Winder with variable tension zones

Details Winder with variable tension zones Winder with variable tension zones

2001-02-14

2002-06-11

Jillions, John M. (Department: 3654)

Winding, tensioning, or guiding

Tension control or brake

Supply controlled

C242S419600, C242S530200, C242S538000

Reexamination Certificate

active

06402077

ABSTRACT:

FIELD OF THE INVENTION
The present invention is directed to a winder. More specifically, the present invention is directed to a method and apparatus for winding viscoelastic material in a manner to reduce distortion of the material after winding of the material onto a roll.
BACKGROUND OF THE INVENTION
Windup of tire components is an important part of the tire manufacturing process. It has obvious advantages such as in handling, storage, transportation and some tire machines are built to accept only wound components either spooled or rolled. However there are also disadvantages. If the wound component is a contoured component, as opposed to a flat sheet material, the component may become distorted in the winding/storage process. If the component is formed from a low rolling resistance material, the problem can worsen, as such material is very tacky and usually softer.
If distortion occurs when tire components such as belts and carcass materials are wound up, the ends-per-inch count of the wire may change and the material may have to be rejected. In other applications, if the components become crushed, separation from the liner becomes difficult, if not impossible. Calendered material may be distorted and flattened in the center of rolls and sometimes has to be cut away from the liner, wasting expensive liner, time, and material.
All of these problems share a common denominator-distortion due to pressure seen in the windup and storage process.
Center driven winders receive the energy to wind the roll by a motor that rotates a shaft connected to either the shell or the core of the roll. Winding tension is applied by pulling on either the support liner or the component wound on the liner or both. Winding tension control, that is, how the applied tension to the component being wound is varied as the package grows in size during winding, is critical in this type of winding setup.
FIG. 3
illustrates a prior art winding bay
10
. A winding platform
1
wheels
14
, has a base
16
of either an open square or two side frames upon which are two vertical support frames
18
,
20
. On each vertical support frame
18
,
20
is an axle
22
,
24
mounted rotatably on the frame
18
,
20
, and a roll
26
,
28
is mounted on each axle
22
,
24
. One roll
28
is the windup roll onto which a liner
30
and a stock material
32
are wound. The other roll
26
is the liner let-off roll off,of which the liner
30
is wound when the stock material
32
is wound onto the windup roll
28
and onto which the liner
30
is wound when stock material
32
is removed from the windup roll
28
. material
32
is wound onto the windup roll
28
and onto which the liner
30
is wound when stock material
32
is removed from the windup roll
28
.
Adjacent to the letoff roll side of the winding platform
12
is the let-off section
34
of the winding bay
10
, comprising a plurality of guide rolls. In the illustrated guide mechanism, the liner
30
passes over two top guide rolls
36
,
38
, through a guide
40
whose function is to spread and de-wrinkle the liner, and over guide rolls
42
,
44
. The liner
30
then passes under the winding platform
12
and about another pair of rolls
46
. After passing about guide roll
48
, the liner
30
then contacts the stock material
32
at roll
50
and is wound onto the windup roll
28
. The stock material
32
is also guided by rolls
52
,
54
before contacting the liner
30
.
The primary function of the tension in the liner
30
is to provide proper tracking, guiding, and de-wrinkling during winding. Due to other factors, e.g. misaligned rolls, bearings that are not freely turning, miswound support liners, higher winding tensions are needed to guide and de-wrinkle the liner
30
. To provide a high quality wind, one that imparts minimal damage to the wound component, the actual winding tension needed is low.
Thus, the liner
30
, during winding and unwinding, is subject to high tension. High winding tension is developed in the letoff section
34
of the winder
10
to provide sufficient tracking and de-wrinkling. This tension is carried into the windup roll
28
and into the stock material
32
being wound. The tension can be thought of as energy that is wound into the roll
28
. The dissipation of this energy occurs through the viscoelastic rubber of the stock material
32
, causing the stock material
32
to flow, resulting in distortion of the profiles and contours of the component, and sticking to the liner
30
.
SUMMARY OF THE INVENTION
The present invention is directed to a winding bay and a method of winding that overcomes the limitations of the known winders and winding systems and provides for a high quality wind in the winding bay, minimizing component distortion and stuck-to-liner problems.
Disclosed is a method of winding a viscoelastic material wherein the material and a supporting liner are to be wound onto a roll. The method includes unwinding a liner from a roll, guiding the liner under high tension, guiding the viscoelastic material onto the liner, and winding the viscoelastic material and the supporting liner onto a roll. Before guiding the viscoelastic material onto the liner, the tension in the liner is isolated reduce the tension in the liner.
In one aspect of the disclosed invention, passing the liner through a pair of nip rollers isolates the tension.
Also disclosed is a winding bay for winding a viscoelastic material and a supporting liner onto a roll. The winding bay has a let-off roll, a windup roll, and a plurality of guide rolls to guide the viscoelastic material and the supporting liner. A tension isolation device is located prior to the windup roll to reduce the tension in the liner prior to winding the material and the liner onto the windup roll.
In one aspect of the disclosed invention, the tension isolation device is a pair of nip rollers. In another disclosed aspect, the tension isolation device employs an “s” wrap or “omega” wrap geometry.


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