Single face splicer and method of using the same

• US 6,027,591 A
• Filed: 09/08/1997
• Issued: 02/22/2000
• Est. Priority Date: 09/16/1996
• Status: Expired due to Fees

• Current Assignee: United Container Acquisition Corp.
• Original Assignee: United Container Machinery, Inc. (Barry-Wehmiller Group Incorporated)
• Inventors: O'Dwyer, John
• Primary Examiner(s): Crispino, Richard
• Assistant Examiner(s): Koehler, Robert R.
• Application Number:
  US08/925,374
• Time in Patent Office: 897 Days
• Field of Search: 156/157, 156/210, 156/462, 156/470, 156/504, 156/361
• US Class Current: 156/157
• CPC Class Codes: B65H 19/14 Accumulating surplus web for advancing to machine while changing the web roll
• CPC Class Codes: Y10T 156/1025 to form undulated to corrugated sheet and securing to base with parts of shaped areas out of contact

Abstract

A single face splicer for creating a splice between a running web from a first source of single face material and a ready web from a second source of single face material to provide an uninterrupted supply of single face material to a double backer system in the manufacture of corrugated cardboard. The splicer includes an upper and lower bridge positioned above the first and second sources of single face material, and a splice head adjacent the upper bridge for creating the splice between the running web and the ready web. A drive system draws the running web through the splice head at an output speed which is greater than the speed at which the double backer system draws the running web from the splicer. The running web is deposited on an upper bridge supply belt which rotates at a speed which is slower than the output speed thereby causing the running web to accumulate on the upper bridge supply belt. As the splice is made, the double backer system draws from the accumulated storage on the upper bridge supply belt. To allow for pre-acceleration of the first and second supplies of single face material, the running or ready webs is deposited onto a first or second lower bridge supply belt which is rotating at a speed which is slower than the output speed of the first or second supply. An accumulation of running or ready web is created on the first or second lower bridge supply belt which allows for pre-acceleration of the first or second supply prior to the initiation of a splice.

Claims

1. A single face splicer for supplying a running web of single face material to a double backer system said splicer comprising:

first and second sources of single face material, said first source providing said running web of single face material and said second source providing a ready web of single face material, said single face material including a fluted web and a backing adhered to said fluted web;

an exit bridge positioned downstream from said first and second sources of single face material for accumulating said running web;

a splice head positioned intermediate said exit bridge and said first and second sources of single face material for creating a splice between said running web of single face material and said ready web of single face material;

a drive system for drawing said running web through said splice head at an output speed which is greater than a double backer speed at which the double backer system draws said running web from said splicer;

an exit conveyor operably connected to said exit bridge,

wherein said drive system is adapted for depositing said running web onto said exit conveyor at said output speed, and wherein said exit conveyor is adapted for movement relative to said exit bridge at an exit conveyor speed which is slower than said output speed to cause said running web to accumulate on said exit conveyor to provide an uninterrupted supply of said running web to the double backer system as said splice is created; and

an entrance bride positioned intermediate said exit bridge and said second source of single face material for accumulating said ready web.

2. A single face splicer according to claim 1, wherein said exit conveyor speed is about one-third of said double backer speed for accumulating said running web in storage loops on said exit conveyor.

3. A single face splicer according to claim 1, wherein said exit conveyor has a length of about twenty feet.

4. A single face splicer according to claim 1 further comprising:

an entrance conveyor operably connected to said entrance bridge adjacent said second source of single face material;

wherein said entrance conveyor is adapted to receive said ready web at an in input speed from said second source of single face material, and wherein said entrance conveyor is adapted for movement relative to said entrance bridge at an entrance conveyor speed which is slower than said input speed to thereby cause said ready web to accumulate on said entrance conveyor to allow for pre-acceleration of said second source of single face material prior to initiation of said splice.

5. A single face splicer according to claim 4 further comprising a pair of opposed single face input belts positioned intermediate said second source of single face material and said entrance conveyor, and wherein said ready web is carried onto said entrance conveyor between said pair of opposed single face input belts.

6. A single face splicer according to claim 4, wherein said entrance conveyor speed is about one-third of said double backer speed for accumulating said ready webs in storage loops on said entrance conveyor.

7. A single face splicer according to claim 4, wherein said entrance conveyor has a length of about twenty feet.

8. A single face splicer according to claim 1, said splicer further comprising:

a first entrance conveyor operably connected to said entrance bridge adjacent said first source of single face material; and

a second entrance conveyor operably connected to said entrance bridge adjacent said second source of single face material,

wherein said first entrance conveyor is adapted to receive said running web at a first input speed from said first source of single face material, and wherein said first entrance conveyor is adapted for movement relative to said entrance bridge at a first entrance conveyor speed which is slower than said first input speed to thereby cause said running web to accumulate on said first entrance conveyor to allow for pre-acceleration of said first source of single face material prior to drawing of said running web through said splice head by said drive system,

and wherein said second entrance conveyor is adapted to receive said ready web at a second input speed from said second source of single face material, and wherein said second entrance conveyor is adapted for movement relative to said entrance bridge at a second entrance conveyor speed which is slower than said second input speed to thereby cause said ready web to accumulate on said second entrance conveyor to allow for pre-acceleration of said second source of single face material prior to initiation of said splice.

9. A single face splicer according to claim 8 further comprising a first pair of single face input belts positioned intermediate said first source of single face material and said first entrance conveyor, a second pair of single face input belts positioned intermediate said second source of single face material and said second entrance conveyor, and wherein said running web is carried onto said first entrance conveyor between said first pair of opposed single face input belts, and said ready web is carried onto said second entrance conveyor between said second pair of opposed single face input belts.

10. A single face splicer according to claim 8, wherein said first and second entrance conveyor speeds are about one-third of said double backer speed for accumulating said running and ready webs in storage loops on said first and second entrance conveyors.

11. A single face splicer according to claim 8, wherein said first and second entrance conveyors have lengths of about twenty feet.

12. A method of supplying single face material to a double backer system comprising:

providing a single face splicer, said splicer comprising;

first and second sources of single face material, said first source providing a running web of single face material and said second source providing a ready web of single face material, said single face material including a fluted web and a backing adhered to said fluted web;

an entrance bridge and an exit bridge positioned downstream from said first and second sources of single face material, said entrance bridge positioned intermediate said exit bridge and said second source of single face material;

a splice head intermediate said exit bridge and said first and second sources of single face material for creating a splice between said running web and said ready web;

a drive system for drawing said running web through said splice head at an output speed which is greater than a double backer speed at which the double backer system draws said running web from said splicer;

an entrance conveyor operably connected to said entrance bridge adjacent said second source of single face material; and

an exit conveyor operably connected to said exit bridge, wherein said entrance conveyor is adapted to receive said ready web at an input speed from said second source of single face material, and wherein said entrance conveyor is adapted for movement relative to said entrance bridge at an entrance conveyor speed which is slower than said input speed to thereby cause said ready web to accumulate on said entrance conveyor to allow for pre-acceleration of said second source of single face material prior to initiation of said splice,

and wherein said drive system is adapted for depositing said running web onto said exit conveyor at said output speed, and wherein said exit conveyor is adapted for movement relative to said exit bridge at an exit conveyor speed which is slower than said output speed to cause said running web to accumulate on said exit conveyor to provide an uninterrupted supply of said running web to the double backer system as said splice is created;

moving said exit conveyor at said exit conveyor speed;

operating said drive system to deposit said running web onto said exit conveyor thereby causing accumulation of said running web on said exit conveyor, said accumulation providing an uninterrupted supply of said running web as said splice is created;

moving said entrance conveyor at said entrance conveyor speed;

pre-accelerating said second source of single face material to supply said ready web onto said entrance conveyor prior to initiation of said splice; and

initiating said splice when said first source of single face material is nearly exhausted, whereby after said splice is created said second source of single face material provides said running web and said first source of said single face material provides said ready web.

13. A method according to claim 12, wherein said splicer further comprises a pair of opposed single face input belts positioned intermediate said second source of single face material and said entrance conveyor, and wherein said ready web is supplied onto said entrance conveyor between said pair of opposed single face input belts.

14. A method according to claim 12, wherein said exit conveyor speed is about one-third of said double backer speed.

15. A method according to claim 12, wherein said entrance conveyor speed is about one-third of said double backer speed.

16. A single face splicer for supplying a web of single face material to a double backer, said splicer comprising:

a first source of single face material providing a running web of single face material;

a second source of single face material positioned in spaced relation to said first source of single face material and providing a ready web of single face material;

said single face material including a fluted web and a backing adhered to said fluted web;

a splice head positioned downstream from said first and second sources of single face material for creating a splice between said running web of a single face material and said ready web of a single face material;

an entrance web storage region for receiving and accumulating said ready web, said entrance web storage region positioned intermediate said second source of single face material and said splice head; and

an exit web storage region for receiving and accumulating said running web, said exit web storage region positioned downstream from said splice head.

17. The single face splicer according to claim 16 wherein said entrance web storage region includes:

an entrance bridge;

an entrance conveyor supported for movement relative to said entrance bridge; and

an entrance conveyor drive system operably connected to said entrance conveyor for driving said entrance conveyor in motion.

18. The single face splicer according to claim 17 wherein said exit web storage region includes:

an exit bridge;

an exit conveyor supported for movement relative to said exit bridge; and

an exit conveyor drive system operably connected to said exit conveyor for driving said exit conveyor in motion.

19. The single face splicer according to claim 18 further comprising an input conveyor positioned intermediate said second source of single face material and said entrance conveyor, wherein said ready web is carried onto said entrance conveyor by said input conveyor.

20. The single face splicer according to claim 19 further comprising a wet end control system in communication with said entrance and exit conveyor drive systems for controlling motion of said entrance and exit conveyors thereby controlling accumulation of said ready web on said entrance conveyor and controlling accumulation of said running web on said exit conveyor.

21. The single face splicer according to claim 20 further comprising a single face drive system for drawing said running web through said splice head at an output speed wherein said wet end control system is operably connected to said single face drive system for controlling said output speed.

22. The single face splicer according to claim 16 wherein said first and second sources of single face material comprise first and second single facers, each of said first and second single facers supplied by first and second sources of web material.

23. A single face splicer comprising:

a first source of single face material providing a running web of single face material;

a second source of single face material positioned in spaced relation to said first source of single face material and providing a ready web of single face material;

said single face material including a fluted web and a backing adhered to said fluted web;

a splice head positioned downstream from said first and second sources of single face material for creating a splice between said running web of a single face material and said ready web of a single face material;

a first entrance conveyor for receiving said running web, said first entrance conveyor positioned intermediate said first source of single face material and said splice head;

a first entrance conveyor drive system operably connected to said first entrance conveyor for driving said first entrance conveyor in motion;

a second entrance conveyor for receiving and accumulating said ready web, said second entrance conveyor positioned intermediate said second source of single face material and said splice head; and

a second entrance conveyor drive system operably connected to said second entrance conveyor for driving said second entrance conveyor in motion.

24. The single face splicer according to claim 23 further comprising:

a first input conveyor positioned intermediate said first source of single face material and said first entrance conveyor, said first input conveyor driven in motion by said first entrance conveyor drive system;

a second input conveyor positioned intermediate said second source of single face material and said second entrance conveyor, said second input conveyor driven in motion by said second entrance conveyor drive system; and

wherein said running web is carried onto said first entrance conveyor by said first input conveyors and said ready web is carried onto said second entrance conveyor by said second input conveyor.

25. The single facer according to claim 24 further comprising a wet end control system in communication with said first and second entrance conveyor drive systems for controlling motion of said first and second entrance conveyors and said first and second input conveyors thereby controlling accumulation of said running web on said first entrance conveyor and controlling accumulation of said ready web on said second entrance conveyor.

26. A method of supplying a continuous web of single face material, said method comprising the steps of:

providing a first source of single face material for supplying a running web of single face material;

providing a second source of single face material for supplying a ready web of single face material;

said single face material including a fluted web and a backing adhered to said fluted web;

providing a splice head downstream of said first and second sources of single face material for receiving said running and ready webs of single face material;

conveying said running web downstream through said splice head;

depositing said running web on an exit conveyor downstream from said splice head;

accumulating said running web on said exit conveyor;

forming a Splice between said running web and said ready web within said splice head;

pre-accelerating said second source of single face material;

depositing said ready web on an entrance conveyor upstream from said splice head;

accumulating said ready web on said entrance conveyor during said splicing step; and

consuming at least some of said accumulated running web during said step of forming said splice, whereby after said splice is complete said second source of single face material provides said running web.

27. The method according to claim 26 further comprising the step of transferring said ready web accumulated on said entrance conveyor to said exit conveyor after said step of forming said splice.

28. The method according to claim 26 wherein said step of forming said splice comprises:

stopping said running web and said ready web within said splice head;

attaching said ready web to said running web within said splice head; and

severing said running web, whereby said ready web becomes said running web.