Method and apparatus for forming a roll of material

Abstract

An oscillating assembly for oscillating a winding of a web of material includes a controller configured to determine a speed of the web of material, a winding roller configured to wind the web of material thereon into a roll of material, and a shifting assembly slidably coupled to a fixture. The shifting assembly supports the winding roller. The oscillating assembly also includes an actuating mechanism coupled to the shifting assembly. The actuating mechanism includes an actuating rod coupled to the shifting assembly, wherein the actuating rod is movable in a direction substantially transverse to a direction of the winding of the web. The actuating mechanism also includes a driver configured to receive a signal from said controller based on the speed of the web of material, and configured to move said actuating mechanism based on the signal received from said controller.

1 . An oscillating assembly for oscillating a winding of a web of material, wherein the oscillating assembly comprises: 
 a controller configured to determine a speed of the web of material;    a winding roller configured to wind the web of material thereon into a roll of material;    a shifting assembly slidably coupled to a fixture, said shifting assembly for supporting said winding roller;    an actuating mechanism coupled to said shifting assembly, said actuating mechanism comprising an actuating rod coupled to said shifting assembly, wherein said actuating rod is movable in a direction substantially transverse to a direction of the winding of the web, and a driver configured to receive a signal from said controller based on the speed of the web of material, and configured to move said actuating mechanism based on the signal received from said controller.    
     
     
         2 . An oscillating assembly in accordance with  claim 1  wherein said controller receives a signal from an encoder relating to the speed of the web.  
     
     
         3 . An oscillating assembly in accordance with  claim 1  wherein the controller is programmable by a user such that said controller is configured to send a signal to said driver relating to at least one of an oscillation period, an oscillation amplitude, and an oscillation waveform of the winding of the web of material.  
     
     
         4 . An oscillating assembly in accordance with  claim 1  wherein said actuating mechanism comprises a servo motor configured to receive a signal from said controller relating to at least one of an oscillation period, an oscillation amplitude, and an oscillation waveform of the winding of the web of material.  
     
     
         5 . An oscillating assembly in accordance with  claim 1  wherein said actuating mechanism further comprises an encoder for determining the position of said actuating rod with respect to a datum such that said actuating mechanism facilitates functioning as a closed loop system.  
     
     
         6 . An oscillating assembly in accordance with  claim 5  wherein said encoder comprises a linear potentiometer.  
     
     
         7 . An oscillating assembly in accordance with  claim 1  wherein said shifting assembly comprises at least one mounting bracket configured to be slidably mounted to a corresponding guide rail coupled to the fixture.  
     
     
         8 . An oscillating assembly in accordance with  claim 1  wherein said shifting assembly is configured to shift in a linear direction parallel to an axis of rotation of said winding roller.  
     
     
         9 . An oscillating assembly in accordance with  claim 1  wherein the web of material includes a shrink sleeve material including a seam of adhesive extending continuously along the web of shrink sleeve material, said actuating mechanism configured to oscillate said shifting mechanism and said winding roller such that said seam is configured to provide support for the roll of material.  
     
     
         10 . A shrink sleeve forming apparatus for forming a web of material into a roll of shrink sleeve material, said forming apparatus comprising: 
 an unwind roller configured to receive the web of material;    a first nip roller mechanism comprising a first nip roller and a first pinch roller, said first nip roller mechanism configured to receive the web of material from said unwind roll, said first pinch roller facilitates retaining the web in substantial contact with said first pinch roller;    a shrink sleeve folding assembly configured to fold the web of material to form a web of shrink sleeve material;    a second nip roller mechanism comprising a second nip roller and a second pinch roller, said second nip roller mechanism configured to receive the web of material from said first nip roller mechanism, said second pinch roller facilitates retaining the web in substantial contact with said second nip roller; and    a winding roller configured to form the web of shrink sleeve material into a roll of shrink sleeve material, said winding roller configured to oscillate in a direction substantially transverse to the direction of winding of the roll of shrink sleeve material.    
     
     
         11 . A forming apparatus in accordance with  claim 10  wherein said first nip roller and said second nip roller are driven by a motor such that said first and second nip rolls direct the web of material through said forming apparatus.  
     
     
         12 . A forming apparatus in accordance with  claim 10  further comprising a plurality of idler rolls for positioning the web of material.  
     
     
         13 . A forming apparatus in accordance with  claim 10  further comprising a dancer roller positioned downstream of said second nip roller mechanism, said dancer roller configured to move laterally with respect to said winding roller based on the amount of tension desired in the web of material.  
     
     
         14 . A forming apparatus in accordance with  claim 10  wherein said forming apparatus further comprises a first tension zone defined between said unwinding roller and said first nip roller mechanism, a second tension zone defined between said first roller nip mechanism and said second nip roller mechanism, and a third tension zone defined between said second nip roller mechanism and said winding roll.  
     
     
         15 . A forming apparatus in accordance with  claim 14  wherein said second nip roller operates at a faster speed than said first nip roller to establish said second tension zone.  
     
     
         16 . A forming apparatus in accordance with  claim 10  wherein said shrink sleeve folding assembly comprises a plow wheel configured to initiate the folding of the web of material, and a shoe configured to fold a first end of the web of material onto a second end of the web of material to form the web of shrink sleeve material.  
     
     
         17 . A forming apparatus in accordance with  claim 10  wherein the winding roller is coupled to an actuating mechanism configured to oscillate said winding roller based on a signal from a controller relating to at least one of a web speed, an oscillation period, an oscillation amplitude, and an oscillation waveform of the winding of the web of material.  
     
     
         18 . A forming apparatus in accordance with  claim 10  further comprising: 
 a shifting assembly slidably coupled to said forming apparatus, said shifting assembly facilitates supporting said winding roll; and    an actuating mechanism coupled to said shifting assembly, said actuating mechanism comprising an actuating rod coupled to said shifting assembly, said actuating rod movable in a direction substantially transverse to the direction of the winding of the roll of material, said actuating mechanism further comprising a driver configured to receive a signal from a controller based on the speed of the web of material and configured to move said actuating mechanism based on the signal received from said controller.    
     
     
         19 . A solvent applicator system for a web of material, wherein the web of material passes through said solvent applicator system, said solvent applicator system comprising: 
 a plurality of rollers configured to direct the web of material through said solvent applicator system, said plurality of rollers comprising an unwind roller configured to receive an un-oscillated roll of the web of material, and a rewind roller configured to oscillate in a direction substantially transverse to the direction of winding of said rewind roller such that an oscillated roll of the web of material is formed on said rewind roller; and    a solvent applicator positioned between said unwind roller and said rewind roller, said solvent applicator configured to apply a continuous seam of solvent along the web of material as it is directed between said unwind roller and said rewind roller.    
     
     
         20 . An applicator system in accordance with  claim 19  wherein said plurality of rollers further comprise: 
 a first nip roller mechanism comprising a first nip roller and a first pinch roller, said first nip roller mechanism configured to receive the web of material from said unwind roller, said first pinch roller facilitates retaining the web in substantial contact with said first nip roller; and    a second nip roller mechanism comprising a second nip roller and a second pinch roller, said second nip roller mechanism configured to receive the web of material from said first nip roller mechanism, said second pinch roller facilitates retaining the web in substantial contact with said second nip roller.    
     
     
         21 . An applicator system in accordance with  claim 19  further comprising a shrink sleeve folding assembly positioned downstream from said solvent applicator such that the seam of solvent is applied to the web of material prior to the web of material being directed through said folding assembly, said folding assembly configured to fold the web of material to form a web of shrink sleeve material.  
     
     
         22 . An applicator system in accordance with  claim 21  wherein said shrink sleeve folding assembly comprising a plow wheel configured to initiate the folding of the web of material, and a shoe configured to fold a first end of the web of material onto a second end of the web of material to form a continuous web of shrink sleeve material.  
     
     
         23 . An applicator system in accordance with  claim 19  wherein said rewind roller is coupled to an actuating mechanism configured to oscillate said rewind roller based on a signal from a controller relating to at least one of a web speed, an oscillation period, an oscillation amplitude, and an oscillation waveform of the winding of the web of material.  
     
     
         24 . An applicator system in accordance with  claim 19  further comprising: 
 a shifting assembly slidably coupled to a fixture, said shifting assembly facilitates supporting said rewind roller; and    an actuating mechanism coupled to said shifting assembly, said actuating mechanism comprises an actuating rod coupled to said shifting assembly, wherein said actuating rod is movable in a direction substantially transverse to the direction of the winding of said rewind roller, said actuating mechanism further comprises a driver configured to receive a signal from a controller based on the speed of the web of material and configured to move said actuating mechanism based on the signal received from said controller.    
     
     
         25 . A method of forming a roll of shrink sleeve material from a web of material, said method comprising: 
 providing a shrink sleeve forming apparatus including an unwind roller, and a rewind roller;    positioning an unwind roll of material on the unwind roller;    directing the material from the unwind roller through the forming apparatus; and    oscillating the rewind roller such that the material forms an oscillated roll of material on the rewind roller.    
     
     
         26 . A method in accordance with  claim 25  wherein said providing a shrink sleeve forming apparatus further comprises providing a shrink sleeve forming apparatus including a folding assembly, said positioning an unwind roll of material on the unwind roller comprises positioning a roll including continuous web of material on the unwind roller, and said directing the material from the unwind roller through the forming apparatus comprises directing the web of material to the folding assembly, said method further comprising folding the web of material into a continuous web of tubular material using the folding assembly.  
     
     
         27 . A method in accordance with  claim 26  wherein said providing a shrink sleeve forming apparatus further comprises providing a shrink sleeve forming apparatus including a first nip roller mechanism and a second nip roller mechanism, wherein the folding assembly is positioned between the first and second nip roller mechanisms.  
     
     
         28 . A method in accordance with  claim 27  further comprising operating the second nip roller mechanism at an overspeed with respect to first nip roller mechanism such that the material therebetween is under tension.  
     
     
         29 . A method in accordance with  claim 25  further comprising: 
 slidably coupling a shifting assembly to the forming apparatus; and    coupling the rewind roller to the shifting assembly.    
     
     
         30 . A method in accordance with  claim 29  further comprising: 
 coupling an actuating mechanism to the shifting assembly, wherein the actuating mechanism includes an actuating rod coupled to the shifting assembly and movable in a direction substantially transverse to the direction of the winding of the rewind roll of material; and    controlling the actuating mechanism with a driver configured to receive a signal from a controller based on the speed of the web of material and configured to move the actuating mechanism based on the signal received from the controller.    
     
     
         31 . A method in accordance with  claim 25  wherein said oscillating the rewind roller comprises oscillating the rewind roller in a direction substantially transverse to the direction of winding of the roll of shrink sleeve material.