COMPOSITE CYLINDER WITH METAL BEARING BAND

Abstract

A winding core that is a composite cylinder with a metal bearing band to prevent splitting and fraying of the cylinder when supported by a support wheel, and a method for manufacturing the same.

Claims

1. A method for manufacturing a winding core with a metal bearing band, the method comprising: providing an extruded wood fiber cylinder to serve as at least a portion of a winding cylinder; and affixing at least one metal bearing band about an end of said winding cylinder.

2. The method of claim 1, further comprising: forming a winding cylinder through securing a plurality of staves to the outer surface of the extruded fiber cylinder.

3. The method of claim 2, wherein: the staves are wooden staves or plastic staves.

4. The method of claim 1, further comprising: prebending said metal bearing band prior to the affixing.

5. The method of claim 1 further comprising: applying an adhesive agent prior to the affixing.

6. The method according to claim 5, wherein: the adhesive agent is a foaming adhesive.

7. The method according to claim 1, wherein the affixing comprises: securing a first end of the metal bearing band to one end the winding cylinder using at least one first screw; causing a second end of the metal bearing band to overlap the first end of the metal bearing band by a screwing margin; and securing the second end of the metal bearing band to the one end of the winding cylinder using at least one second screw, wherein: the at least one second screw passes through the first end of the metal bearing band and is screwed into the winding cylinder.

8. The method according to claim 7, wherein the affixing further comprises: securing at least one non-end portion of the metal bearing band to the winding cylinder using at least one third screw.

9. The method according to claim 8, wherein: the extruded wood fiber cylinder is a hollow extruded wood fiber cylinder having a hollow core that, in a cross section that is perpendicular to the lengthwise direction of said extruded wood fiber cylinder, has a regular polygonal shape having a plurality of sides of substantially equal length and substantially equal interior angles; and the at least one first screw, the at least one second screw, and the at least one third screw are each screwed into the winding cylinder from the outside of winding cylinder at cross-sectional locations corresponding to radial projections from an axis of the extruded wood fiber cylinder through substantially middles of sides of the polygonal shape.

10. The method according to claim 1, wherein the affixing further comprises: causing a second end of the metal bearing band to overlap a first end of the metal bearing band by a welding margin; securing the second end of the metal bearing band to the first end of the metal bearing band through spot welding; and fitting the welded metal bearing band onto an end of the winding cylinder.

11. A winding core with a metal bearing band, comprising: a cylindrical extruded wood fiber cylinder that serves as at least part of a winding cylinder; and at least one metal bearing band affixed about an end of said winding cylinder.

12. The winding core of claim 11, wherein: the winding cylinder further comprises a plurality of staves secured to the outer surface of the extruded wood fiber cylinder.

13. The winding core of claim 12, wherein: the staves are wooden staves or plastic staves.

14. The winding core of claim 11, further comprising: an adhesive agent interposed between the winding cylinder and the at least one metal bearing band.

15. The winding core of claim 14, wherein: the adhesive agent is a foaming adhesive.

16. The winding core of claim 11, wherein: a first end of the metal bearing band is affixed to one end the winding cylinder using at least one first screw; a second end of the metal bearing band overlaps the first end of the metal bearing band by a screwing margin; and the second end of the metal bearing band is affixed to the one end of the winding cylinder using at least one second screw, wherein: the at least one second screw passes through the first end of the metal bearing band and is screwed into the winding cylinder.

17. The winding core of claim 16, wherein: at least one non-end portion of the metal bearing band is secured to the winding cylinder using at least one third screw.

18. The winding core of claim 17, wherein: the extruded wood fiber cylinder is a hollow extruded wood fiber cylinder having a hollow core that, in a cross section that is perpendicular to the lengthwise direction of said extruded wood fiber cylinder, has a regular polygonal shape having a plurality of sides of substantially equal length and substantially equal interior angles; and the at least one first screw, the at least one second screw, and the at least one third screw are each screwed into the winding cylinder from the outside of the winding cylinder at cross-sectional locations corresponding to radial projections from an axis of the wood fiber cylinder through substantially middle of sides of the polygonal shape.

19. The winding core of claim 11, wherein: a second end of the metal bearing band overlaps a first end of the metal bearing band by a welding margin; the second end of the metal bearing band is secured to the first end of the metal bearing band through spot welding; and the welded metal bearing band is fitted onto an end of the winding cylinder.

20. The winding core of claim 11, wherein: the metal bearing band is made from galvanized steel plate.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] FIG. 1 is a schematic perspective view showing the use of a winding core according to an embodiment.

[0028] FIG. 2A is a perspective diagram of an embodiment wherein the winding cylinder is an extruded wood fiber cylinder; FIG. 2B is a perspective diagram of an embodiment wherein the winding cylinder is an extruded wood fiber cylinder cladded with wooden or plastic staves; and po FIG. 2C is a perspective diagram of an embodiment wherein the winding cylinder is an extruded wood fiber cylinder cladded with a reinforcing paper wrap.

[0029] FIG. 3 is a cross-sectional diagram illustrating locations for securing the bearing band with screws in an embodiment wherein a hollow core is provided.

[0030] FIG. 4 is a process flow diagram illustrating a method for manufacturing a winding core according to an embodiment.

[0031] FIG. 5 is a process flow diagram illustrating details of a method for manufacturing a winding core according to an embodiment.

[0032] FIG. 6 is a process flow diagram illustrating details of another method for manufacturing a winding core according to an embodiment.

DETAILED DESCRIPTION

[0033] Prior to describing embodiments of winding cores 10, FIG. 1 will be referenced to describe the functions and use scenarios for exemplary winding cores 10. As depicted in FIG. 1, winding cores 10 according to embodiments are envisioned for use as carriers for sheet products 12 that are wound thereon for transportation, storage, and use. Non-limiting examples of such sheet products 12 that may be stored and/or transported on winding cores 10 include: paper products such as printing paper, newsprint, tissue paper, packaging paper (e.g., kraft paper), and wallpaper; plastic films such as stretch film (used in wrapping pallets), plastic wrap (e.g., cling film), shrink wrap, polyethylene or polypropylene films, and adhesive films (e.g., vinyl for signs); textiles such as fabrics (cotton, polyester, etc.), carpets and rugs, synthetic materials (e.g., nylon or spandex), and non-woven fabrics; adhesive products such as adhesive tapes (e.g., masking tape, duct tape), label stock, and self-adhesive vinyls; metal foils such as aluminum foil, copper foil, and steel or stainless steel foils; rubber products such as rubber sheet and rubber flooring; packaging materials such as corrugated cardboard sheet, bubble wrap, and foam sheet; printing and graphic materials such as banner materials, photographic paper, and canvas for printing; insulation materials such as fiberglass insulation sheet and rubber or foam insulation sheet; and the like. In embodiments, the sheet product 12 is stored and/or transported in the form of a wound roll 18, wherein the sheet product 12 is wound onto a winding core 10.

[0034] As referenced above and illustrated in FIG. 1, during winding and/or unwinding (feeding) of the sheet product 12, the wound roll 18 may be supported on supporting wheels 15 or a similar structure. As will be described below, bearing of the weight of the wound roll 18 on portions of the winding core 10 in the vicinities of the ends of the winding core 10, as illustrated in FIG. 1, causes a concentration of forces in the vicinities of the ends of the winding core 10 which, in the absence of the bearing band 50, illustrated in FIG. 2A through FIG. 2C and described below, may cause splitting or fraying of the ends of the winding core 10.

[0035] Having explained the functions and use scenarios for exemplary winding cores 10 in reference to FIG. 1, the structure of exemplary winding cores 10, illustrated in FIG. 2A through FIG. 2C will be explained below. As illustrated in FIG. 2A through FIG. 2C, in embodiments, the winding core 10 comprises a winding cylinder 20, with bearing bands 50 affixed in the vicinities of both ends thereof.

[0036] As illustrated in FIG. 2A, in embodiments the winding cylinder 20 comprises an extruded wood fiber cylinder 30. In embodiments, the extruded wood fiber cylinder 30 is formed, through an extrusion process that uses a hollow profile die and/or a mandrel, so as to have a circular profile and a hollow core 35. In embodiments this hollow core 35 may have a cross-sectional shape that is substantially a regular polygon, such as an equilateral triangle, a square, and pentagon, or the like. Note that in this disclosure, being substantially a regular polygon is meant to mean a shape that has sides of equal length and equal interior angles, within a tolerance of 10%.

[0037] In embodiments, as illustrated in FIG. 2B, the winding cylinder 20 further comprises a plurality of staves 40 attached to the outer periphery of the wood fiber cylinder 30. These staves 40 provide additional reinforcement and impact protection to the winding cylinder 20. The staves 40 may be attached to the wood fiber cylinder 30 using an adhesive, through screws, through nails, through melt fusion, or through a combination thereof. In embodiments where an adhesive is used, the adhesive may be a foam adhesive, to compensate for variability in the surface of the wood fiber cylinder 30 caused by the extrusion process. In embodiments the staves 40 may be made of wood, and the inner surfaces thereof may be contoured to fit with the outer periphery of the wood fiber cylinder 30. In other embodiments the staves 40 may be formed of extruded plastic, such as HDPE, providing an advantage in regulatory compliance in avoiding the need for kiln drying of the wooden staves that is required for export to certain markets.

[0038] In embodiments, the staves 40 may be configured with an exterior profile such that when each stave 40 is applied to the wood fiber cylinder 30 such that the elongate length of the stave 40 is parallel to the axis of the wood fiber cylinder 30, the exterior profile of the stave is rounded to form an arc, and the arcs of, for example, eight staves combine to form a circular cross section.

[0039] In embodiments, the staves 40 may comprise eight staves disposed about the circumference of the extruded core, while in alternative embodiments, different numbers of staves may be employed. Similarly, various cross-sectional shapes may be imparted to the extruded wood fiber cylinders 30. In alternative embodiments where extrusions of square, polygonal, pentagonal, hexagonal, heptagonal, octagonal, nonagonal, or decagonal cross section or cross sections of any number of sides, staves 40 with flat interior sides may be provided. In such embodiments same number of staves 40 as of sides may be used. It is noted, however, that polygonal cross sections can reduce the waist rate of milled wooden staves as the milled staves need only be milled on the exterior.

[0040] In other embodiments, the staves 40 may be formed through extrusion of a plastic, such as HDPE, with a shape that conforms to the outer profile of the extruded word fiber cylinder 30, and which provides a suitable shape on the outer surfaces of the staves 40. In such embodiments, the adhesive is selected for compatibility with both the material of the extruded wood fiber cylinder 30 and the plastic material that is used for the staves 40.

[0041] Glues used in the adhesion of the staves 40 to the wood fiber cylinder 30 are chemically and structurally compatible with the resins used in the wood fiber cylinder 30. Degradation of the wood fiber cylinder 30 could compromise strength of the system. In one embodiment wood glue, such as that available under the trademarks Elmer's and Tightbond, may be used. Alternatively, resins similar to or identical with that used in the wood fiber extrusion may be used. Alternatively, foaming adhesives, such as those available under the trademark Gorilla Glue, may be used to compensate for variability in the surface of the wood fiber cylinder 30. In one such embodiment both the extrusion and the glue are urea-formaldehyde resins. The setting of the urea-formaldehyde resin may be accelerated using catalysts. Examples of catalysts used include various metal salts, such as aluminum sulfate.

[0042] In embodiments, as depicted in FIG. 2C, the winding cylinder 20 may be formed through wrapping some or all of the outer periphery of the extruded wood fiber cylinder 30 in a reinforcing paper wrap 45, to provide additional structural support and impact resistance. In embodiments the reinforcing paper wrap 45 may be used in conjunction with the staves 40, interposed between the staves 40 and the extruded wood fiber cylinder 30. In embodiments the reinforcing paper wrap 45 may be secured through an adhesive, in the same manner as described above, or may be self-adhering.

[0043] In embodiments, bearing bands 50 are affixed about ends of the winding cylinder 20. Note that the bearing bands 50 are bands that are configured to bear and distribute the forces that are applied ends of the winding cylinder 20 when supported by, for example, supporting wheels 15, as illustrated in FIG. 1. to the In embodiments these bearing bands 50 may be structured from galvanized steel plate or another material with suitable tensile strength, yield strength, hardness, fatigue strength, impact resistance, flexural strength, shear strength, wear resistance, and the like, to prevent splitting or fraying of the ends of the winding cylinder 20 (the ends of extruded wood fiber cylinder 30 and/or the ends of the staves 40) when supported on, for example, the supporting wheels depicted in FIG. 1. While the specific material properties required, and the specific materials and specific dimensions used, for the bearing bands 50 will depend on the use application (the weight of the sheet product 12, the dimensions of the supporting wheels 15, and the like), in embodiments the bearing bands 50 may be made from 25 gauge (0.0209 inches/0.531 mm thick) galvanized steel strips that are 2 inches (5.08 cm) wide. In embodiments the bearing bands 50 may be affixed directly to the extruded wood fiber cylinder 30, as illustrated in FIG. 2A, or affixed over the staves 40, as illustrated in FIG. 2B, or affixed over the reinforcing paper wrap 45, as illustrated in FIG. 2C. In other embodiments, not illustrated, the bearing bands 50 may be affixed directly to the extruded wood fiber cylinder 30, with staves 40 and/or reinforcing paper wrap 45 covering portions of the extruded wood fiber cylinder 30 other than the portions to which the bearing bands 50 are affixed.

[0044] In embodiments, the bearing bands 50 may be formed as looped bands, with overlapping first and second ends, affixed to the winding cylinder 20. While the amount of overlap is set as appropriate depending on the affixing method, as described below, in embodiments it may be between 5/16 inches (7.94 mm) and 2.5 inches (76.4 mm).

[0045] In embodiments, each bearing band 50 may be affixed to the winding cylinder 20 by one or more first screws 80 that secure one end (a first end) of the bearing band 50 to the winding cylinder 20, and one or more second screws 90 that secure the other end (a second end) of the bearing band 50 to the winding cylinder 20, passing through the first end of the bearing band 50 as well in a screwing margin 70 wherein the two ends overlap each other. In embodiments, the bearing band 50 may be secured to the winding cylinder 20 through third screws 100 as well, at non-end portion that are locations other than in the vicinities of the ends of the bearing band 50. The bearing band 50 may be secured further through the use of an adhesive 60, which, in embodiments, may be a foam adhesive to compensate for variability in the outer surface of the winding cylinder 20.

[0046] In other embodiments, the bearing band 50 may be formed into a loop by spot-welding the ends together at a welding margin 110 wherein the two ends are overlapping. In embodiments, this looped and welded bearing band 50 may be secured further through one or more third screws 100 as well, and may be secured further through the use of an adhesive 60, similar to that which was described above.

[0047] In embodiments wherein the extruded wood fiber cylinder 30 is a circular cylindrical shape that has a hollow core 35 of a substantially polygonal cross-sectional shape, the first, second, and/or third screws 80, 90, and 100 may secure the bearing band 50 to the winding cylinder 20 at locations where the extruded wood fiber between the outside of the hollow core 35 and the outside of the extruded wood fiber cylinder 30 is thickest, as illustrated in FIG. 3. That is, the first, second, and/or third screws 80, 90, and 100 may each be screwed into the winding cylinder 20 at cross-sectional locations corresponding to radial projections from the center of the extruded wood fiber cylinder 30 through substantially the middles of the sides of the polygonal cross-sectional shape of the hollow core 35, as illustrated in FIG. 3. Here substantially the middles means within 25% of the middle of the side, to account for manufacturing tolerances. In embodiments, the first, second, and/or third screws 80, 90, and 100 may be provided corresponding to all sides of the polygonal cross-sectional shape of the hollow core 35, or at a selected subset thereof.

[0048] Embodiments of methods for manufacturing a winding core 10 will be described in reference to FIG. 4 through FIG. 6. As depicted in FIG. 4, first an extruded wood fiber cylinder 30 is provided 200 and, in embodiments, a plurality of wooden or plastic staves 40 is obtained 210. A foaming adhesive is applied 220 to the inner surfaces of the staves 40 and/or the outer surface of the extruded wood fiber cylinder 30, the staves 40 are adhered 230 to the outer surface of the extruded wood fiber cylinder 30 to form a winding cylinder 20, and the staves 40 are further secured 240 through screws, nails, or the like. In other embodiments the staves 40, and the steps for securing them to the extruded wood fiber cylinder 30, may be omitted.

[0049] In embodiments a bearing band 50 is prebent 250 to form an open loop. In other embodiments this prebending 250 may be omitted. The bearing band 50 is then affixed 260 to an end of the winding cylinder 20. In embodiments this affixing may be achieved through a method such as described in reference to FIG. 5. In other embodiments this affixing may be achieved through a method such as described in reference to FIG. 6.

[0050] A first method for affixing the bearing band 50 to an end of the winding cylinder 20 will be described in reference to FIG. 5. In embodiments, a foaming adhesive 60 is first applied 300 to the inner surface of the bearing band 50 and/or the applicable portion of the outer surfaces of the winding cylinder 20. In embodiments this foaming adhesive 60 may be omitted instead. The bearing band 50 is then positioned 310 over the applicable location at one end of the winding cylinder 20. In embodiments, two first screws 80 are then screwed 320 through one end of the bearing band 50 and the applicable stave 40 into the extruded wood fiber cylinder 30 at a location as indicated in FIG. 3. In other embodiments this may be only a single first screw 80. In embodiments the first screw 80 may be screwed into only the stave 40 without passing into the extruded wood fiber cylinder 30. In other embodiments, the stave 40 may be omitted, and the first screw 80 may be screwed directly into the extruded wood fiber cylinder 30.

[0051] The prebent bearing band 50 is then wrapped 330 around the winding cylinder 20 so that the ends overlap to form a screwing margin 70, as depicted in FIG. 3. Two second screws 90 are then screwed 340 through the screwing margin 70 (i.e., both ends of the bearing band 50) through the same stave 40 (if present in the applicable embodiment) into the extruded wood fiber cylinder 30 at the same location as indicated in FIG. 3 (offsetted in the lengthwise direction of the winding cylinder 20 so as to prevent interference between screws). In other embodiments, only a single screw 90 is used. Three third screws 100 are then screwed 350 through respective staves 40 (if present in the applicable embodiment) into the extruded wood fiber cylinder 30 at the thick locations indicated in FIG. 3. This process is then repeated 360 for the other bearing band 50 at the other end of the winding cylinder 20.

[0052] A second method for affixing the bearing band 50 to an end of the winding cylinder 20 will be described in reference to FIG. 6. The bearing band 50 is bent 400 into a loop slightly larger than the outer diameter of the winding cylinder 20, with the ends overlapping to form a welding margin 110. The two ends of the bearing band 50 are spot welded 410 together at the welding margin 110. In embodiments a foaming adhesive 60 is applied 420 to the outer surface of the winding cylinder 20, while in other embodiments this foaming adhesive 60 may be omitted. The welded metal bearing band 50 is then fitted 430 onto an end of the winding cylinder 20. Third screws 100 are then screwed 440 into all four of the thick locations indicated in FIG. 3. In other embodiments the third screws 100 may be screwed into less than all four of the thick locations that are indicated, or may be omitted altogether. In other embodiments the third screws may be screwed into other locations instead.

[0053] The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of this disclosure. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto.

EXPLANATIONS OF REFERENCE NUMERALS

[0054] 10: Winding Core [0055] 12: Sheet Product [0056] 15: Supporting Wheel [0057] 18: Wound Roll [0058] 20: Winding Cylinder [0059] 30: Extruded Wood Fiber Cylinder [0060] 35: Hollow Core [0061] 40: Staves [0062] 45: Reinforcing Paper Wrap [0063] 50: Bearing Band [0064] 60: Adhesive [0065] 70: Screwing Margin [0066] 80: First Screw [0067] 90: Second Screw [0068] 100: Third Screw [0069] 110: Welding Margin [0070] 120: Weld