阅读说明：本技术 生产织物卷的方法和由此制成的卷 (Method for producing a roll of fabric and roll thus produced ) 是由 F·科努克格鲁 M·帕拉科博拉特 K·塞比 I·阿卡 K·T·伊矣多耿 M·欧兹德米尔 于 2019-09-11 设计创作，主要内容包括：通过将织物(4)围绕至少两个卷轴缠绕而生产织物卷,这些卷轴同轴对准,彼此间隔开,并且所具有的总长度(L)小于所述织物卷(11)的宽度(Wr)。(A roll of fabric is produced by winding the fabric (4) around at least two reels, which are coaxially aligned, spaced apart from each other and have a total length (L) less than the width (Wr) of the roll (11).)

1. A method of producing a fabric roll (11), wherein a fabric (4) is wound around a reel (T) to provide a roll (11), characterized in that the fabric (4) is wound around at least two reels, which are coaxially aligned and spaced apart from each other, having a total length (L) smaller than the width (Wr) of the fabric roll (11).

2. A method according to claim 1, characterized in that the reeling shaft is positioned at least at the end of the width of the roll to support the edge (9) of the fabric roll (11).

3. Method according to claim 1 or 2, characterized in that the length (L) of each reel_i) Is L₁、……、L_nAnd the sum of the lengths of the reelsLess than the width (Wr) of the roll (11)

4. A method according to claim 3, wherein the sum of the lengths of the spoolsIs at least 13% of the width (Wr) of the roll, preferably at least 40% of the width (Wr) of the roll.

5. The method according to any of the preceding claims, comprising a starting step, wherein the edge (7) of the fabric (4) is tensioned over its width and attached to the at least two reels.

6. The method according to any one of claims 1 to 4, comprising a starting step in which the edge (7) of the fabric (4) is tensioned over its width and manually wound at least once around the reel.

7. The method according to any one of claims 2 to 6, further comprising a reel spool (2) centrally positioned with respect to the width (Wr) of the fabric roll (11).

8. Method according to any of the preceding claims, characterized in that it comprises the following steps: a selection shaft (14); positioning the at least two reels (1-3) on the shaft such that the reels are spaced apart from each other and the shaft is inside the reels; -retaining the reel (1-3) in a selected position on the shaft (14); -winding the fabric (4) on the reel and on the shaft to provide a fabric roll (11); removing the shaft (14) from the reel, thereby retaining the reel in the fabric roll (11).

9. Method according to claim 8, characterized in that the shaft has a plurality of elements which are radially expandable with respect to the shaft axis to temporarily hold the reels (1-3) in the desired position.

10. The method of claim 9, wherein the shaft is a pneumatically actuated shaft and the element expands under pneumatic pressure.

11. A roll of fabric (11) comprising at least two spools around which the fabric is wound, the spools being coaxially aligned and spaced apart from each other, the at least two spools having a total length less than the width (Wr) of the roll of fabric.

12. The fabric roll (11) according to claim 11, characterized in that the reeling shaft is positioned at least at the ends of the width of the roll to support the edges (9) of the fabric roll (11).

13. The fabric roll (11) according to claim 11 or 12, characterized in that the length L of each reel is such that_iIs L₁、L₂、L_nAnd the sum of the lengths of the reelsLess than the width (Wr) of the roll (11)

14. A roll (11) of fabric according to claim 13, characterized in that the sum of the lengths of the winding shaftsIs at least 13% of the width (Wr) of the roll, preferably at least 40% of the width (Wr) of the roll.

15. The fabric roll (11) according to any of the claims 11 to 14, characterized in that the edge (7) of the fabric (4) in contact with the at least two reels is tensioned over its width and attached to the at least two reels.

16. The fabric roll (11) according to claim 15, characterized in that the fabric (4) is attached to the reel by means of a double-sided adhesive tape (14).

17. The fabric roll (11) according to any one of claims 12 to 16, further comprising a winding shaft centrally positioned with respect to the width (Wr) of the fabric roll (11).

18. Use of a plurality of reels in a process for producing a roll of fabric (11).

19. Reel system for a fabric roll (11) according to any one of claims 11 to 17, comprising a plurality of reels (L) for a single fabric roll (11).

Technical Field

The present invention relates to a method for producing a roll of fabric and to the roll of fabric thus obtained. More in detail, the present invention relates to a method of winding a fabric on a reel in a fabric production step.

Background

The fabric is typically stored and transported as rolls; in a roll, the fabric is wound or wrapped around a spool. Typically, the spools are selected to extend from one side of the web to the opposite side in order to support the web roll. The wrapping spools used in the web packaging process are of various lengths. The length of the reel spool may vary between 700mm and 2200mm depending on the width of the web to be wound on the reel spool.

Thus, in the known fabric wrapping step, rolls of fabric of different lengths (sizes) are produced. For each size of roll, a suitable reel is required; this results in the need to obtain different reels with different lengths to be used according to the width of the fabric web. Another problem with the known method is that the reel is usually made of cardboard or plastic, and the use of the reel results in the weight of the reel being added to the weight of the fabric roll. Another problem is that after the fabric has been unwound from the reel, the wrapping reel cannot be used any more; the used reels can thus become industrial waste or, if possible, they can be sent away (for example to a plastic recycling process) to recover their material.

Therefore, there is a need to solve the above problems and to provide a new method for producing rolls of fabric.

Disclosure of Invention

The object of the present invention is to solve the above problems. This object is achieved by a method for producing a roll of fabric according to claim 1. That is, the method of the present invention provides a method of producing a fabric roll in which a fabric web is wound (i.e. wrapped) around a spool to provide a roll, characterized in that the fabric is wound around at least two spools, the spools being coaxially aligned and spaced apart from each other, at least two spools having a total length that is less than the width of the fabric roll. Another object of the invention is a roll of fabric according to claim 8; that is, a roll of fabric is characterized by comprising at least two spools that are coaxial or substantially coaxially aligned and spaced apart from each other. As mentioned, the plurality of (at least two) reels replaces the single reel of the prior art in the fabric roll. The number of reels suitable for the present invention is at least two and also depends on the width of the reel, i.e. on the length of the reel to be used according to the prior art (which length will correspond to the width of the fabric, or the width of the roll).

In an embodiment, two reels are positioned at least at the ends of the width of the roll to support the edges of the fabric roll and to avoid that the fabric is not supported at the edges of the reels, which may easily damage the fabric. In more detail, the outer edge of the spool may be offset from the edge of the roll of fabric by a value of about 10cm, i.e., the edge or end of the spool may be spaced about 10cm from the edge of the roll of fabric; the offset may be towards the outside, i.e. the reel protrudes from the roll, or towards the inside of the roll, i.e. the outer edge of the reel is accommodated inside the roll. In an embodiment, the additional reel is centrally located with respect to the width of the fabric roll; in this embodiment, there will be two spools at the ends of the spool line (i.e. at the edges) and a further spool between the edge spools, which is preferably located centrally to the axis of the fabric roll.

Typically, when there are n spools (e.g., three spools, n being 1-3), the length L of each of the n spools₁To L_nThe sum (e.g. L)₁+L₂+L₃) Less than the transverse length of the roll, i.e., less than the width W. The above relationship can be summarized by the following formula:wherein L is_iIs the length of each of said reels, and the reels have n, i.e. n, reels of length L₁To L_nSum of (2)Less than the width (Wr) of the roll. In an embodiment, the sum of the lengths of the reelsIs at least 13% of the width Wr of the roll, preferably at least 40% of the width Wr of the roll. In the preferred embodiment, the length L₁－L_nSum of (2)Is 91% of the width Wr of the fabric, preferably 60% of the width Wr of the fabric, i.e. generally the relationship is

In an embodiment, the method comprises a starting step, wherein the edges of the fabric are attached to the at least two reels to avoid folds and wrinkles on the fabric; preferably, the fabric edge is tensioned across its width so as to remain attached to the spool and avoid deformation in the first wrap of fabric on the spool. In a similar embodiment, the initiating step comprises manually wrapping the web around a spool, preferably with the web tensioned to avoid the formation of creases and wrinkles.

Suitable materials for the reel are conventional materials for the purpose. Preferably, the reel is made of cardboard (natural fibers such as cellulose) and synthetic or synthetic materials (such as PP, PE, PET, ABS, rubber, PU, etc.). The material is selected according to its specific gravity, preferably a lightweight material. In order to make the reel lighter, the surface of the reel may have a porous structure, i.e. have a plurality of holes, or there may be a plurality of regions on the reel (i.e. portions of the reel) having a reduced thickness relative to the rest of the reel. In an embodiment, the total area of the holes or reduced thickness portions in the surface of the roller is 40% to 80%, preferably at least 60%, of the area of the surface of the roller. But the ratio may be between 0% and 90%.

Preferably, the reel of packages has at least one of the following features: the inner diameter of the reel is between 40 and 50 mm; the outside diameter of the reel is between 45 and 57 mm. The preferred range of reel thickness is 3-4 mm. The linear weight of the spool averaged 3 grams per centimeter (3 grams/cm).

In order to provide a high quality roll of fabric, the individual stub rolls must be aligned and the individual rolls must have the same circumferential movement as the roll of fabric during wrapping. Otherwise, quality defects may occur on the surface of the fabric roll. To provide smooth wrapping, wrapping equipment is used in positioning the stub roll. There are several commercially available products that can be used in the present invention; in the following, preferred devices and methods are disclosed and claimed in claims 8 to 10.

The number of spools to be used depends on the width of the fabric. The invention provides at least two reels, which are suitable for example for fabrics having a width of e.g. 700 mm. Larger fabrics, such as those having a width of 2200mm, may use three or four spools; thus, in embodiments, the number of spools used is in the range of 2 to 4. As mentioned before, the invention provides that the reels are spaced apart from each other, i.e. that two adjacent reels are spaced apart by a certain distance. The distance between two adjacent reels depends on the width Wr of the fabric, the number n of reels and their length L_i. For example, in a fabric having a fabric width Wr of 1000mm, the length of the roll is 200mm, and preferably 2 rolls are used; the reel is located ± 10cm from the edge of the roll. In this embodiment, the gap, i.e. the distance between two adjacent reels, is 1000- (200+200) ═ 600 mm; the possible offset of the reel edge with respect to the fabric side is 20cm to add to or subtract from the distance. In an embodiment where the web roll width Wr is 2200mm and three 200mm spools are used, the total gap is 2200- (200 x 3) 1600mm and the distance between adjacent spools is 1600/2 800 mm.

The present invention provides several advantages over the prior art. A first advantage is that the reel spool of the invention can have a reduced number of lengths, since two or more reel spools can be used depending on the width of the fabric web to be wound on the reel spool. The reduced number of reel types results in a significant reduction in the inventory costs of the package reels for the warehousing of fabric rolls of different widths. In addition, the roll of fabric is lighter in weight due to the shorter length of the reel; the transport costs of the packaged fabric roll can thus also be reduced. Finally, shorter reels result in a smaller amount of waste, thus providing sustainability without changing the quality of the packaging process.

Drawings

The invention will now be further described with reference to the accompanying schematic drawings in which:

figure 1 is a top view of a conventional reel and three reels according to the invention able to replace the conventional reel;

figure 2 is a perspective view of the three reels of figure 1 on a portion of fabric;

figure 3 is a partial perspective view of a fabric roll comprising an offset winding shaft;

figure 4 is a perspective view of a reel with a porous structure;

figures 5 to 7 are schematic views of the steps of positioning the reel on the pneumatic alignment shaft.

Detailed Description

Referring to FIG. 1, there is schematically shown a spool T having a length L suitable for use with a fabric having a width Wr_TA conventional reel. The roll T is a one-piece roll which can extend from one side or edge of the fabric 4, whereby the length of the roll T is the same or substantially the same as the width Wr of the fabric 4. In fig. 1, the reel system according to the invention is shown below the reel T. The reel system shown in fig. 1 has three reels 1-3, each having a length L₁、L₂、L₃(ii) a As immediately visible, length L₁+L₂+L₃Is less than the length L of the reel T_TAnd also less than the width Wr of the fabric web 4, which fabric web 4 is to be wound into a fabric roll with three reeling shafts 1-3 in the centre of the fabric roll.

Fig. 2 schematically shows the reeling shaft 1-3 of fig. 1, the reeling shaft 1-3 being positioned on the fabric 4 in an initial step of the method of the invention. The reels 1-3 are positioned so that the two outer reels and the fabric web areThe sides 5 and 6 of the 4 are aligned or slightly offset and the third reel 2 is located in the centre of the width of the fabric 4. Preferably, the arrangement of the reels is symmetrical or substantially symmetrical with respect to the longitudinal axis a-a of the fabric, with respect to said axis. The spools are coaxially or substantially coaxially aligned along the axis B-B of the roll 11 (fig. 2 and 3). The number of spools to be used depends on the width of the fabric. The present invention provides a minimum of two spools. In fig. 2, this embodiment has three reels 1, 2 and 3 spaced from each other, i.e. for the reels 1-2 two adjacent reels are marked D₁Are spaced apart, and for reels 2-3, by the reference D₂Are spaced apart. The distance between two adjacent reels depends on the width Wr of the fabric, the number n of reels and their length L_i。

As mentioned above, the preferred embodiment of the method provides the step of attaching the leading edge 7 of the fabric web 4 to a plurality of spools 1-3. This can be done by manually winding the edge 7 of the fabric onto the reel or by attaching the edge 7 of the fabric to the reels 1-3; for this purpose, the reels 1-3 are provided with suitable attachment means, preferably strips of double-sided adhesive tape 14.

In the embodiment of fig. 2, the two reels 1 and 3 are positioned at least at the ends of the width of the roll to support the edges of the fabric roll and to avoid that the fabric is not supported at the edges of the reels, which could easily damage the fabric. However, as can be seen in fig. 3, it is possible that the edges 10 of the reels 1 and 3 are offset from the edges 9 of the fabric roll 11 by a distance 8, which distance 8 has a value of at most about 10 cm. In other words, the edge or end 10 of the roll 1 may be spaced about 10cm from the edge or side 9 of the roll; the offset may be towards the outside, i.e. the reel protrudes from the roll as shown in fig. 3, or towards the inside of the roll 11, i.e. the outer edge 10 of the reel 1 is accommodated inside the roll 11.

Suitable materials for the reels are cardboard or similar materials of natural fibres, such as cellulose fibres, and artificial or synthetic materials, such as PP, PE, PET, ABS, rubber, PU. Lightweight materials are preferred. In order to make the reel lighter, the surface of the reel may have a porous structure as shown in fig. 4, i.e. have a plurality of holes, or there may be a plurality of regions on the reel (i.e. parts of the reel) having a reduced thickness relative to the rest of the reel. In the embodiment of fig. 4, the reel 1 is provided with a plurality of through holes 12. The total area of the holes or the total area of the reduced thickness portions in the surface of the spool may be in the range 40% to 80%, preferably at least 60%, of the area of the outer surface 13 of the spool 1. The ratio may be in the range between 0% and 90%.

In another embodiment, the method may include the use of an alignment shaft to ensure optimal condition and coaxial alignment between the spools to facilitate the desired positioning and spacing of the spools for each fabric roll. The cross-sectional diameter of the alignment shaft is smaller than the inner diameter of the spool to allow insertion of the shaft into the spool. At least a portion of the outer surface of the shaft is configured to radially expand to increase its outer diameter and thereby engage the inner surface of the spool to hold them in a desired position. The shaft is preferably a pneumatic shaft, wherein at least a portion of the surface or at least one element arranged on said surface is capable of providing the required radial expansion by feeding pressurized air into the shaft.

As shown in fig. 5, the pneumatic shaft 14 positions the spools 1, 2 and 3 coaxially spaced from one another as required, and in particular for the two outermost spools 1 and 3 (one at each end of the shaft 14), the spools 1 and 3 are positioned at the two side edges of the fabric 11 as previously described.

The shaft 14 has a tubular body with longitudinal elements or tabs on its circumferential outer surface, which extend in the length direction parallel to its longitudinal axis (see fig. 5 and 6). The pneumatic shaft 14 has a gas-tight hollow core, the circumferential wall of which has the following means: this arrangement allows the pneumatic shaft 14 to expand radially once air is fed under pressure into the interior of its hollow core. This is preferred.

Thus, the method involving the use of the pneumatic spindle 14 implies the following steps for mounting the reels 1-3:

sequentially positioning the reels along the pneumatic shaft 14, spaced as required (see fig. 7);

pressurizing the pneumatic shaft 14 with air under pressure to allow radial expansion of the shaft, preferably by radial expansion of the longitudinal element 15 of the pneumatic shaft 14, so as to lock the previously installed reels 1-3 in position. To this end, it should be noted that any circumferential sliding between the reels 1, 2 and 3 and the shaft 14 is minimized by the circumferential contact between the elements 15 of the shaft 14 and the reels 1-3. Similarly, longitudinal movement of the spools 1-3 is prevented due to the rigidity of each spool core;

inserting the pneumatic shaft 14 into the winding module of the fabric winding machine ready for the production process of the fabric roll.

The method then has a second stage involving winding the fabric 11 according to the following steps:

-starting winding the fabric 11 at a speed in the range of 5-25 m/min, preferably at a speed of about 10 m/min and winding the desired length of fabric 11 on reels 1, 2 and 3 mounted on a pneumatic shaft 14;

ending the winding operation and evacuating air from inside the core of the pneumatic shaft 14;

extracting the pneumatic shaft 14 (which has recovered its nominal diameter) from the core of the fabric roll 11;

at the end of the process, the reels remain in the core of the roll, i.e. they remain in a selected position on the shaft, which is in fact the desired position of the reels with respect to the width of the roll. The spools are coaxially aligned and held in this aligned and spaced position by the rigidity of the overall structure of the spools.