Turret unwinding and splicing unit and method of use

Abstract

The web unwinding and splicing unit includes a turret unwind having a turret arm with a rotatable shaft at an opposite end for unwinding a running web from a finished roll of web material and unwinding a standby web from a new roll of web material. A unit housing operable with the turret unwind includes a web deflector for forcing the running web onto the standby web to splice the running web with the standby web, and a cutting device for selectively cutting the running web. A vacuum system sucks the cut web remaining on the finished roll of web material. Methods of use are also disclosed.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] none

[0002] Disclosed herein is a turret unwind and splicing unit and method for using the same. A turret unwind unit is disclosed that automatically splices a finished roll of material to a waiting roll of material, the turret unwind unit including a recovery system for recovering the end of the material carried by the finished roll and automatically separating the finished roll core from the finished material. Two waste streams, each of a single material, are generated, making recycling and downstream processing of the finished roll core and finished material easier and more efficient. [Background technology]

[0003] A turret unwind and splicing unit is described in U.S. Patent No. 11,325,801, which is commonly owned by the assignee of the present application and incorporated herein by reference. U.S. Patent No. 11,325,801 discloses a turret unwind unit that includes a vacuum structure for recovering the free end of the severed web after the splice has been initiated. The vacuum structure disclosed in U.S. Patent No. 11,325,801 may not be optimal for recovering the free end. An improved design for recovering the free end is desirable. Summary of the Invention [Problem to be solved by the invention]

[0004] A method and apparatus are provided for minimizing waste and improving quality and production in web processing operations in high speed, small footprint environments. [Means for solving the problem]

[0005] A turret unwind unit is disclosed that automatically splices a finished roll of material with a waiting roll of material, the turret unwind unit including a recovery system that recovers an end of the material carried by the finished roll. [Brief explanation of the drawings]

[0006] The drawings illustrate embodiments presently contemplated for carrying out the present disclosure.

[0007] The drawings are as follows:

[0008] [Figure 1] FIG. 1 is a front view of a first embodiment of a turret unwinding and splicing unit for transporting a finished roll of material and a standby roll of material. [Figure 2] FIG. 1 is a front view of a first embodiment of a turret unwinding and splicing unit for transporting a finished roll of material and a standby roll of material. [Figure 3] FIG. 1 is a front view of a first embodiment of a turret unwinding and splicing unit for transporting a finished roll of material and a standby roll of material. [Figure 4] FIG. 1 is a front view of a first embodiment of a turret unwinding and splicing unit for transporting a finished roll of material and a standby roll of material. [Figure 5] FIG. 1 is a front view of a first embodiment of a turret unwinding and splicing unit for transporting a finished roll of material and a standby roll of material. [Figure 6] FIG. 1 is a front view of a first embodiment of a turret unwinding and splicing unit for transporting a finished roll of material and a standby roll of material. [Figure 7] FIG. 1 is a front view of a first embodiment of a turret unwinding and splicing unit for transporting a finished roll of material and a standby roll of material.

[0009] [Figure 8] FIG. 10 is a front view of a second embodiment of a turret unwinding and splicing unit for transporting a finished roll of material and a standby roll of material. [Figure 9]FIG. 10 is a front view of a second embodiment of a turret unwinding and splicing unit for transporting a finished roll of material and a standby roll of material.

[0010] [Figure 10] FIG. 10 is a front view of a third embodiment of a turret unwinding and splicing unit for transporting a finished roll of material and a standby roll of material. [Figure 11] FIG. 10 is a front view of a third embodiment of a turret unwinding and splicing unit for transporting a finished roll of material and a standby roll of material.

[0011] [Figure 12] FIG. 10 is a front view of a fourth embodiment of a turret unwinding and splicing unit for transporting a finished roll of material and a standby roll of material. [Figure 13] FIG. 10 is a front view of a fourth embodiment of a turret unwinding and splicing unit for transporting a finished roll of material and a standby roll of material.

[0012] [Figure 14] FIG. 10 is a front view of an alternative embodiment of a roller for use with a turret unwind and splicing unit. [Figure 15] FIG. 10 is a front view of an alternative embodiment of a roller for use with a turret unwind and splicing unit. [Figure 16] FIG. 10 is a front view of an alternative embodiment of a roller for use with a turret unwind and splicing unit. [Figure 17] FIG. 10 is a front view of an alternative embodiment of a roller for use with a turret unwind and splicing unit. DETAILED DESCRIPTION OF THE INVENTION

[0013] While the present disclosure may be capable of embodiments in different forms, specific embodiments have been shown in the drawings and are described in detail herein, with the understanding that the disclosure is to be considered as an exemplification of the principles of the disclosure and is not intended to limit the disclosure to that illustrated.

[0014] Thus, reference to a feature or aspect is intended to describe the feature or aspect of one example of the disclosure and does not imply that all embodiments thereof must have the described feature or aspect. Furthermore, it should be noted that the description illustrates several features. While some features are combined to illustrate potential system designs, the features may also be used in other combinations not expressly disclosed. Thus, the illustrated combinations are not intended to be limiting unless otherwise specified.

[0015] A turret unwind and splicing unit 10 is disclosed that can be used to form products such as diapers, but can also be applied to a wide variety of web-based converting processes. The turret unwind and splicing unit 10 is used to join a finished roll 12 to a standby roll 14. Each roll 12, 14 has a roll core 16 around which a material 18 is wrapped. In one embodiment, the standby roll 14 has a joining material 20, such as an adhesive or tape, provided thereon, as is known in the art. In an alternative embodiment, a joining unit (not shown) may be provided to mechanically join the material 18 of the finished roll 12 to the material 18 of the standby roll 14.

[0016] The turret unwind and splicing unit 10 includes a unit base 22 on which a web take-up unit mount 24 is rotatably mounted on a central pivot shaft 26 that rotates about an axis of rotation 28. The web take-up unit mount 24 extends from the pivot shaft 26 and includes first and second turret arms 30, 32 having rotatable shafts 34, 36 mounted thereon, respectively, and third and fourth turret arms 38, 40 also extending from the pivot shaft 26 and having cylindrical rollers 42, 44 mounted thereon. Each shaft 34, 36 has an axis of rotation 46, 48 and is independently driven by a motor (not shown), and each roller 42, 44 has an axis of rotation 50, 52 and is freely rotatable on the turret arms 38, 40. The shafts 34, 36 are spaced equidistant from the axis 28 of the central pivot shaft 26, and the rotation axes 46, 48 may be parallel to each other and to the axis 28 of the central pivot shaft 26 and aligned along a first imaginary line passing through the axis 28. The rotatable shafts 34, 36 support the rolls 12, 14 in use. The rollers 42, 44 are spaced a distance from the axis 28 of the central pivot shaft 26, and the rotation axes 50, 52 may be parallel to each other and to the axis 28 of the central pivot shaft 26 and aligned along a second imaginary line passing through the central pivot axis 28 that intersects the first imaginary line. The rollers 42, 44 may be spaced further from the central pivot shaft 26 than the shafts 34, 36. In the exemplary arrangement shown in the drawings, the web take-up unit mount 24 is in a first position with shaft 34 at the 12 o'clock position, roller 44 at the 3 o'clock position, shaft 36 at the 6 o'clock position, and roller 42 at the 9 o'clock position. As described herein, the web take-up unit mount 24 rotates in a second position such that shaft 36 is at the 12 o'clock position, roller 42 at the 3 o'clock position, shaft 34 at the 6 o'clock position, and roller 44 at the 9 o'clock position. In alternative embodiments, rollers 42, 44 may be spaced in any number of different relative positions while operating in a manner similar to that described herein; therefore, the clock face positions referenced herein should be understood to be non-limiting and provided for illustrative purposes only.Additionally, the web take-up unit mount 24 may be configured to rotate clockwise as shown herein, or counterclockwise for alternative winding configurations.

[0017] The turret unwinding and splicing unit 10 further includes a splicer unit device 110 positioned below the central pivot shaft 26 and offset to one side thereof so as to be adjacent to the standby roll 14 when in the first use position.

[0018] The splicer unit apparatus 110 includes a non-movable base structure 112 having a fixed rail 114 at its upper end. A unit housing 116 is mounted on and movable along the rail 114. The unit housing 116 houses rollers 118, a cutting device 120, such as a cutting wire or knife unit, and a web deflection device 122, such as a bump arm. The cutting device 120 and web deflection device 122 may be actuated by air cylinders or motor drives.

[0019] In a first position, the unit housing 116 is slid along the rails 114 so that it is within the rotational path of the web take-up unit mount 24, and in a second position, the unit housing 116 is slid along the rails 114 so that it is not within the rotational path of the web take-up unit mount 24. In the exemplary arrangement shown in the drawings, the unit housing 116 is positioned between the 6 o'clock position and the 9 o'clock position in the first position. It will be understood that a mirror image of the turret unwinding and splicing unit 10 can be provided, with the unit housing 116 being positioned between the 3 o'clock position and the 6 o'clock position in the first position.

[0020] In one embodiment shown in FIGS. 1-7 , a vacuum structure 124 coupled to a negative pressure source (not shown) is fixedly mounted on the unit housing 116 so that the vacuum structure 124 moves with the unit housing 116 along the rail 114. The vacuum structure 124 includes a plate 126 having an opening therethrough and a pipe 128 connected to the plate 126 that draws a vacuum through the opening in the plate 126. The plate 126 is positioned adjacent to the roller 42 or 44 during use. The plate 126 is preferably attached to the end of the pipe 128 and has a flat portion 130 through which the opening is provided and a curved portion 132 extending outward therefrom. The curvature of the curved portion 132 generally mirrors the curvature of the cylindrical rollers 42, 44, allowing the drawn air to flow smoothly into the pipe 128. The pipe 128 may include a Venturi tube to accelerate the flow of fluid drawn therethrough.

[0021] In one embodiment, as shown in FIGS. 8 and 9 , the vacuum structure 224 is separate from the unit housing 116 and instead pivotally mounted on a fixed structure 2434, such as a floor, separate from the splicer unit apparatus 110. The vacuum structure 224 includes a base structure 236 coupled to a negative pressure source (not shown) and pivotally mounted to the fixed structure 234, a pipe 228 coupled to the base structure 236, and a plate 226 having an opening therethrough. The pipe 228 draws a vacuum through the opening in the plate 226. The plate 226 preferably has a flat portion 230 attached to the end of the pipe 228 and having an opening therethrough, and a curved portion 232 extending outward therefrom. The curvature of the curved portion 232 generally mirrors the curvature of the cylindrical rollers 42, 44, allowing the drawn air to flow smoothly into the pipe 228. The pipe 228 may include a Venturi tube to accelerate the flow of fluid drawn therethrough. The base structure 236 is pivotable relative to the unit base 22 and the splicer unit apparatus 110 to move the plate 226 from a first position within the rotational path of the web take-up unit mount 24 to a second position outside the rotational path of the web take-up unit mount 24. As shown in FIG. 8 , the plate 226 is positioned adjacent to the roller 42 or 44 in the first position.

[0022] In one embodiment shown in FIGS. 10 and 11 , the vacuum structure 324 is pivotally mounted to the unit base 22. The vacuum structure 324 includes a base structure 336 coupled to a negative pressure source (not shown) and pivotally mounted to the unit base 22, a pipe 328 coupled to the base structure 336, and a plate 326 having an opening therethrough. The pipe 328 draws a vacuum through the opening in the plate 326. The plate 326 preferably has a flat portion 330 attached to the end of the pipe 328 and having the opening, and a curved portion 332 extending outward therefrom. The curvature of the curved portion 332 generally mirrors the curvature of the cylindrical rollers 42, 44, allowing the drawn air to flow smoothly into the pipe 328. The pipe 328 may include a Venturi tube to accelerate the flow of fluid drawn therethrough. The base structure 336 is pivotable relative to the unit base 22 and the splicer unit apparatus 110 to move the plate 326 from a first position within the rotational path of the web take-up unit mount 24 to a second position outside the rotational path of the web take-up unit mount 24. As shown in FIG. 10 , the plate 326 is positioned adjacent to the roller 42 or 44 in the first position.

[0023] Operation of the turret unwind and splicing unit 10 will be described with respect to the embodiment shown in Figures 1-7, with the understanding that operation of the embodiment of Figures 8-11 is the same. In use to perform a splice sequence, the web take-up unit mount 24 is in its first position, and the splicer unit apparatus 110 / vacuum structure 124 is disposed in its / their first position. The running web of material 18 on the finish roll 12 is unwound from the roll 12, passes around roller 42, between roller 42 and plate 126, over and around roller 118, between the web deflection device 122 and fresh material 18 on the standby roll 14, and then to a further line processing station (not shown). The web deflection device 122 is adjacent to, but spaced from, the standby roll 14.

[0024] 3 , the standby roll 14 of material 18 is driven by its controlled motor, and at the moment of splicing, the material 18 of the finishing roll 12 is pressed against the splice material 20 by a web deflection device 122, joining the material 18 of the finishing roll 12 to the splice material 20 of the standby roll 14. Simultaneously with the pressing, a cutting device 120 cuts the material 18 of the finishing roll 12, creating a leading portion of the material 18 of the finishing roll 12 and a trailing portion of the material 18 of the finishing roll 12. In this way, the leading portion of the finishing roll 12 is instantly joined to the material 18 of the standby roll 14. In some embodiments, the splicing is timed based on the calculated roll diameter. In an alternative embodiment, an optional vision system or photo eye (not shown) is provided to detect when the roll 12 mounted on the shaft 34 is nearing completion (compare the size of the completed roll 12 in FIG. 1 with FIG. 2), and an optional vision system or photo eye (not shown) is provided to detect the position of the splice material 20 on the roll 14.

[0025] Referring now to FIG. 4 , at the moment the material 18 is cut, a free end 54 of the material 18 of the finished roll 12 is generated. Just before or when the material 18 is cut, a vacuum is initiated and pulled by the vacuum structure 124. The free end 54 may rebound and contact the plate 126. The curvature of the curved portion 132 of the plate 126 causes air drawn into the pipe 128, and thus the free end 54, to move along and enter the pipe 128. The material 18 is sucked into the pipe 128 as shown in FIG. 5 . By locating the unit housing 116 / vacuum structure 124 in the position shown in FIGS. 4 and 5 (as well as FIGS. 8 and 10 ), the movement of the free end 54 into the pipe 128 is optimized. In one embodiment, the material 18 is unwound by rotation of the shaft 34 and sucked into the pipe 128 until the entire material 18 separates from the roll core 16. At this point, shaft 34 no longer needs to rotate until required to start rotating the next finished roll. Thus, in this embodiment, material 18 is automatically separated from finished roll core 16. In this embodiment, two single material waste streams are created, one being roll core 16 of finished roll 12 and the other being finished material 18, making recycling and downstream processing of finished roll core 16 and finished material 18 easier and more efficient because there is no need to manually handle the waste streams.

[0026] 6 (as well as FIGS. 9 and 11), the web deflection device 122 and cutting device 120 are retracted and the unit housing 116 / vacuum structure 126 moves to its / their second position.

[0027] The web take-up unit mount 24 rotates to its second position, rotating the roll 14 clockwise, placing the roll 14 in the end-roll position (because roll 14 is now the ending roll 12), preferably in the upper vertical position of the web take-up unit mount 24. The clockwise rotation of the web take-up unit mount 24 also places the shaft 34 (still carrying the roll core 16 of the ending roll 12) in the standby roll position to receive the standby roll 14. It is desirable to vary V2 from the standby position to the end-roll position during the rotation of the web take-up unit mount 24 to maintain a constant tension and feed rate of the material 18 to the downstream processing operation.

[0028] 7, the web take-up unit mount 24 rotates to bring the finish roll 14 to the finish roll position, and the unit housing 116 / vacuum structure 126 is returned to its first position as shown in FIG. 1 (or FIGS. 8 and 10) for the next splice sequence. The roll core 16 is removed from the shaft 34 for disposal, and then the standby roll 14 is loaded onto the shaft 34.

[0029] In one embodiment, after cutting material 18 to form free end 54, but before material 18 is completely terminated from roll 14, vacuum structure 124 is stopped and rotation of shaft 34 is reversed to rewind material 18 onto roll core 16 of roll 12 for disposal before web take-up unit mount 24 moves to its second position, as shown in FIG. 7 .

[0030] 12 and 13, a splicer unit apparatus 410 and a vacuum structure 424 are mounted between two unit bases 22a, 22b, both of which operate continuously. Like elements in this embodiment are designated with like reference numerals, and like elements are labeled with numbers in the 400 series.

[0031] The splicer unit apparatus 410 includes a non-movable base structure 412 having a fixed rail 414 at its upper end. A unit housing 416 is mounted on the rail 414 and can be moved along the rail 414 to approach each unit base 22a, 22b to perform the splicing sequence as needed. The unit housing 416 includes a roller 418, a cutting device 420, such as a cutting wire or knife unit, and a pair of web deflection devices 422a, 422b, such as bump arms. The cutting device 420 and the web deflection devices 422a, 422b can be actuated by air cylinders or motor drives. In the exemplary arrangement shown in the drawings, when positioned adjacent to the right-most unit base 22a, as shown in FIG. 12, the unit housing 416 is positioned between the 6 o'clock and 9 o'clock positions in use. In an alternative configuration, the unit housing 416 may be positioned to contact the roll 14 at any position between the 6 o'clock and 11 o'clock positions when positioned adjacent to the rightmost unit base 22a. As shown in FIG. 13, when positioned adjacent to the leftmost unit base 22b, the unit housing 416 is positioned between the 3 o'clock and 6 o'clock positions in the use position. In an alternative configuration, the unit housing 416 may be positioned to contact the roll 14 at any position between the 1 o'clock and 3 o'clock positions when positioned adjacent to the leftmost unit base 22b.

[0032] The unit housing 416 is slidably mounted on the rails 414 so that it can move to a first position within the rotational path of the rightmost web take-up unit mount 24 and a second position within the rotational path of the leftmost web take-up unit mount 24. In some embodiments, the unit housing 416 is slidably mounted on the rails 414 so that it can be disposed in a third position outside the rotational paths of both web take-up unit mounts 24.

[0033] In the illustrated embodiment, a vacuum structure 424 coupled to a negative pressure source (not shown) is mounted on the unit housing 416 so that the vacuum structure 424 moves with the unit housing 416. The vacuum structure 424 includes a plate 426 pivotally mounted to the unit housing 416 and having an opening therethrough, and a pipe 428 connected to the plate 426 and drawing a vacuum through the opening in the plate 426. The plate 426 is positioned adjacent to the roller 42 or 44 of the respective unit drive 22a, 22b during use. The plate 426 preferably has a pair of curved portions 432a, 432b. The curvature of the curved portions 432a, 432b generally mirrors the curvature of the cylindrical rollers 42, 44, facilitating the flow of drawn air into the pipe 428. The pipe 428 may include a venturi tube to accelerate the flow of fluid drawn therethrough.

[0034] In use to perform a splice sequence, the web take-up unit mount 24 of the rightmost unit base 22a is in its first position, and the unit housing 416 / vacuum structure 424 is disposed in its first position. The vacuum structure 424 is pivoted relative to the unit housing 416 to move to the first position. The running web of material 18 on the finish roll is unwound from the roll 12, around the roller 42, between the roller 42 and the plate 426, over and around the roller 418, between the web deflection device 422 and the standby roll 14, and then to a further line processing station (not shown). The web deflection device 422 is adjacent to but spaced from the standby roll 14.

[0035] The standby roll 14 is driven by its controlled motor, and at the moment of splicing, the material 18 of the finishing roll 12 is pressed against the splice material 20 by the web deflection device 422, joining the material 18 of the finishing roll 12 to the splice material 20 of the standby roll 14. Simultaneously with the pressing, the cutting device 420 cuts the material 18 of the finishing roll 12, creating a leading portion of the material 18 of the finishing roll 12 and a trailing portion of the material 18 of the finishing roll 12. In this way, the leading portion of the finishing roll 12 is instantly joined to the material 18 of the standby roll 14. In some embodiments, the splicing is timed based on the calculated roll diameter. In an alternative embodiment, an optional vision system or photo eye (not shown) is provided to detect when the roll 12 attached to the shaft 34 is nearing the end, and an optional vision system or photo eye (not shown) is provided to detect the position of the splice material 20 of the roll 14.

[0036] At the moment the material 18 is cut, a free end of the material 18 on the finished roll 12 is created. Just before or when the material 18 is cut, a vacuum is initiated and pulled by the vacuum structure 424. The free end may rebound and contact the plate 426. The curvature of the curved portion 432a of the plate 426 causes air drawn into the pipe 428, i.e., the free end, to move along and enter the pipe 428. (The curvature of the curved portion 432b of the plate 426 causes air drawn into the pipe 428, i.e., the free end, to move along and enter the pipe 428 when used with the leftmost unit base 22b.) The material 18 is sucked into the pipe 428. By locating the unit housing 416 / vacuum structure 424 in the position shown in FIGS. 12 and 13, movement of the free end into the pipe 428 is optimized. In one embodiment, material 18 is unwound by the rotation of shaft 34 and sucked into pipe 428 until the entire material 18 separates from roll core 16. At this point, shaft 34 no longer needs to rotate until required to begin rotating the next finished roll. Thus, in this embodiment, material 18 automatically separates from finished roll core 16. In this embodiment, two single material waste streams are generated, one being the roll core 16 of finished roll 12 and the other being the finished material 18, eliminating the need for manual waste stream handling, making recycling and downstream processing of finished roll core 16 and finished material 18 easier and more efficient.

[0037] The web deflection device 422 and cutting device 420 are retracted, and the unit housing 416 / vacuum structure 424 moves to its second position adjacent the leftmost unit base 22b and performs a similar splicing operation for the leftmost unit base 22b. The vacuum structure 424 is pivoted relative to the unit housing 416 and moves to its first position relative to the leftmost unit base 22b.

[0038] The web take-up unit mount 24 of the rightmost unit base 22a rotates to its second position, rotating the roll 14 clockwise and positioning the roll 14 in an end-roll position (because roll 14 is now the end-roll 12), preferably in the upper vertical position of the web take-up unit mount 24. The clockwise rotation of the web take-up unit mount 24 also positions the shaft 34 (still carrying the roll core 16 of the end-roll 12) in a standby-roll position to receive the standby roll 14. During the rotation of the web take-up unit mount 24 of the rightmost unit base 22a, it is desirable to vary V2 from the standby position to the end-roll position during the rotation of the standby roll 14 in order to maintain a constant tension and feed rate of the material 18 to the downstream processing operation.

[0039] The web take-up unit mount 24 on the right-most unit base 22a rotates to bring the finish roll 14 to the finish roll position, and the unit housing 416 is returned to its first position for the next splice sequence. The roll core 16 is removed from the shaft 34 for disposal, and then the standby roll 14 is loaded onto the shaft 34.

[0040] In one embodiment, after cutting the material 18 to form the free end 54, but before the material 18 is completely terminated from the roll 14, the vacuum structure 424 is stopped and the rotation of the shaft 34 is reversed to rewind the material 18 onto the roll core 16 of the roll 12 for disposal before the web rewinding unit mount 24 moves to its second position.

[0041] Although the vacuum structure 424 is shown and described as being mounted to the unit housing 416, the vacuum structure 424 may be pivotally mounted to the floor so as to pivot between the base units 22a, 22b.

[0042] 16-19 show alternative structures for collecting material 18 after free end 54 has been cut. When these structures are used, vacuum structures 124, 224, 324, 424 are not provided.

[0043] 13 shows that rollers 42, 44 have tactile surfaces 56 thereon. Tactile surfaces 56 may be formed from a sticky material, a rough surface, a plurality of spikes extending outward from rollers 42, 44, a hook-shaped material, or the like, which causes material 18 to adhere to or frictionally engage rollers 42, 44 when tension is removed from material 18 as a result of cutting material 18. To collect material 18, as roll 12 moves to the 6 o'clock position, as shown in FIG. 7, rotation of shaft 34 is reversed to rewind material 18 onto roll core 16 of roll 12 for disposal.

[0044] FIG. 14 shows that electrostatic generators 58 are provided within rollers 42, 44. Once material 18 is cut, electrostatic generator 58 is activated, thereby securing material 18 to rollers 42, 44 as tension is removed from material 18 as a result of cutting material 18. To collect material 18, as roll 12 moves to the 6 o'clock position, as shown in FIG. 7, rotation of shaft 34 is reversed to rewind material 18 onto roll core 16 of roll 12 for disposal. After material 18 is collected, electrostatic generator 58 is deactivated.

[0045] FIG. 15 illustrates that the rollers 42, 44 are provided with a vacuum system 60. By way of example, each roller 42, 44 includes a perforated roller 62 having a plurality of openings 64 therein that rotates around a base roller 66 having a plurality of openings 68 therein and is vacuum-coupled. Once the material 18 is cut, the vacuum system 60 is activated, and once the openings 64, 68 are aligned with one another, a vacuum is drawn on the outer surface of the roller 62, thereby securing the material 18 to the rollers 42, 44 when tension is removed from the material 18 as a result of the material 18 being cut. To collect the material 18, as shown in FIG. 7, the roll 12 moves to the 6 o'clock position, and the rotation of the shaft 34 is reversed to rewind the material 18 onto the roll core 16 of the roll 12 for disposal. After the material 18 is collected, the vacuum system 60 is stopped.

[0046] FIG. 16 illustrates that rollers 42, 44 are provided with a pin structure 70. By way of example, pin structure 70 includes a plurality of retractable, spring-loaded pins 72 that can be extended through openings 74 in rollers 42, 44 by suitable means and retracted into rollers 42, 44 by suitable means. When material 18 is cut, pin structure 70 is actuated, causing pins 72 to extend from rollers 42, 44 and penetrate material 18 when tension is removed from material 18 as a result of cutting material 18, securing material 18 to rollers 42, 44. To collect material 18, as roll 12 moves to the 6 o'clock position, as shown in FIG. 7, rotation of shaft 34 is reversed to rewind material 18 onto roll core 16 of roll 12 for disposal. After material 18 is collected, pins 72 are retracted.

[0047] The foregoing is considered to be merely illustrative of the principles of the present disclosure. Moreover, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the disclosure to the exact construction and operation as shown and described. While preferred embodiments have been described, details may be changed without departing from the present disclosure as defined by the claims. [Prior art documents] [Patent documents]

[0048] [Patent Document 1] U.S. Patent No. 11,325,801

Claims

1. 1. A turret unwinding and splicing unit, comprising: a web winding unit mount rotatably supported on a rotating shaft; a first shaft rotatably coupled to the web take-up unit mount and configured to support a finished roll of material; a second shaft rotatably coupled to the web take-up unit mount and configured to support a standby roll of material; a roller rotatably coupled to the web take-up unit mount between the first shaft and the second shaft, wherein material from the finish roll contacts and at least partially wraps around the roller during a splicing sequence; and a cutting device configured to cut the finished roll of material, thereby generating a free end of the finished roll of material; a web deflection device configured to selectively interface the ending roll of material with a standby roll of material; a vacuum system configured to collect a free end of the finished roll of material, the vacuum system being positioned under the roller as the free end is formed and configured to create a vacuum to draw the free end into the vacuum system; A turret unwinding and splicing unit comprising:

2. The turret unwind and splicing unit of claim 1 , wherein the vacuum system includes a plate having at least one curved portion, the plate coupled to a pipe through which the vacuum is drawn.

3. The turret unwind and splicing unit of claim 1 , wherein the vacuum system is pivotally mounted to the web take-up unit mount.

4. 2. The turret unwind and splicing unit of claim 1, further comprising a unit housing to which the vacuum system and the cutting device are mounted, the unit housing being movable toward and away from the web take-up unit mount.

5. The turret unwind and splicing unit of claim 4 , wherein the unit housing is slidably mounted on rails.

6. The turret unwind and splicing unit of claim 4 , wherein the unit housing is mounted on a structure separate from the web take-up unit mount and is pivotable relative to the web take-up unit mount.

7. 2. The turret unwinding and splicing unit of claim 1, further comprising a unit housing to which the cutting device is mounted, and wherein the vacuum system is mounted on a structure separate from the web winding unit mount and the unit housing and is movable relative to the web winding unit mount and the unit housing.

8. 2. The turret unwinding and splicing unit of claim 1, wherein the web winding unit mount, the rotating shaft, the first shaft, the second shaft, and the roller form a first unit base, and further includes a second unit base, and the cutting device, the web deflection device, and the vacuum system are disposed between the first unit base and the second unit base.

9. 1. A turret unwinding and splicing unit, comprising: a web winding unit mount rotatably supported on a rotating shaft; a first shaft rotatably coupled to the web take-up unit mount and configured to support a finished roll of material; a second shaft rotatably coupled to the web take-up unit mount and configured to support a standby roll of material; a cutting device configured to cut the finished roll of material, thereby generating a free end of the finished roll of material; a web deflection device configured to selectively interface the ending roll of material with a standby roll of material; a vacuum system configured to collect a free end of the finished roll of material, the vacuum system including a plate coupled to a pipe through which a vacuum is applied to suck the free end into the vacuum system, the plate having at least one curved portion; A turret unwinding and splicing unit comprising:

10. The turret unwind and splicing unit of claim 9 , wherein the vacuum system is pivotally mounted to the web take-up unit mount.

11. 11. The turret unwind and splicing unit of claim 10, further comprising a unit housing to which the vacuum system and the cutting device are mounted, the unit housing being movable toward and away from the web take-up unit mount.

12. The turret unwind and splicing unit of claim 11 , wherein the unit housing is slidably mounted on rails.

13. The turret unwind and splicing unit of claim 11 , wherein the unit housing is mounted on a structure separate from the web take-up unit mount and is pivotable relative to the web take-up unit mount.

14. 12. The turret unwinding and splicing unit of claim 11, further comprising a unit housing to which the cutting device is mounted, and wherein the vacuum system is mounted on a structure separate from the web winding unit mount and the unit housing and is movable relative to the web winding unit mount and the unit housing.

15. 2. The turret unwinding and splicing unit of claim 1, wherein the web winding unit mount, the rotating shaft, the first shaft, and the second shaft form a first unit base, and further includes a second unit base, and the cutting device, the web deflection device, and the vacuum system are disposed between the first unit base and the second unit base.

16. 1. A turret unwinding and splicing unit, comprising: a web winding unit mount rotatably supported on a rotating shaft; a first shaft rotatably coupled to the web take-up unit mount and configured to support a finished roll of material; a second shaft rotatably coupled to the web take-up unit mount and configured to support a standby roll of material; a cutting device configured to cut the finished roll of material, thereby generating a free end of the finished roll of material; a web deflection device configured to selectively interface the ending roll of material with a standby roll of material; a roller rotatably coupled to the web rewinding unit mount between the first shaft and the second shaft, the roller having one of: 1) a tactile surface that adheres the material of the finished roll to the roller when tension is removed from the material as a result of cutting the material to form the free end; 2) an electrostatic generator that, when activated, adheres the material of the finished roll to the roller when tension is removed from the material as a result of cutting the material to form the free end; 3) a vacuum system that adheres the material of the finished roll to the roller when tension is removed from the material as a result of cutting the material to form the free end; and 4) a plurality of retractable pins that can extend through openings that secure the material of the finished roll to the roller when tension is removed from the material as a result of cutting the material to form the free end; A turret unwinding and splicing unit comprising:

17. The turret unwind and splicing unit of claim 14 , wherein the tactile surface is formed from one of an adhesive material, a roughened surface, and a hook material.

18. The turret unwind and splicing unit of claim 15, wherein the vacuum system includes a roller having a plurality of openings.

19. The turret unwind and splicing unit of claim 14, wherein the retractable pin is spring loaded.

20. 1. A method for splicing a running web of a finished roll of material with a waiting web of a new roll of material, comprising: providing a running web from a finish material roll mounted on a first rotatable shaft; providing a roller about which the running web at least partially wraps; providing a standby web of new material roll mounted on a second rotatable shaft; cutting the running web via a cutting device, thereby generating a leading portion of the running web and a trailing portion of the running web; splicing a leading portion of the running web with the standby web via a web deflection device; collecting the trailing portion of the running web via a vacuum system positioned below the roller; A method comprising:

21. The step of collecting the trailing portion of the running web comprises: after cutting the running web, sucking the free end of the trailing portion into the vacuum system; and collecting the remaining portion of the trailing portion of the running web on the finishing roll of material.

22. 20. The method of claim 19, further comprising moving the web deflector and the vacuum system away from the roller after collecting the trailing portion of the running web.

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