the art, all language, such as "up to," "at least," "greater than," "less than," "more than," "or more," etc., are inclusive of the recited numbers, and such terms refer to ranges that can subsequently be broken down into sub-ranges as discussed above. In the same manner, all ratios recited herein also include all sub-ratios that fall within the broader ratios. Thus, specific values ​​recited for radicals, substituents, and ranges are for illustration only; they do not exclude other defined values ​​or other values ​​within defined ranges for radicals and substituents.

Claims

1. A roll transfer assembly (20) for a web handling system (100), the roll transfer assembly (20) comprising: a support beam (22) movably mounted to a frame (100F) of the web handling system (100); a segmented drum assembly (24) rotatably mounted to the support beam (22), the segmented drum assembly (24) comprising a first end segment (24A), a second end segment (24B), a central segment (24C) positioned between the first end segment (24A) and the second end segment (24B), a first transfer drum (26A) positioned between the first end segment (24A) and the central segment (24C), and a second transfer drum (26B) positioned between the second segment (24B) and the central segment (26C); an actuation assembly (28) connected to the support beam (22), the first conveyor roll (26A), and the second conveyor roll (26B), the actuation assembly (28) comprising a first drive system configured to translationally move the first conveyor roll (26A) and the second conveyor roll (26B) relative to the support beam (22) between a storage position and an extended position; as well as A second drive system is connected to the frame (100F) and the support beam (22) and is configured to move the roll transport assembly (20) translationally relative to the frame (100F).

2. The roll transport assembly (20) of claim 1, further comprising a belt auxiliary conveyor assembly (60) movably connected to the frame (100F) between a retracted position and an engaged position.

3. The roll conveying assembly (20) according to claim 2, wherein: The belt-type auxiliary conveyor assembly (60) includes a first continuous conveyor belt (60B) mounted and driven around first conveyor rollers (60R1, 60R2) and a second continuous conveyor belt (60B) mounted and driven around second conveyor rollers (60R1, 60R2).

4. The roll conveying assembly (20) according to claim 3, wherein: The first transfer drum (26A) may be positioned opposite the first continuous conveyor belt (60B) and the second transfer drum (26B) may be positioned opposite the second continuous conveyor belt (60B) to urge the web strip (WN) to attach to the leader strip.

5. The web transfer assembly (20) of claim 4, further comprising a transfer web slitter (70) configured to form the web strips (WN) in the continuous web (W).

6. A rotary hopper system (30) for a web handling system (100), the rotary hopper system (30) comprising: a track assembly (30A) mounted to the frame (100F); as well as A core drum (30R) is rotatably movable along the track (30A) between an operating position, a winding position and an unloading position, and the core drum (30R) is configured to wind a web (W).

7. The rotary hopper system (30) of claim 6, further comprising a knife slitter (40) configured to cut the web (W) and separate the web (W) from a normal downstream process.

8. The rotary hopper system (30) of claim 6, further comprising an adhesive (AD) applied to an outer surface of the core reel (30R).

9. The rotary hopper system (30) of claim 8, further comprising a paster roll (30P) rotatably mounted to the frame (100F) and configured to move toward and away from the core roll (30R), the paster roll (30P) being configured to push the cut web material (W) against the core roll (30R) so that the cut web material (W) is adhered to the core roll (30R) due to the adhesive (AD).

10. The rotary hopper system (30) of claim 6, further comprising a backup idler roller (33) located below and laterally offset from the core roller (30R), the backup idler roller (33) being configured to guide the web (W) between the transfer roller assembly (20) and the core roller (30R) during a transition step from the rotary hopper to the winder spindle winding process to allow for proper cutting geometry between the web (W) and the transfer slitter (21).

11. The rotary hopper system (30) of claim 7, wherein: The normal downstream process includes the web (W) traveling to a dual turret winding system (200), and separation of the web (W) from the normal downstream process includes preventing the web (W) from traveling to the dual turret winding system (200).

12. The rotary hopper system (30) of claim 6, further comprising a drive unit configured to rotate the core reel (30R) to cause the web material to be wound around the core reel (30R).

13. A web processing system (100), comprising: (a) a web winding system (200); (b) a roll transfer assembly (20) located upstream of the web winding system (200), the roll transfer assembly (20) comprising: a support beam (22) movably mounted to a frame (100F) of the web handling system (100); a segmented drum assembly (24) rotatably mounted to the support beam (22), the segmented drum assembly (24) comprising a first end segment (24A), a second end segment (24B), a central segment (24C) positioned between the first end segment (24A) and the second end segment (24B), a first transfer drum (26A) positioned between the first end segment (24A) and the central segment (24C), and a second transfer drum (26B) positioned between the second segment (24B) and the central segment (26C); an actuation assembly (28) connected to the support beam (22), the first transfer roll (26A) and the second transfer roll (26B), the actuation assembly (28) comprising a first drive system configured to translationally move the first transfer roll (26A) and the second transfer roll (26B) relative to the support beam (22) between a storage position and an extended position; and a second drive system connected to the frame (100F) and the support beam (22) and configured to translate the roll transport assembly (20) relative to the frame (100F); and A rotary hopper system (30) located upstream of the web winding system (200), the rotary hopper system (30) comprising: a track assembly (30A) mounted to the frame (100F); and A core drum (30R) is rotatably movable along the track (30A) between an operating position, a winding position and an unloading position, and the core drum (30R) is configured to wind a web (W).

14. The web handling system (100) of claim 13, further comprising a first slitter system (40) located upstream of the web winding system (200) and configured to cut the web (W) from the web winding system (200).

15. The web handling system (100) of claim 13, further comprising a paster reel (30P) movably mounted to the frame (100F) toward and away from the core reel (30R) and configured to transfer the web (W) to the core reel (30R).

16. The web handling system of claim 13, further comprising: a leader supply system (50U, 50L) located downstream of the first slitter system (40), the leader supply system (50U, 50L) including a supply of leader web material (52U, 52L) stored therein; The roll transfer system (20) is configured to cut the web (W) from the core roll (30R) and transfer the web (W) to the leader web (52U, 52L), and the leader web (52U, 52L) is inserted into the web winding system (200).

17. The web handling system of claim 13, wherein: At least one of the first end segment (24A), the second end segment (24B), and the center segment (24C) includes nozzles configured to discharge gas therefrom.

18. A method for conveying web material from and to a continuous process flow leading to a winding system, the method comprising: Providing a web handling system (100) for feeding a web to a winding system (200); providing a rotary hopper system (30) located upstream of the web handling system (200) and having a core reel (30R) therein; providing an applicator roll (30R) which is movably mounted to the frame (100F) toward and away from the core roll (30R); providing a first web slitter (40) located upstream of the web handling system (200); Providing a transfer reel assembly (20) upstream of the web handling system (200), the transfer reel assembly (20) comprising a second web slitter (21); providing a belt-type auxiliary conveyor assembly (60) located upstream of the web handling system (200); providing a leader supply system (50U, 50L) downstream of the first slitter system (40), the leader supply system (50U, 50L) including a supply of leader web (52U, 52L) stored therein and fed to the web handling system (200); cutting the web via the first web slitter (40) so that the web is not fed into the web handling system (100); transferring the web (W) to the rotary hopper system (30) via the applicator drum (30R); severing the web from the core reel (30R) via at least the second web slitter (21); and The web material (W) is transferred to a leading member web (52U, 52L) via the transfer reel assembly (20) and the belt-type auxiliary conveyor assembly (60).

19. The method of claim 18, wherein: The web (W) has a first layer (W1) and a second layer (W2); supplying a first leader web among the leader webs (52U) and a second leader web among the leader webs (52L) via the leader supply system (50U, 50L); transferring the first layer (W1) to the first leader web (52U); and The second layer (W2) is transferred to the second leader web (52L).

Images