Web Splicer

Abstract

An apparatus (100) is provided for splicing a patterned web (108). The apparatus includes first and second unwind spindles (110, 114) that respectively engage a new roll (112) of patterned web (108) and a finished roll (116) of patterned web, a first web indexing mechanism (104) capable of linearly translating the patterned web from the new roll (112) along its direction of travel, a first clamping surface (129) extending across the patterned web from the new roll, a second clamping surface (131) extending across the patterned web from the finished roll (116), and a cutting mechanism (132, 132') for cutting the patterned web from the finished roll (116). The apparatus further includes a second web indexing mechanism capable of linearly translating the patterned web from the finish roll along its direction of travel, the first and second web indexing mechanisms being independently operable to align registration features of the patterned web on the new roll and the finish roll with respect to one another. The first and second clamping surfaces can be brought together to create an aligned splice of the patterned web between the new roll and the finish roll.

Description

[Technical field]

[0001] A mechanism and method are provided for splicing continuously produced webs. [Background technology]

[0002] In the manufacturing process of a continuous web, it is often necessary to splice the end of a web from an expiring roll with the leading end of a web from a new roll. According to a known method, the expiring web and the new web are passed between a pair of rollers that are aligned to contact a portion of the expiring web with a portion of the new web and then splice them together by superimposing a suitable adhesive between them. In the case of an overlap splice, this adhesive may be provided by a double-sided adhesive tape that has been manually pre-applied by the operator to the leading end of the new web. Summary of the Invention

[0003] The manufacturing process may use a variety of web splicing equipment with varying degrees of automation. However, unique product specifications and requirements can present challenges in reliably splicing different webs. One of these challenges relates to web alignment for webs with repeating visual patterns used for decorative and / or functional purposes. Products produced on a converting line may contain precisely located patterns and / or images on the product itself or its packaging. There are productivity and waste reduction benefits to splicing these incoming webs such that the pattern / image on the web from the ending roll is precisely aligned with the pattern / image on the web of the new incoming roll. Two webs aligned and spliced ​​in this manner are known as an aligned splice. There is a significant technical advantage in automatically creating an aligned splice with minimal or no interruption to the web manufacturing process to maximize throughput and reduce costs.

[0004] In a first aspect, an apparatus for splicing a patterned web is provided. The apparatus includes first and second unwind spindles engaging a new roll of patterned web and a finish roll of patterned web, respectively, a first web indexing mechanism capable of linearly translating the patterned web from the new roll along its direction of travel, a first clamping surface extending across the patterned web from the new roll, a second clamping surface extending across the patterned web from the finish roll, a cutting mechanism for cutting the patterned web from the finish roll, and a second web indexing mechanism capable of linearly translating the patterned web from the finish roll along its direction of travel. The first and second web indexing mechanisms are independently operable to align patterned web registration features on the new roll and the finish roll with one another, thereby allowing the first and second clamping surfaces to mate to create an aligned splice of the patterned web between the new roll and the finish roll.

[0005] In a second aspect, a method is provided for splicing a patterned web, the method including: using a first web indexing mechanism to position a first segment of the patterned web from a new roll between opposing first and second clamping surfaces at a first aligned position; using a second web indexing mechanism to position a second segment of the patterned web from a finished roll between opposing first and second clamping surfaces at a second aligned position; bringing the first and second clamping surfaces together to create an aligned splice; and using a cutting mechanism to cut the patterned web from the finished roll upstream of the aligned splice. [Brief description of the drawings]

[0006] [Figure 1]FIG. 1 is a front view of an apparatus for splicing a continuous web according to a first exemplary embodiment. [Diagram 2] FIG. 2 is a partial view showing modules within the apparatus of FIG. 1 in preparation for a splicing operation. [Diagram 3] 3 is a fragmentary view similar to that of FIG. 2, but showing the splicing operation being performed; [Figure 4] FIG. 2 is a front view of an apparatus for splicing a continuous web according to a second exemplary embodiment. [Diagram 5] FIG. 5 is a partial view showing a module within the device of FIG. 4.

[0007] Repeat use of reference characters in the specification and drawings is intended to represent the same or similar features or elements of the present disclosure. It is to be understood that those skilled in the art can devise numerous other modifications and embodiments that are within the scope and spirit of the principles of the present disclosure. The figures may not be drawn to scale. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] As used herein, the terms "preferred" and "preferably" refer to embodiments described herein that may offer certain advantages, under certain circumstances, although other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, nor is it intended to exclude other embodiments from the scope of the invention.

[0009] As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to an element followed by "a" or "the" may include one or more of the element and equivalents thereof known to those skilled in the art. Furthermore, the term "and / or" refers to one or all of the listed elements or a combination of any two or more of the listed elements.

[0010] It should be noted that the term "comprises" and variations thereof do not have a limiting meaning when these terms appear in the accompanying description. Furthermore, "a", "an", "the", "at least one" and "one or more" are used interchangeably herein. Relative terms such as left, right, front, rear, top, bottom, side, above, below, horizontal, vertical, etc. may be used herein, when taken from the perspective seen in a particular drawing. However, these terms are used merely for ease of description and in no way limit the scope of the invention.

[0011] Throughout this specification, references to "one embodiment," "a particular embodiment," "one or more embodiments," or "an embodiment" mean that a particular feature, structure, material, or characteristic described with respect to that embodiment is included in at least one embodiment of the invention. Thus, the appearances of phrases such as "in one or more embodiments," "in a particular embodiment," "in one embodiment," or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment of the invention. Where applicable, product names are written in all capital letters.

[0012] An apparatus is provided that can provide an aligned splice of two sections of a continuous web. Advantageously, the process can be performed automatically or semi-automatically. Useful applications of the apparatus and process include the manufacture or processing of any web-based product that can have a patterned exterior surface. Such webs can be used in adhesive-backed tapes, patterned films, reflective sheeting, commercial laminates, and graphic wraps. Depending on the application, the pattern present on the web can be decorative, functional, or both.

[0013] To minimize waste generated as a result of the splice, it is desirable for the equipment used to splice new rolls of material while maintaining the pattern. Splices made using conventional methods typically produce a few rejected parts. However, if alignment is not maintained, the equipment may produce a large number of rejected parts, depending on the size of the parts in question. A second, potentially larger impact is that if alignment is not maintained in some processes, significant downtime in the manufacturing process may occur as a result of jamming caused in a die module located downstream of the splicer or the web tearing from the machine.

[0014] An exemplary apparatus for splicing a patterned web is shown in Figure 1 and is referred to herein by the numeral 100. The apparatus 100 includes various subassemblies including a splicing module 102, a web indexing mechanism 104, and a web accumulator 106. Also as shown in Figure 1, a continuous patterned web 108 moves through the aforementioned subassemblies in the same order as listed above.

[0015] The splicing module 102, web indexing mechanism 104, and web accumulator 106 cooperate to provide a configuration that allows the web 108 to be continuously fed through the apparatus 100 at a constant line speed before, during, and after splicing. Advantageously, this configuration helps to eliminate the need for interruptions during the manufacturing or conversion process, maximizing throughput, reducing waste, and lowering production costs.

[0016] Within the apparatus, the splicing module 102 includes a first spindle from which the web 108 is unwound and spliced. A web indexing mechanism 104 disposed downstream of the splicing module 102 engages and pulls the web 108 from the splicing module 102 at a predetermined speed, which is not particularly limited and can be controlled by a computer, such as a programmable logic controller (PLC), operably coupled to the web indexing mechanism 104.

[0017] The web indexing mechanism 104 can operate using any known method to engage and move a continuous web with minimal speed variation. In a preferred embodiment, the web indexing mechanism 104 is comprised of a pull nip. The pull nip is comprised of a pair of nip rollers that are pressed together to grip and pull the web 108 from the splicing module in a controlled manner. At least one of the nip rollers is typically made from a low durometer material (e.g., rubber) so that the roller maintains good contact with the web 108 and avoids slippage. A motor is typically engaged to the PLC to drive the nip rollers and advance the web 108 on demand.

[0018] 1, the web indexing mechanism 104 also includes a top alignment sensor 109. The top alignment sensor 109 is capable of detecting one or more alignment features on the web 108. This capability can then be used to assist the web indexing mechanism 104 in adjusting the position of the web 108 to a precise predetermined location when creating an aligned splice of the web 108. The top alignment sensor 109 and its operation are described in more detail below.

[0019] A web accumulator 106 is positioned downstream of the web to allow core changes and web splicing to occur while the manufacturing or converting process continues at a constant line speed. The web accumulator can have any known configuration. Festoon-type web accumulators as shown in FIG. 1 are most common, although others, such as horizontal coil accumulators, are possible.

[0020] 2 illustrates features of the splicing module 102 in greater detail. As shown, the splicing module 102 includes a first unwind spindle 110 and a second unwind spindle 114. A new roll 112 of web 108' is attached to the first unwind spindle 110, and a finish roll 116 of web 108 is attached to the second unwind spindle 114. The web 108' from the new roll 112 to be spliced ​​to the web 108 is guided around a lower idler roll 118, an upper idler roll 122, and has an end segment secured to a first clamping surface 129.

[0021] It should be noted here, for clarity, that the term "patterned web" can be used to refer to the patterned web from a new roll, the patterned web from a finished roll, or both. Where applicable, reference numbers 108 and 108' distinguish between those portions of the patterned web that ultimately become one and the same after being spliced ​​together.

[0022] The web 108 from the finishing roll 116 is guided around the lower idler roll 120, past the upper idler roll 124, past the second clamping surface 131, additional idler rolls, and finally fed into the web indexing mechanism 104 (located above the splicing module 102 and not shown in FIG. 2). In this embodiment, the web 108 does not contact the second clamping surface 131. However, sliding contact between these bodies is permitted as long as such contact does not impede transport of the web 108 through the splicing module 102.

[0023] 2, the splicing module 102 is further assisted by a second web indexing mechanism. Optionally, this second indexing mechanism is provided by a retention nip 126 including an arm 127 extending upwardly from a pivot joint 128 and terminating in a pressure roll 130. Upon request, a PLC or other computer can rotate the arm either clockwise or counterclockwise about the pivot joint 128 to pinch the webs 108', 108 between the pressure roll 130 and the respective upper idler rolls 122, 124.

[0024] The splicing module 102 further includes a pair of cutting mechanisms 132, 132' located downstream of the holding nip 126 and upstream of the first and second clamping surfaces 129, 131. The cutting mechanisms 132, 132' are configured to cut the respective webs 108, 108' on demand and can be electronically controlled by a computer. In a simple embodiment, the cutting mechanisms 132, 132' consist of a physical blade capable of slicing the webs 108, 108' perpendicular to the direction of web travel (and perpendicular to the plane of the paper in FIG. 2). Although not shown here, it is possible to use a single cutting mechanism capable of selectively cutting either the web 108 or the web 108'. Cutting mechanisms based on other principles are also possible for certain applications, including those using lasers or high-pressure water jets.

[0025] Advantageously, the clamping surfaces 129, 131, the holding nip 126 and the cutting mechanism 132, 132' are components of a registration carriage 140. The registration carriage 140 is operatively coupled to a motor that allows these components to translate collectively along the direction of web movement while having a fixed position relative to each other. Here, in the figures, the direction of translation is upwards or downwards. The translation of the registration carriage 140 occurs relative to the stationary components of the splicing module 102, in particular the first and second unwind spindles 110, 114 and the lower idler rolls 118, 120. As shown in FIG. 2, the registration carriage can move along a direction that is at a slight angle to the web movement direction, and these directions do not have to be exactly parallel to each other.

[0026] Adjacent to the webs 108, 108' are lower alignment sensors 141, 143, which are located downstream of the first and second unwind spindles 110, 114 and upstream of the lower idler rolls 118, 120. However, it should be understood that this particular configuration is exemplary only, and that the lower alignment sensors 141, 143 can achieve their purpose when fixed in any of a number of locations upstream of the alignment carriage 140. Additionally, the upper alignment sensor 109 can be located in any location downstream of the alignment carriage 140. Thus, both the upper alignment sensor 109 and the lower alignment sensors 141, 143 move independently of the alignment carriage 140.

[0027] 3 shows the splicing module 102 in the process of a splicing operation, the steps of which are described below with reference to both FIG.

[0028] First, the web 108' is fed from a new roll 112 on the first unwind spindle 110 and threaded to the first clamping surface 129. An end segment of the web 108' can be attached to the first clamping surface 129 using a single-sided adhesive tape 150 (also shown in FIG. 2), with the adhesive-coated side of the single-sided adhesive tape facing the opposing second clamping surface 131. The adhesive tape 150 extends slightly beyond the end segment of the web 108' such that a portion of the adhesive is directly adhered to the web 108' while the remainder of the adhesive remains exposed, as shown in FIG. 2. The adhesive tape 150 itself can be secured to the first clamping surface 129 pneumatically (e.g., by suction), using a temporary adhesive, clips, or any other reversible securing mechanism. In an exemplary embodiment, this step is performed manually by an operator, although this step can be automated if desired.

[0029] With the end segment of the web 108' secured to the first clamping surface 129, the retention nip 126 can be moved leftward to allow the pressure roll 130 to clamp the web to the upper idler roll 122. This provides sufficient securement to assist the registration carriage 140 in pulling the end segment of the web 108' upward therewith, generally in the direction of web travel. The PLC then directs a servo motor coupled to the registration carriage 140 to translate the registration carriage upward in a linear motion, pulling additional material from the new roll 112 while applying tension to the web 108'. In a preferred embodiment, the servo motor and the lower registration sensor 143 communicate with each other via the PLC.

[0030] While the web 108' is being pulled, the PLC can use the lower alignment sensor 143 to find a predetermined alignment feature on the web 108' from the new roll 112. The alignment feature can be any distinctive marking on the web 108' that provides information about the position of the web. Typically, the alignment feature is a visual indicia, such as a distinctive image, line, edge, pattern, or color. The alignment feature can in some cases be based on a topological feature, such as a ridge, groove, or bump.

[0031] For visual alignment feature detection, a given alignment sensor can have any degree of sophistication. In some embodiments, the sensor is an optical sensor. Optical sensors can use any combination of components for illumination, lenses, visual processing, image sensing, and / or communication. Detection of features can be accomplished using charge-coupled device (CCD) or complementary metal oxide semiconductor (CMOS) based sensors that convert light into electrical signals. These signals can be processed into digital images with sufficient detail to provide reliable alignment to specific locations on the patterned web 108' and be recognized by processing software. The precision of the position information obtained from the alignment sensor can vary depending on the sensor used. In some embodiments, a repeatability of 20 ms, 10 ms, or even 5 ms can be achieved based on a line speed of 230 centimeters / second. At this line speed, a repeatability of 5 ms corresponds to a spatial resolution of about 11 micrometers.

[0032] When this alignment feature is detected, the translation of the alignment carriage 140 immediately stops, fixing the web 108 ′ in the aligned position and orientation relative to the reference frame of the apparatus 100 .

[0033] When the end roll 116 is almost exhausted, a signal is sent to the PLC indicating that the splicing operation should commence. The PLC then actuates a motor operatively coupled to the web indexing mechanism 104, both of which communicate with the upper alignment sensor 109 via the PLC. Assisted by the motor, the web indexing mechanism 104 engages and pulls the web 108 from the end roll 116 through the splicing module 102 until it detects a predetermined alignment feature on the web 108 from the end roll 116. In particular, the alignment feature used to position the web 108 may be the same as or different from the alignment feature detected by the lower alignment sensor 143 in the previous step above. When this alignment feature is detected, the PLC commands the web indexing mechanism 104 to stop the web 108.

[0034] At this time, the registration features of each of the webs 108, 108' are precisely aligned with one another between the clamping surfaces 129, 131. Thus, as described in this exemplary process, the holding nip 126 mounted on the registration carriage 140 and the web indexing mechanism 104 operate independently to align the registration features of the patterned webs 108, 108' on the new roll 112 and the finished roll 116 with one another.

[0035] While the web 108 is stopped in the splicing module 102, the web accumulator 106 allows the entire apparatus 100 to continue to feed the web 108 at a constant, predetermined speed. At this point, the two segments of the web 108 from the new roll and the ending roll are aligned with each other along the first and second clamping surfaces 129, 131. The PLC then brings the first and second clamping surfaces 129, 131 together, creating an aligned splice between the webs 108, 108'. Figure 3 shows the configuration of the splicing module 102 at this exact moment.

[0036] The cutting mechanism 132 is then actuated to sever the web 108 from the finishing roll 116. Once severed, the retention nip 126 and the first and second clamping surfaces 129, 131 are disengaged and a new roll 112 begins supplying the patterned web 108'.

[0037] From this moment on, the new roll 112 of the web 108' finally becomes the new finish roll, and the previous finish roll 116 can be discarded and replaced with the new roll. Advantageously, the symmetry of the splicing module 102 allows further splicing operations to be performed continuously, with the new roll and the finish roll exchanging positions after each splicing operation. In the subsequent splicing operation, the designations of the rolls 112, 116 (and the associated idler rolls 118, 120) are reversed. Furthermore, the lower alignment sensor 141 and the cutting mechanism 132' are used in the subsequent splicing operation instead of the lower alignment sensor 143 and the cutting mechanism 132.

[0038] At least some of the sequence of steps described above are preferably performed in an automated manner. To this end, the various steps may be directed with the aid of a PLC or other computer. For example, a computer may be used to guide one or more of the described actions, including translating the alignment carriage 140, stopping the feeding of the termination roll 116, bringing the first and second clamping surfaces 129, 131 together, and cutting the web 108 downstream of the aligned splice. In a preferred embodiment of the splicing process, a computer is used to perform all of these steps in the order listed above.

[0039] A second embodiment is illustrated by the apparatus 200 in FIG. 4. The apparatus 200 is configured to provide a butt-splice of the patterned web, rather than an overlap splice. Similar to the apparatus 100, the apparatus 200 includes various subassemblies, including unwind spindles 210, 214, a splicing module 202, a web indexing mechanism 204, and a web accumulator 206. A left alignment sensor 241 and a right alignment sensor 243 are positioned to find alignment features on the continuous pattern web, which are omitted in FIGS. 4 and 5. The patterned continuous web moves through the aforementioned subassemblies in the same order as listed above. Unlike the previously described apparatus 100, there is no alignment carriage, and each of the previously described components is generally fixed within a single reference frame.

[0040] 5 shows certain details of the splicing module 202, including the retaining clamping surfaces 270, 272, the first and second tail pull nips 260, 262, and the first and second cutting drums 264, 266. The first and second cutting drums 264, 266 each have a respective cutting mechanism 232', 232 on one side and a respective clamping surface 229, 231 on the other side. In general, the operation of the apparatus 200 is similar in many respects to that of the apparatus 100, except that the apparatus 200 does not use a web indexing mechanism based on a retaining nip on a moveable carriage. Instead, the first and second web indexing mechanisms are provided by either the web indexing mechanism 204 and the tail pull nips 260, 262, respectively, depending on whether a new roll is on the first or second unwind spindle 210, 214.

[0041] In an exemplary process, a new roll of patterned web is attached to a first unwind spindle 210 and threaded to the splicing module 202. Tension is then applied by a tail pull nip 260, which pulls the web through the space between a first cutting drum 264 and a second cutting drum 266, stopping as soon as a predetermined alignment feature is detected by the left alignment sensor 241.

[0042] As the ending roll from the second unwind spindle 214 nears the end, the machine uses a web indexing mechanism 204 that interfaces with an alignment sensor 209 to detect a predetermined alignment feature and lock the ending portion of the web in the proper aligned position. Once this position is reached, the web is stopped in the splicing module 202 while the web accumulator 206 allows upstream processing or manufacturing equipment to continue to run.

[0043] At this point, the portions of the web from the new and finished rolls are aligned with each other, allowing the holding clamping surfaces 270, 272 to come together. The end of the web is then formed by cutting the new and finished sections of the web and then immediately splicing them together with a strip of adhesive-backed tape. Both of these operations can be performed in rapid succession using the first and second cutting drums 264, 266, which instantly rotate 180° to switch between (1) a cutting direction, in which the cutting mechanism 232, 232' cuts the web, and (2) a taping direction, in which one of the opposing first and second clamping surfaces 229, 231 applies a pre-attached adhesive-backed tape across the cut. After the clamping surfaces 229, 231 are separated, the web accumulator 206 can be paused and the upstream manufacturing or converting process can be resumed. The finished roll can then be replaced with a new roll.

[0044] Here, the new and ending rolls are reversed on the first and second unwind spindles 210, 214, and the functions of the other mirror image splice components described above are switched as well. Further options and advantages apply to apparatus 200, which are essentially similar to those already described with respect to apparatus 100 and need not be repeated here.

[0045] All documents, patent documents or patent applications cited in the above patent application on Letters Patent are incorporated herein by reference in their entirety in a consistent manner. In the event of any inconsistency or discrepancy between any of the incorporated references and this application, the information in the foregoing description shall prevail. The foregoing description is intended to enable a person skilled in the art to practice the disclosure as set forth in the claims, and should not be construed as limiting the scope of the present disclosure, which is defined by the claims and all equivalents thereof.

Claims

1. 1. An apparatus for seaming patterned webs, comprising: first and second unwind spindles engaging the new roll of patterned web and the finished roll of patterned web, respectively; a first web indexing mechanism capable of linearly translating the patterned web from the new roll along its direction of travel; a first clamping surface extending across the patterned web from the new roll; a second clamping surface extending across the patterned web from the finishing roll; a cutting mechanism for cutting the patterned web from the finished roll; a second web indexing mechanism capable of linearly translating the patterned web from the finish roll along its direction of travel; An apparatus for splicing a patterned web, wherein the first and second web indexing mechanisms are independently operable to align registration features of the patterned web on the new roll and the finished roll with respect to one another, thereby enabling the first and second clamping surfaces to come together to create an aligned splice of the patterned web between the new roll and the finished roll.

2. 2. The apparatus of claim 1, further comprising an alignment carriage capable of translating along a direction of movement of the patterned web, wherein the first and second clamping surfaces, the first web indexing mechanism, and the cutting mechanism are coupled to the alignment carriage, and the first and second unwind spindles and the second web indexing mechanism are not coupled to the alignment carriage.

3. The apparatus of claim 2 , wherein the alignment carriage further comprises a retention mechanism that assists in pulling the patterned web off the first unwind spindle as the alignment carriage translates linearly.

4. The apparatus of claim 3 , wherein the retention mechanism comprises a retention nip.

5. The apparatus of any one of claims 2 to 4, further comprising a first alignment sensor disposed downstream of the first unwind spindle and upstream of the alignment carriage, the first alignment sensor being capable of detecting alignment features on the pattern web.

6. The apparatus of claim 5 , further comprising a first motor for linearly translating the alignment carriage, the first motor in communication with the first alignment sensor.

7. The apparatus of claim 5 or 6, further comprising a second alignment sensor disposed downstream of the alignment carriage and capable of detecting alignment features on the patterned web.

8. The apparatus of claim 7 further comprising a second motor for operating the first web indexing mechanism, the second motor in communication with the second alignment sensor.

9. 9. The apparatus of claim 8, further comprising at least one programmable logic controller in communication with each alignment sensor and each motor, the at least one programmable logic controller capable of causing the first and second clamping surfaces to align after alignment of the patterned web between the new roll and the finished roll is determined.

10. The apparatus of claim 1 , wherein the first and second web indexing mechanisms each comprise a pull nip.

11. 1. A method for seaming a patterned web, comprising: positioning a first segment of the patterned web from a new roll between opposing first and second clamping surfaces at a first aligned position using a first web indexing mechanism; positioning a second segment of the patterned web from a finished roll between the opposing first and second clamping surfaces at a second aligned position using a second web indexing mechanism; bringing the first and second clamping surfaces together to create an aligned splice; and severing the patterned web from the finishing roll upstream of the aligned splice using a cutting mechanism; A method for seaming a patterned web comprising:

12. The method of claim 11 , wherein the first and second web indexing mechanisms are guided by respective first and second alignment sensors capable of detecting alignment features on the patterned web.

13. The method of claim 12 , wherein the first and second alignment sensors comprise optical sensors in communication with a computer.

14. 14. The method of claim 13, wherein the computer is further in communication with first and second motors that operate the first and second web indexing mechanisms, respectively.

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