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CA2212025A1 - Coreless plastic film roll - Google Patents

Coreless plastic film roll

Info

Publication number
CA2212025A1
CA2212025A1 CA002212025A CA2212025A CA2212025A1 CA 2212025 A1 CA2212025 A1 CA 2212025A1 CA 002212025 A CA002212025 A CA 002212025A CA 2212025 A CA2212025 A CA 2212025A CA 2212025 A1 CA2212025 A1 CA 2212025A1
Authority
CA
Canada
Prior art keywords
mandrel
roll
web
plastic film
film
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
CA002212025A
Other languages
French (fr)
Inventor
Richard G. Salzsauler
Edward R. Salzsauler
Donald J. Salzsauler
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Saltech Inc
Original Assignee
Saltech Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Saltech Inc filed Critical Saltech Inc
Priority to CA002212025A priority Critical patent/CA2212025A1/en
Priority to CA002228020A priority patent/CA2228020C/en
Priority to DE69827134T priority patent/DE69827134T2/en
Priority to ES98902881T priority patent/ES2231958T3/en
Priority to NZ503080A priority patent/NZ503080A/en
Priority to CN98809442A priority patent/CN1085606C/en
Priority to PT98902881T priority patent/PT1001908E/en
Priority to AU59765/98A priority patent/AU733174B2/en
Priority to AT98902881T priority patent/ATE280121T1/en
Priority to EP98902881A priority patent/EP1001908B1/en
Priority to PCT/CA1998/000081 priority patent/WO1999006312A1/en
Priority to US09/021,505 priority patent/US6102313A/en
Priority to ZA981136A priority patent/ZA981136B/en
Publication of CA2212025A1 publication Critical patent/CA2212025A1/en
Priority to HK00107567A priority patent/HK1031112A1/en
Priority to HK01101314A priority patent/HK1030405A1/en
Abandoned legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65HHANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H75/00Storing webs, tapes, or filamentary material, e.g. on reels
    • B65H75/02Cores, formers, supports, or holders for coiled, wound, or folded material, e.g. reels, spindles, bobbins, cop tubes, cans, mandrels or chucks
    • B65H75/18Constructional details
    • B65H75/24Constructional details adjustable in configuration, e.g. expansible
    • B65H75/242Expansible spindles, mandrels or chucks, e.g. for securing or releasing cores, holders or packages
    • B65H75/243Expansible spindles, mandrels or chucks, e.g. for securing or releasing cores, holders or packages actuated by use of a fluid
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65HHANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H18/00Winding webs
    • B65H18/08Web-winding mechanisms
    • B65H18/26Mechanisms for controlling contact pressure on winding-web package, e.g. for regulating the quantity of air between web layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65HHANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H18/00Winding webs
    • B65H18/28Wound package of webs
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65HHANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2301/00Handling processes for sheets or webs
    • B65H2301/30Orientation, displacement, position of the handled material
    • B65H2301/32Orientation of handled material
    • B65H2301/325Orientation of handled material of roll of material
    • B65H2301/3251Orientation of handled material of roll of material vertical axis
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65HHANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2701/00Handled material; Storage means
    • B65H2701/10Handled articles or webs
    • B65H2701/18Form of handled article or web
    • B65H2701/184Wound packages
    • B65H2701/1846Parts concerned

Landscapes

  • Storage Of Web-Like Or Filamentary Materials (AREA)

Abstract

A roll of plastic film wrap formed without an interior core, and a method of forming such a roll onto an expandable mandrel while the plastic wrap is being pre-stretched.

Description

CA 0221202~ 1997-07-30 CORELESS PLASTIC FILM ROLL

Field of the Invention This invention relates to a method of forming a plastic film in a roll. In 5 particular, this invention relates to a method of forming a plastic film roll which does not have a separate core.

Background of the Invention Plastic film is generally supplied as a roll wound on a rigid cardboard or 10 plastic core. Generally, the core is a hollow tube which helps to m~int~in the shape of the roll. A hollow core also allows the roll to be mounted on a spindle and the film unwound from the roll.

There are a number of disadvantages associated with the use of cores in rolls 15 of plastic film. The cores used in conventional plastic film rolls are relatively expensive.
They form a significant component of the cost of each roll.

Cardboard cores, especially those intended for large commercial rolls of plastic film, have to withstand the crushing forces of the film rolled upon them. As a result, 20 the cores are made of heavy cardboard, with a high glue content for added rigidity.

These thick, heavy cores add to the total radial dimension and weight of each roll of film. Thus, the use of cores increases the cost of shipping rolls of film by decreasing the number of rolls which can be packed and shipped in a container, and increasing the 25 weight of the shipment.

Further, the high glue content in the cores makes them unsuitable for recycling, with the consequence that they must be discarded in a landfill site, or in other non-environmentally friendly manners.

CA 0221202~ 1997-07-30 Summary of the Invention It is desirable to provide a novel expandable mandrel for forming a roll of coreless plastic film.

It is further desirable to provide a novel method of forming a roll of coreless plastic film.

It is further desirable to provide a novel coreless roll of plastic film.

According to an embodiment of the present invention, there is provided a coreless roll of plastic film, comprising a web of said film wherein said web is wound on an expandable mandrel such that air is trapped in gaps formed between successive layers of said web, said mandrel being in an expanded state, and wherein said mandrel is collapsed and removed after said web is wound thereon.

According to an embodiment of the present invention, there is provided a coreless roll of plastic film, comprising a web of said film wherein said web is wound on an expandable mandrel such that air is trapped in gaps formed between successive layers of said web, said mandrel being heated to weld a plurality of layers of said film together, said mandrel being in an expanded state, and wherein said mandrel is collapsed and removed after said web is wound thereon.

According to a further embodiment of the present invention, there is provided a method of manufacturing a coreless roll of plastic film, comprising the steps of:
feeding a web of said film to a winding means;
winding said web at a low tension around an expandable mandrel, said mandrel being in an expanded state, to form a roll of said film with air trapped in gaps between each successive layer of said film;
radially collapsing said mandrel; and removing said collapsed mandrel from said roll.

CA 0221202~ 1997-07-30 According to a fu~ther embodiment of the present invention there is provided an expandable mandrel for manufacturing a coreless roll of plastic film, comprising:
a support having an original radial dimension;
expansion means for increasing said radial dimension;
collapsing means for restoring said mandrel to said original radial dimension.

The mandrel as described above, having heating means.

Brief Description of the Dr~ gs The present invention may be better understood by reference to the following detailed description and attached drawings, in which:
Figure 1 is a schematic view of an a~paldLIls for manufacturing coreless rolls of plastic film, according to an embodiment of the present invention;
Figure 2 is an endwise cross-section of a web of plastic film for forming a 15 coreless roll, according to a further embodiment of the present invention;
Figure 3 is an axial cross-section of a roll formed from the web of Figure 2;
Figure 4 is an axial cross-section of an expandable mandrel in an expanded state, according to a further embodiment of the present invention;
Figure 5 is a radial cross-section of the mandrel of Figure 4, in a collapsed 20 state;
Figure 6 is a radial cross-section of the mandrel of Figure 4, in an expanded state; and Figure 7 is a side view of a dispensing spindle for a roll of coreless roll of plastic film, according to a fu~ther embodiment of the present invention.
Detailed Description Figure 1 shows an apparatus, generally indicated as 10, for forming a coreless roll of plastic film, according to an embodiment of the present invention.

A master roll 20 of plastic film is mounted on a feed spindle 24. The plastic film is in the form of a web 22 which can be unrolled from master roll 20. The plastic film CA 0221202~ 1997-07-30 can be linear low density polyethylene or any other suitable plastic film commonly supplied in rolls.

The plastic film can be pre-stretched for added strength, or pre-stretched and embossed, as disclosed in commonly assigned U.S. Patent No.5,531,393, entitled "Stretch Film", which is incorporated herein by reference. An endwise cross-section of a web 22 of such a pre-stretched film, with l~min:~ted edge strips 28 is shown in Figure 2.

Generally, film which has not been pre-stretched should be aged for several 10 weeks before it is formed into a coreless plastic film roll. It is believed that aging the plastic film allows certain residual products of manufacture to dissipate from the film. As a result, the film is strengthened.

Web 22 is unwound from master roll 20 by a roller 30. Roller 30 is driven by 15 conventional drive means to unwind web 22. A toothed gear,32 is fixed to rotate with roller 30 and to drive a chain 36. Belt 36 in turn drives a roller 40, identical to roller 30, by means of a second toothed gear 34.

Second gear 34 is larger than first gear 32. The relative sizes of the gears 34 20 and 34 are chosen such that roller 40 rotates at a lesser rate than roller 30 and, consequently, the longitudinal tension originally exerted on web 22 by the pulling action of drive roller 30 is lessened by a predetermined amount. As a result, web 22 can be fed from 40 with a predetermined tensile loading. It is expected that this tensile loading will be such that the web is not subjected to any appreciable tension.
To create a roll 50 of the plastic film, an expandable mandrel 100 is urged against roller 40 by a mandrel support 60. Mandrel 100 is attached to support 60 so that it can rotate freely about its axis.

As mandrel 100 is urged into frictional contact with roller 40, mandrel 100 rotates with roller 40, though in an opposite sense. Web 22, which has been fed around roller 40 to the point where roller 40 and mandrel 100 touch, is taken up by mandrel 100 which acts CA 0221202~ 1997-07-30 as a temporary core for the resulting roll 50. Since mandrel 100 is driven directly by roller 40, web 22 winds onto mandrel 100 with substantially no tension. Mandrel 100 may also be heated to fuse or weld together the first few layers of the roll 50, therefore providing increased structural support to roll 50.

As will be ~palellL to those skilled in the art, support 60 pivots about its base away from roller 40 as roll 50 grows in thickness, but continues to urge roll 50 against roller 40. When roll 50 is a desired size, web 22 can be cut and support 60 can be pivoted away from contact with roller 40.
Referring to Figure 3, a section of roll 50 is shown where successive layers of web 22 can be seen in cross-section. As a result of the lack of tension exerted on web 22 as it is being wound onto mandrel 100, the formerly taut web 22 of Figure 2 relaxes slightly, especially at its unreinforced centre 42. This relaxation allows air to be trapped in gaps 26 between the successive layers. The trapped air provides a rigidity to the completed roll 50, much as filling a balloon with air gives it structural form. This rigidity allows mandrel 100 to be collapsed and removed from roll 50, forming a coreless roll of plastic film.

In Figures 4 and 6, mandrel 100 is shown in cross-section in its expanded state as an temporary core for roll 50 (shown in dashed outline). In Figure 5, mandrel is shown in its collapsed state where it can be removed from roll 50.

Mandrel 100 comprises a tube 110 with an internal bladder 120. Tube 110 is made of a rigid material such as steel, and is at least as long as web 22 is wide. A plurality of slots 124, having closed ends, are axially pierced in tube 110. Slots 124 are equally circumferentially spaced and extend nearly the length of tube 110. Tube 110 has a radial dimension which is defined herein as the original radial dimension of mandrel 100.

Bladder 120 is an inflatable tubular bladder made of a resilient plastic, rubberor rubberized fabric. When llninfl~te~17 bladder 120 conforms to the interior wall of tube 110, as best illustrated in Figure 5. When infl~te~1, sections 130 of bladder 120 protrude from slots 124 and effectively increase the radial dimension of mandrel 100, as shown in Figure 6.

CA 0221202~ 1997-07-30 In the illustrated embodiment, tube 110 of mandrel 100 is shown having four equally circumferentially spaced slots 124. However, as will be apparent to those skilled in the art, the desired increase in radial dimension of mandrel 100 can be effected with three or more spaced slots.

In operation, mandrel 100 is urged against roller 40 with bladder 120 inflated.
In this expanded state, as shown in Figure 6, mandrel 100 acts as a temporary core for roll 50 as web 22 is wound thereon. As shown in Figure 5, when roll 50 has reached a desired size, bladder 120 is deflated, decreasing the diameter of mandrel 100 and allowing it to be 10 withdrawn from the interior of roll 50 and thereby forming a dimensionally stable, coreless roll of plastic film with a hollow central section 132 approximately equal in diameter to the expanded diameter of mandrel 100.

In Figure 8, a dispensing spindle 200 is shown. The spindle 200is generally cylindrical with a bulbous centre portion 210. The spindle 200 can be inexpensively produced from polyvinyl chloride ("PVC"), other suitable rigid plastic, wood or metal.

When it is desired to unroll, or dispense, plastic film from a coreless roll of the present invention, spindle 200is inserted into the interior of the roll. The spindle 200 has a 20 length sufficient to allow both ends of the spindle 200 to extend beyond the edges of the roll.
The centre portion 210 has a diameter sufficient to engage the interior surface 140 of roll 50.

A person can then grasp the ends of the inserted spindle 200 and proceed to dispense film from the roll by allowing the spindle to rotate in the hands while, for example, 25 ~ldl)pillg a pallet load. The frictional engagement between the centre portion 210 and interior surface 140 causes the roll to rotate with the spindle 200. Alternatively, spindle 200 can be mounted so that it can rotate freely, as is well known in the dispensing art, and the plastic film can be pulled from the roll.

As is apparelll to those skilled in the art, the coreless roll of the present invention provides significant production and shipping cost savings over prior art rolls CA 0221202~ 1997-07-30 requiring expensive, heavy cores. Moreover, there is no core of which to dispose, in contrast to the unrecyclable cores the prior art.

It will also be al)palell~ that the present invention is not limited to plastic film 5 wrap, but can be used for any suitable material commonly rolled on a core, including PVC
film and Tough GuardTM.

It will be apparent to those skilled in the art that the foregoing is by way of example only. Modifications, variations and alterations may be made to the described 10 embodiments without departing from the scope of the invention which is defined solely in the claims.

Claims (3)

1. A coreless roll of plastic film, comprising a web of said film wherein said web is wound on an expandable mandrel such that air is trapped in gaps formed between successive layers of said film, said mandrel being in an expanded state, and wherein said mandrel is collapsed and removed after said web is wound thereon.
2. A method of manufacturing a coreless roll of plastic film, comprising the steps of:
feeding a web of said film to a winding means;
winding said web at a low tension around an expandable mandrel, said mandrel being in an expanded state, to form a roll of said film with air trapped in gap between each successive layer of said film;
radially collapsing said mandrel; and removing said collapsed mandrel from said roll.
3. An expandable mandrel for manufacturing a coreless roll of plastic film, comprising:
a support having an original radial dimension;
expansion means for increasing said radial dimension;
collapsing means for restoring said mandrel to said original radial dimension.
CA002212025A 1997-07-30 1997-07-30 Coreless plastic film roll Abandoned CA2212025A1 (en)

Priority Applications (15)

Application Number Priority Date Filing Date Title
CA002212025A CA2212025A1 (en) 1997-07-30 1997-07-30 Coreless plastic film roll
CA002228020A CA2228020C (en) 1997-07-30 1998-01-23 Method and apparatus for producing coreless rolls of sheet material
AU59765/98A AU733174B2 (en) 1997-07-30 1998-02-10 Method and apparatus for producing coreless rolls of sheet material and a coreless roll of material
EP98902881A EP1001908B1 (en) 1997-07-30 1998-02-10 Method and apparatus for producing coreless rolls of sheet material and a coreless roll of material
NZ503080A NZ503080A (en) 1997-07-30 1998-02-10 Apparatus for producing coreless rolls of sheet material by winding outer layer at higher tension than inner layer
CN98809442A CN1085606C (en) 1997-07-30 1998-02-10 Method and apparatus for producing coreless rolls of sheet material
PT98902881T PT1001908E (en) 1997-07-30 1998-02-10 METHOD AND APPARATUS FOR PRODUCING ROLLS WITHOUT NUCLEUS MATERIAL FOR SHEET AND A ROLL WITHOUT NUCLEUS MATERIAL
DE69827134T DE69827134T2 (en) 1997-07-30 1998-02-10 METHOD AND DEVICE FOR PRODUCING CORE-FREE ROLLS FROM RAIL MATERIAL AND A NON-CORE MATERIAL ROLL
AT98902881T ATE280121T1 (en) 1997-07-30 1998-02-10 METHOD AND DEVICE FOR PRODUCING CORELESS ROLLS FROM WEB MATERIAL AND A CORELESS ROLL OF MATERIAL
ES98902881T ES2231958T3 (en) 1997-07-30 1998-02-10 PROCEDURE AND APPLIANCE TO PRODUCE ROLLS WITHOUT NUCLEO OF MATERIAL IN SHEET AND ROLL WITHOUT NUCLEUS OF MATERIAL.
PCT/CA1998/000081 WO1999006312A1 (en) 1997-07-30 1998-02-10 Method and apparatus for producing coreless rolls of sheet material and a coreless roll of material
US09/021,505 US6102313A (en) 1997-07-30 1998-02-10 Method and apparatus for producing coreless rolls of sheet material and a coreless roll of material
ZA981136A ZA981136B (en) 1997-07-30 1998-02-11 Method and apparatus for producing coreless rolls of sheet material and a coreless roll of material
HK00107567A HK1031112A1 (en) 1997-07-30 2000-11-24 Method and apparatus for producing coreless rolls of sheet material and a coreless roll of material.
HK01101314A HK1030405A1 (en) 1997-07-30 2001-02-23 Method and apparatus for producing coreless rolls of sheet material and a coreless roll of material

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA002212025A CA2212025A1 (en) 1997-07-30 1997-07-30 Coreless plastic film roll

Publications (1)

Publication Number Publication Date
CA2212025A1 true CA2212025A1 (en) 1999-01-30

Family

ID=4161163

Family Applications (1)

Application Number Title Priority Date Filing Date
CA002212025A Abandoned CA2212025A1 (en) 1997-07-30 1997-07-30 Coreless plastic film roll

Country Status (2)

Country Link
CA (1) CA2212025A1 (en)
ZA (1) ZA981136B (en)

Also Published As

Publication number Publication date
ZA981136B (en) 1998-11-16

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Legal Events

Date Code Title Description
FZDE Discontinued