Methods and apparatus for a turn-up procedure using an adhesive composite sheet

Abstract

Methods and apparatus to form tear-off composite adhesive sheets that adhesively attach a paper web to an empty web spool. In some embodiments, the composite adhesive sheet is applied in several layers to an empty web spool, each layer suitable for fixedly attaching a paper web to the empty spool. Multiple layers of composite adhesive sheet allow for use during multiple turn-up procedures with one layer of composite adhesive sheet used per turn-up procedure. In some examples, the composite adhesive sheet may be applied to a paper spool tangentially along the spool face and perpendicular to the axis of rotation of the spool. In other examples, the composite adhesive sheet may be spirally wrapped around the paper spool.

What is claimed is: 
     
         1 . A method of transferring a paper web from a full web spool to an empty web spool, the method comprising the steps of:
 winding a composite adhesive sheet onto a first spool face of the empty web spool, the composite adhesive sheet comprising a spool face adhesive and a first paperweb adhesive;   fixedly attaching the composite adhesive sheet to the first spool face with the spool face adhesive;   rotating the empty web spool and the composite adhesive sheet at a rotational speed approximate to a rotational speed of a surface of a paperweb being wound on a first full web spool;   contacting the paperweb with a first quantity of the first paperweb adhesive included in the composite adhesive sheet;   adhesively binding a first portion of the paperweb to the empty web spool with the first quantity of the first paperweb adhesive;   performing a turn-up process causing a first volume of paper web to spool on the empty web spool;   unwinding the first volume of paper web from the spool; and   removing a tear away strip to separate a first portion of the composite adhesive sheet from a second portion of the composite adhesive sheet.   
     
     
         2 . The method of  claim 1  further comprising:
 spooling the first volume of paper web onto the empty web spool to form a second full web spool; 
 transferring the second full web spool to a paper processing apparatus; 
 unspooling a first volume of paperweb from the second full web spool to convert the second full web spool back into the empty web spool; 
 removing a first quantity of paperweb adhesive and the corresponding composite adhesive sheet from the empty web spool to expose a second quantity of paperweb adhesive; 
 adhesively binding a second portion of the paperweb to the second quantity of paperweb adhesive while the empty web spool is rotating; and 
 performing a second turn-up process causing a second volume of paper web to spool on the empty web spool. 
 
     
     
         3 . The method of  claim 2  wherein the composite adhesive sheet further comprises a plurality of perforations, and the step of removing the first quantity of paperweb adhesive and corresponding composite adhesive sheet from the empty web spool comprises tearing the composite adhesive sheet along the plurality of perforations. 
     
     
         4 . The method of  claim 3  wherein the step of removing the first quantity of paperweb adhesive and corresponding composite adhesive sheet follows the unspooling of the first volume of paperweb from the second full web spool and before the step of performing the second turn-up process. 
     
     
         5 . The method of  claim 1  wherein the composite adhesive sheet comprises a width equal to or less than a width of a spool face of the empty web spool and the composite adhesive sheet is wrapped approximately perpendicular to an axis of the empty web spool. 
     
     
         6 . The method of  claim 1  wherein the composite adhesive sheet is wrapped in a spiral fashion around the empty web spool. 
     
     
         7 . The method of  claim 6  wherein the composite adhesive sheet is formed with an angular cut out at an initial edge the method additionally comprises the step of aligning the angular cut out with an axis of the empty web spool. 
     
     
         8 . The method of  claim 7  additionally comprising the step of determining a desired spiral shape of a wrap in the spiral fashion. 
     
     
         9 . A composite adhesive sheet comprising:
 a substrate formable for wrapping around an empty web spool, a length of the substrate sufficient to wrap the substrate around an empty web spool multiple times;   a first zone coated region comprising a spool face adhesive on a first side of the substrate;   a second zone coated region comprising a release coating of the first side of the substrate, the second zone coated region occupying a majority of the first side of the substrate that is not included in the first zone coated region;   a paper web adhesive coating on a second side of the substrate, the paper web adhesive coating comprising an adhesive comprising sufficient binding strength to burst a paper web being spooled on a full web spool; and   a tear away strip laterally positioned across the substrate.   
     
     
         10 . The composite adhesive sheet of  claim 9  further comprising multiple perforations, wherein the multiple perforations are spaced such that when the composite adhesive sheet is wrapped upon a paper spool there is a perforation at each layer of wrapping. 
     
     
         11 . The composite adhesive sheet of  claim 10  wherein a spacing between the multiple perforations is not equal to a circumference of the empty web spool. 
     
     
         12 . The composite adhesive sheet of  claim 9 , further comprising an angular cut-out at an end of the composite adhesive sheet, the angular cutout placeable upon the empty web spool to start a winding of the composite adhesive sheet onto the empty web spool. 
     
     
         13 . The composite adhesive sheet of  claim 12  wherein the angular cut-out aligns the composite adhesive sheet in a position to start a winding of the composite adhesive sheet onto the empty web spool in a spiral pattern. 
     
     
         14 . The composite adhesive sheet of  claim 9  wherein the spool face adhesive has a tensile strength sufficient to hold the composite adhesive sheet in place on the empty web spool but not sufficient to cause damage of a spool face when the composite adhesive sheet is removed. 
     
     
         15 . The composite adhesive sheet of  claim 9  wherein the paper web adhesive coating forms a bond comprising a tensile strength sufficient to adhere to the paper web during a turn-up operation and adhere a wrapped composite adhesive sheet to the empty web spool when the composite adhesive sheet is torn along a perforation in the composite adhesive sheet. 
     
     
         16 . A method of preparing a turn-up composite adhesive sheet, the method comprising
 cutting a substrate to a width target comprising a width of a spool face reduced by a margin distance for one or both ends, and a length based on a number of desired wraps of substrate around the spool face multiplied by a circumference of a paper spool;   applying a spool face adhesive to a length of a first side of the substrate equal to or less than a circumference of the spool face;   applying a release formulation to an uncoated portion of the first side of the substrate; and   applying a paper web adhesive to a second side of the substrate.   
     
     
         17 . The method of preparing a turn-up composite adhesive sheet of  claim 16  further comprising:
 cutting an edge of the substrate at an angle to a side edge to form a start of the turn-up composite adhesive sheet that may be applied to the spool face. 
 
     
     
         18 . A method of preparing a turn-up composite adhesive sheet, the method comprising cutting a substrate layer to a width target calculated as a fraction of a width of a spool face reduced by a margin distance for each end, and a target length based upon a number of desired wraps of the substrate layer around the spool face multiplied by a circumference of the spool face;
 applying a length of spool face adhesive to a first side of the substrate layer based on the circumference of a paper spool;   applying a release formulation to at least a portion of an uncoated part of the first side of the substrate layer; and   applying a web grabbing adhesive formulation to a second side of the substrate layer.   
     
     
         19 . The method of preparing a turn-up composite adhesive sheet of  claim 18  further comprising:
 cutting the substrate layer at an edge at an angle to an adjacent side edge, wherein the angle creates a new edge of the turn-up composite adhesive sheet that may be applied to the paper spool. 
 
     
     
         20 . The method of preparing a turn-up composite adhesive sheet of  claim 19  further comprising:
 cutting a perforation along a body of the substrate layer, wherein a direction of the perforation is aligned to the angle of the new edge of the turn-up composite adhesive sheet.