Method and Apparatus For Producing Coreless Roll Products

Abstract

A coreless log of convolutely wound web material is formed by directing the web around an applicator roller that is in contact with a first surface of the web. An additive is transferred from a supply roller to the applicator roller over a first distance of the web and stopped over a second distance of the web. The web is directed around at least one further roller that is in contact with the second surface of the web that is opposite the first surface. The web is then wound around an elongated mandrel. The first distance of the web comprises a first set of windings nearest the center of the log, and the second distance of the web comprises a second set of windings wound around and extending radially outward from the first set of windings. The mandrel may then be removed to form the coreless log.

1 . A rewinder for winding a web of material about a mandrel into a roll of convolutely wound web material, the rewinder comprising:
 a first winding drum;   a second winding drum opposite the first winding drum;   an applicator roller configured to engage a first surface of the web;   at least one further roller opposite the applicator roller configured to engage a second surface of the web that is opposite of the first side of the web, the at least one further roller being configured to direct the web between a nip formed between the upper winding drum and the lower winding drum in which the roll of convolutely wound web material is wound;   a supply roller opposite the applicator roller, the supply roller being configured to meter a supply of an additive to the applicator roll; and   wherein the applicator roller is configured to apply the supply of the additive to the first side of the web over a first distance of the web material and the applicator roller is configured to cease applying the supply of the additive to the first side of the web over a second distance of the web material,   wherein when the web is wound around the mandrel into the roll, the first distance of the web material comprises a first set of windings nearest the center of the roll, and wherein the second distance of the web material comprises a second set of windings wound around the first set of windings and extending radially outward from the first set of windings; and   wherein when the web is wound around the mandrel into the roll, the mandrel is removable from the roll after the roll is formed.   
     
     
         2 . The rewinder of  claim 1  wherein the supply roller is an anilox roller. 
     
     
         3 . The rewinder of  claim 2  further comprising a doctor chamber configured to meter the additive onto a peripheral surface of the anilox roller. 
     
     
         4 . The rewinder of  claim 1  wherein the at least one further roller comprises a draw roller. 
     
     
         5 . The rewinder of  claim 1  wherein the supply roll is configured for pivoting motion relative to the applicator roller between a supplying position and withholding position, wherein in the supplying position, the supply roller pivots sufficiently adjacent to the applicator roller to meter the supply of the additive to applicator roller over the first distance of the web material and wherein in the withholding position, the supply roller pivots sufficiently away from the applicator roller so as to withhold the supply of the additive from the supply roller to the applicator roller over the second distance of the web. 
     
     
         6 . The rewinder of  claim 5  wherein a source of the supply of the additive is configured to pivot together with the supply roller between the supplying position and the withholding position of the supply roller. 
     
     
         7 . The rewinder of  claim 5  wherein the supply roller is one in a plurality of supply rollers each opposite the applicator roller and configured to meter the supply the additive to the applicator roller. 
     
     
         8 . The rewinder of  claim 1  wherein the applicator roller and the supply roller are configured for pivoting motion together relative to the web between a supplying position and withholding position, wherein in the supplying position, the applicator roller pivots sufficiently adjacent to the first side of the web to apply the supply of the additive to applicator roller over the first distance of the web material and wherein in the withholding position, the applicator roller pivots sufficiently away from the first side of the web so as to cease applying the supply of the additive over the second distance of the web. 
     
     
         9 . The rewinder of  claim 8  wherein a source of the supply of the additive is configured to pivot together with the applicator roller and the supply roller between the supplying position and the withholding position of the applicator roller and the supply roller. 
     
     
         10 . The rewinder of  claim 8  wherein the supply roller is one in a plurality of supply rollers each opposite the applicator roller and configured to meter the supply the additive to the applicator roller. 
     
     
         11 . The rewinder of  claim 1  further comprising a secondary applicator opposite the applicator roller configured to engage the second side of the web. 
     
     
         12 . The rewinder of  claim 11  wherein the secondary applicator includes an actuator, the actuator is configured to actuate the secondary applicator to engage the second side of the web during the first distance of the web material and the actuator is configured to disengage from the second side of the web over the second distance of the web material. 
     
     
         13 . The rewinder of  claim 11  wherein the secondary applicator includes a brush operatively connected with the actuator. 
     
     
         14 . The rewinder of  claim 1  wherein the additive comprises at least one of a hole reinforcement agent, aqueous solutions of adhesive, aqueous solutions of polyanions, solutions of polycations, aqueous solutions of cationic starches, aqueous solutions of anionic starches, aqueous solutions or dispersions of inorganic cationic fillers, and aqueous solutions or dispersions of inorganic cationic nanofillers. 
     
     
         15 . (canceled) 
     
     
         16 . A method of forming a log of convolutely wound web material, the web material comprising a first surface and an opposite second surface, the method comprising the steps of:
 a. directing the web material around an applicator roller, wherein the applicator roller is in contact with the first surface of the web material;   b. metering an additive onto a peripheral surface of a supply roller;   C. transferring the additive from the supply roller to the applicator roller over a first distance of the web material;   d. ceasing to transfer the additive from the supply roller to the applicator roller over a second distance of the web material;   e. directing the web material around at least one further roller, wherein the at least one further roller is in contact with the second surface of the web material;   f. winding the web material around an elongated mandrel to form the log of convolutely wound web material, wherein the first distance of the web material comprises a first set of windings nearest the center of the log, and wherein the second distance of the web material comprises a second set of windings wound around the first set of windings and extending radially outward from the first set of windings; and   g. removing the mandrel from the log.   
     
     
         17 . The method of  claim 16  wherein the supply roller is an anilox roller. 
     
     
         18 . The method of  claim 17  wherein the step of metering the additive comprises metering the additive onto a peripheral surface of the anilox roller with a doctor chamber. 
     
     
         19 - 32 . (canceled) 
     
     
         33 . A method of installing an additive applicator on a rewinder, the method comprising:
 removing an upper outfeed draw roller from the rewinder;   installing an applicator roller in place of the upper outfeed draw roller;   adjacent to the applicator roller, installing the additive applicator, wherein the additive applicator is adapted and configured to alternatingly transfer an additive from a supply roller to the applicator roller over a first distance of a web material passing through the rewinder and cease to transfer the additive from the supply roller to the applicator roller over a second distance of the web material such that when the web material is directed through the rewinder and wound around an elongated mandrel to form a log of convolutely wound web material, the first distance of the web material comprises a first set of windings nearest the center of the log, and the second distance of the web material comprises a second set of windings wound around the first set of windings and extending radially outward from the first set of windings.   
     
     
         34 . The method of  claim 33  wherein the supply roller is an anilox roller. 
     
     
         35 . The method of  claim 34  wherein the additive applicator comprises a doctor chamber adapted and configured to meter the additive onto the anilox roller. 
     
     
         36 - 51 . (canceled)