Web spreader rollers and methods for reducing wrinkles in web material using such web spreader rollers

Abstract

Web spreader rollers and methods for reducing wrinkles in web material using such web spreader rollers are provided. In one embodiment, a web spreader roller includes a body having a first end including a plurality of slits about a perimeter of the first end. Each of the plurality of slits is substantially parallel to a longitudinal axis of the body and define an adjustable taper portion of the first end of the body. The web spreader roller also includes a plug positioned within the first end. The plug is movable relative to the first end to move the adjustable taper portion from a first tapered position to a second tapered position.

What is claimed is: 
     
         1 . A web spreader roller comprising:
 a body having a first end including a plurality of slits about a perimeter of the first end, each of the plurality of slits substantially parallel to a longitudinal axis of the body and defining an adjustable taper portion of the first end of the body; and   a plug positioned within the first end and movable relative to the first end to move the adjustable taper portion from a first tapered position to a second tapered position.   
     
     
         2 . The web spreader roller of  claim 1 , wherein the body is hollow, and the web spreader roller further comprises a shaft including an end plate received within the body and coupled to the first end. 
     
     
         3 . The web spreader roller of  claim 2 , wherein each of the plurality of slits are defined from a distalmost end of the first end to a position adjacent to the end plate. 
     
     
         4 . The web spreader roller of  claim 2 , wherein the plug is movable relative to the shaft. 
     
     
         5 . The web spreader roller of  claim 4 , wherein the plug includes a central bore defining a first plurality of threads and the shaft includes a portion defining a second plurality of threads, and the plug moves relative to the shaft via the engagement between the first plurality of threads and the second plurality of threads. 
     
     
         6 . The web spreader roller of  claim 1 , wherein in the first tapered position, the adjustable taper portion has a negative slope, and in the second tapered position, the adjustable taper portion has a slope of about zero. 
     
     
         7 . The web spreader roller of  claim 1 , wherein the plug is movable relative to the first end to a third tapered position. 
     
     
         8 . The web spreader roller of  claim 7 , wherein in the third tapered position, the adjustable tapered portion has a positive slope. 
     
     
         9 . The web spreader roller of  claim 5 , wherein the plug includes a handle for moving the plug relative to the shaft. 
     
     
         10 . The web spreader roller of  claim 1 , further comprising a motor coupled to the plug that moves the plug relative to the shaft. 
     
     
         11 . The web spreader roller of  claim 10 , further comprising:
 a user input device that receives user input; and   a control module in communication with the motor that outputs one or more control signals to the motor to move the plug relative to the shaft based on the user input.   
     
     
         12 . The web spreader roller of  claim 1 , wherein the body has a second end, and a second adjustable taper portion is coupled to the second end. 
     
     
         13 . The web spreader roller of  claim 1 , wherein the first end of the body further comprises a covering sleeve positionable over the adjustable taper portion. 
     
     
         14 . The web spreader roller of  claim 1 , wherein in the first tapered position, the first end has a first diameter, and in the second tapered position, the first end has a second diameter, with the second diameter different than the first diameter. 
     
     
         15 . A method for reducing wrinkles in a web material, the method comprising the steps of:
 feeding a web material to a web spreader roller, the web spreader roller including a first end with a shaft and a plug movable relative to the shaft, the first end including a plurality of slits defined about a perimeter of the first end extending substantially parallel to the longitudinal axis of the body; and   moving the plug relative to the shaft in a direction substantially parallel to a longitudinal axis of the web spreader roller to adjust a taper of the first end.   
     
     
         16 . The method of  claim 15 , wherein the plug includes a central bore having a plurality of threads that engage a plurality of threads formed on the shaft, and the method further comprises:
 threadably advancing the plug on the shaft from a first position, in which the first end has a first taper, to a second position, in which the first end has a second taper, the second taper different from the first taper.   
     
     
         17 . The method of  claim 16 , wherein the plug is threadably advanced by a motor. 
     
     
         18 . A web spreader roller, comprising:
 a hollow body extending along a longitudinal axis and having a first end opposite a second end;   a shaft coupled to each of the first end and the second end such that the shaft is at least partially received within the hollow body at the first end and the second end, the shaft extending along the longitudinal axis of the hollow body;   a first plug movably coupled to the shaft of the first end, the first plug positioned within the first end; and   a second plug movably coupled to the shaft of the second end, the second plug positioned within the second end,   wherein the first plug and the second plug are movable relative to the shaft in a direction parallel to the longitudinal axis to adjust a taper associated with a respective one of the first end and the second end.   
     
     
         19 . The web spreader roller of  claim 18 , wherein the body has an exterior surface and an interior surface, with a tapered surface formed on the interior surface, and the plug moves along the tapered surface to adjust the taper. 
     
     
         20 . The web spreader roller of  claim 18 , wherein each of the first end and the second end includes a plurality of slits about a perimeter of the first end and the second end, and each of the plurality of slits are defined substantially parallel to the longitudinal axis of the body to enable the movement of the plug relative to the shaft.