Apparatus and method for joining webs of material - Patents.com

Abstract

To provide an improved device that makes it possible to bond a new coil to the end of a finishing coil without stopping or inhibiting the advance of a moving web.SOLUTION: The device for splicing includes: a first web supporting surface 14 that is designed to support a moving web 12 thereon; and a second web supporting surface 22 that is designed to support a replacement web 20 thereon. The first moving web moves in the machine direction. A splicing assembly 2 includes a first web sensor 50 and a web joiner 32. The controller is designed to determine the position of the rear end of the moving web through the first web sensor and to position the front end of the replacement web adjacent to the rear end in response to the determination of the rear end position. The computer is designed to control the web joiner for creating a joint that connects the rear end to the front end.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] [CROSS REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of U.S. Patent Application No. 62 / 902,450, filed Sep. 19, 2019, the disclosure of which is incorporated herein by reference in its entirety.

[0002] The present invention relates generally to manufacturing processes, and more particularly to joining two portions of a feed material for downstream use. [Background technology]

[0003] Personal care absorbent articles, such as disposable diapers, training pants, other baby care products, feminine care products, incontinence products, and other adult care products, are typically manufactured using high speed converting machines that convert one or more stable webs or ribbons of one or more fibrous absorbent materials into the article. Each web is preformed and fed to the machine as a wound roll or coil. As the web unwinds from the coil, it is processed through a fiberizer or fluff generator, which breaks the web down into small fibers that accumulate to form the absorbent core of the article.

[0004] To feed a continuous web into a converting machine, the trailing end of each coil is spliced ​​to the leading end of the next coil. Splicing techniques include overlapping lap splices and butt splices. In one conventional splicing technique, the forward movement of the trailing end of the terminating coil is temporarily stopped so that an operator can manually splice the leading edge of a replacement coil to it. However, one drawback of a stopped web is at least a temporary interruption of the converting machine. In high speed environments, even a temporary stop of a fibrous absorbent web may be undesirable.

[0005] Therefore, there is a need for an improved apparatus which allows for the splicing of a new coil onto the end of a terminating coil without stopping or arresting the advancement of the moving web. Summary of the Invention

[0006] SUMMARY OF THE DISCLOSURE Embodiments of the invention are directed to splicing moving webs, and more particularly, to creating a butt splice between an end of a terminating web and an end of a trailing web.

[0007] According to one aspect of the invention, an apparatus for splicing includes a first web support surface configured to support a moving web thereon and a second web support surface configured to support a replacement web thereon. The first moving web moves in a machine direction. The splicing assembly also includes a first web sensor and a web joiner. The controller is configured to determine a position of a trailing end of the moving web via the first web sensor and, in response to determining the position of the trailing end, position a leading end of the replacement web adjacent the trailing end. The computer is also configured to control the web joiner to create a joint connecting the trailing end to the leading end.

[0008] According to another aspect of the invention, a method of splicing a first web to a second web includes detecting a position of a trailing edge of a moving web moving in a machine direction and positioning a leading edge of a supply web adjacent the trailing edge. The method also includes actuating a web joiner and creating a joint between the trailing edge and the leading edge via the web joiner to connect the trailing edge of the moving web to the leading edge of the supply web.

[0009] According to yet another aspect of the invention, a splicing system includes a first and a second splicing assembly. The first splicing assembly includes first and second support surfaces configured to support respective first and second webs of material thereon and a fastener applicator configured to apply a first fastener to the first and second webs of material. The second splicing assembly includes third and fourth support surfaces configured to support respective third and fourth webs of material thereon and a fastener applicator configured to apply a second fastener to the third and fourth webs of material. The splicing system also includes a web edge detection system, a receiving system configured to receive the first, second, third, and fourth webs of material, and a controller. The controller is configured to control a fastener applicator of the first splicing assembly to determine a location of a trailing end of the first web of material via the web edge detection system, position a leading end of a second web of material adjacent the determined trailing end location of the first web of material, and couple the trailing end of the first web of material to the leading end of the second web of material via the first fastener. The controller is also configured to control a fastener applicator of the first splicing assembly to determine a location of a trailing end of a third web of material via the web edge detection system, position a leading end of a fourth web of material adjacent the determined trailing end location of the third web of material, and couple the trailing end of the third web of material to the leading end of the fourth web of material via the second fastener, and feed the spliced ​​first and second webs of material and the spliced ​​third and fourth webs of material to the receiving system.

[0010] These and other advantages and features will be more readily understood from the following detailed description of preferred embodiments of the invention, which is provided in connection with the accompanying drawings. [Brief description of the drawings]

[0011] The drawings illustrate embodiments presently contemplated for carrying out the invention.

[0012] In the drawing:

[0013] [Figure 1] 1 illustrates a splicing assembly according to an embodiment of the present invention.

[0014] [Figure 1A] 1A shows a top view of a portion of the splicing assembly taken along line 1A-1A of FIG. 1.

[0015] [Diagram 2] 2 illustrates a method of performing a butt splice using the splicing assembly of FIG. 1 according to an embodiment of the present invention. [Diagram 3] 2 illustrates a method of performing a butt splice using the splicing assembly of FIG. 1 according to an embodiment of the present invention. [Figure 4] 2 illustrates a method of performing a butt splice using the splicing assembly of FIG. 1 according to an embodiment of the present invention. [Diagram 5] 2 illustrates a method of performing a butt splice using the splicing assembly of FIG. 1 according to an embodiment of the present invention. [Figure 6] 2 illustrates a method of performing a butt splice using the splicing assembly of FIG. 1 according to an embodiment of the present invention.

[0016] [Figure 7] 1 illustrates an isometric view of a splice fastener applicator according to an embodiment of the present invention.

[0017] [Figure 8] 1 illustrates a splicing assembly according to another embodiment of the present invention.

[0018] [Figure 9] 1 illustrates a splicing assembly system according to another embodiment of the present invention.

[0019] [Figure 10]1 illustrates a splicing assembly according to another embodiment of the present invention.

[0020] [Figure 11] 1 illustrates a splicing assembly according to another embodiment of the present invention.

[0021] [Figure 12] 1 illustrates a splicing assembly according to another embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] An embodiment of the invention provides an apparatus and method for splicing an end of a moving web from a depleting roll to an end of a replacement roll. The brief roll exchange is performed without significantly disrupting or changing the speed of the moving web. Before the moving web from the first roll is depleted, the leading edge of the replacement roll is placed in a waiting position to wait side by side and wait for the end of the depleting roll to be detected. After the end of the depleting roll is detected, the leading edge of the replacement roll is accelerated to a position adjacent the end of the depleting roll such that a splice may be formed to join the adjacent ends to create a continuous web with the replacement roll. The spliced ​​web material may then be sent to various downstream manufacturing processes. In one embodiment, the web material is sent to a fiberizer. In another embodiment, the spliced ​​material may be subjected to one or more processing steps and then separated into individual pieces that form part of a manufactured article. The web material may be, by way of non-limiting examples, a pulp material, a nonwoven material, a woven material, a film, a foam, and / or a composite or laminate of any of these material types.

[0023] FIG. 1 illustrates a splice assembly 2 according to an embodiment of the present invention. A first roll of material 4 and a second roll of material 6 are shown mounted on respective first and second unwind mandrels 8, 10. The first roll of material 4 includes a first web 12 that can be drawn along a first web support surface 14 by a first pair of counter-rotating input rollers 16, 18. The second roll of material 6 includes a second web 20 that can be drawn along a second web support surface 22 by a second pair of counter-rotating input rollers 24, 26. The first and second web support surfaces 14, 22 can be conveyors, guide rolls, rigid surfaces, etc. that can support the first and second webs 12, 20 as they move downstream along their intended paths through the splice assembly 2.

[0024] A pair of output rollers 28, 30 positioned near opposite ends of the first web support surface 14 pull the first and second webs 12, 20 through the splice assembly 2 and past a web joiner 32, such as a splice fastener applicator 34, which includes a wheel 36 having a ridge or protrusion 38 extending therefrom. A fastener application surface 40 of the protrusion 38 is designed to receive and temporarily secure a splice fastener 42 in preparation for applying the splice fastener 42 to the first and second webs 12, 20 to create a butt splice. The splice fastener 42 may be a tape or other adhesive-based coupler configured to join the ends or edges of the first and second webs 12, 20 together. In one embodiment, the second web joiner 32 (i.e., splice fastener applicator 44) may be positioned below the first web support surface 14, as shown in phantom in Figure 1. In this manner, a pair of splice fasteners 42 may be positioned on either side of the butt splice to strengthen the joint. Alternatively, the splice fastener applicator 44 positioned below the first web support surface 14 may be the only applicator in the splice assembly 2 if it is preferred to have the splice fastener 42 at the bottom of the joined webs 12, 20.

[0025] The running or moving web drawn through the pair of output rollers 28, 30 is directed to and fed to a receiving system 46 for further processing of the running web downstream. In one embodiment, the receiving system 46 is a fiberizer that converts the web into small particle absorbent fibers and produces a fluff that can be collected in an adhesive core configured to absorb and retain liquid. In other embodiments, the receiving system 46 may be configured to receive a web of material suitable for gowns, absorbent sanitary products, or other articles to be made from a donor web.

[0026] The second web support surface 22 is positioned offset from the first web support surface 14. As shown, the second web support surface 22 is positioned perpendicularly above the first web support surface 14. However, the second web support surface 22 may be positioned at any offset position sufficient to allow the second web 20 to be directed toward the first web support surface 14. A web turning assembly 48, such as a conveyor belt, is positioned adjacent to the second web support surface 22 to aid in turning the second web 20 toward the first web support surface 14.

[0027] Detection of the placement and position of the first and second webs 12, 20 is accomplished, for example, via a web edge detection system having respective first and second web sensors 50, 52 in the embodiment shown in Figures 1-6 configured to detect the leading and trailing edges of the first and second webs 12, 20. However, as shown and described below in Figure 8, a single web sensor 84 may be configured to detect the placement and position of the first and second webs 12, 20. In all embodiments of the splice assemblies 2, 82, 88, 90 herein, it is contemplated to use any web sensor 50, 52, 84, alone or in combination, to detect the leading and trailing edges of the first and second webs 12, 20. The first and second web sensors 50, 52 may be any type of sensor capable of sensing the ends of a traveling web (e.g., the first web 12). For example, sensors 50, 52 may be visual / optical sensors, such as cameras configured to capture images of the running web within their field of view to determine the location of the end of the running web. Additionally, optical sensors may include one or more IR emitter / detector pairs configured to detect the passing of the end of the running web through a detection zone. However, embodiments of the present invention contemplate other types of optical sensors as well as non-optical detectors / sensors configured to detect the end of a running web.

[0028] The first and second web sensors 50, 52 are coupled to a controller 54 configured to electronically control the splice assembly 2. In one embodiment, the controller 54 can be a single controller or program, while in other embodiments, multiple controllers and / or programs can work together for the single purpose of controlling the splice assembly 2. The controller 54 is coupled to actuators (not shown) that are connected to the pair of output rollers 28, 30, the splice fastener applicator 34, the web redirection assembly 48, the first pair of input rollers 16, 18, and the second pair of input rollers 24, 26.

[0029] FIG. 1 further illustrates optional guides 56 positioned adjacent the web support surfaces 14, 22 and other areas through which the first and second webs 12, 20 pass. The guides 56 can facilitate guiding the first and second webs 12, 20 along their intended route and can help flatten the trailing ends 62 of the first and second webs 12, 20 if they tend to curl and move away from their path of travel. The guides 56 can be, by way of non-limiting example, flat cover plates, conveyors with or without vacuum, flat bars, or alternative known guiding means. FIG. 1A is a top view taken along line 1A-1A of FIG. 1 and illustrates multiple bar guides 56 extending along the machine direction 58 and spaced apart in the cross-machine direction 60. An embodiment of the present invention can include a single guide 56 or multiple side-by-side guides 56 as shown in FIG. 1A to help guide the webs 12, 20 traveling along their paths. Additionally, the guides 56 can be positioned below the webs in alternative embodiments.

[0030] 1-6, a method of making a butt splice will now be described. FIG. 1 shows a first web 12 on a supply roll 4 being drawn into and through the splice assembly 2 via a first pair of input rollers 16, 18 and a pair of output rollers 28, 30 as it is fed towards a receiving system 46. A controller 54 controls the first pair of input rollers 16, 18 and the pair of output rollers 28, 30 to draw the web 12 through the splice assembly 2. The supply roll 4 is shown with the web 12 fully extending through the splice assembly 2, but is shown in FIG. 1 as being near its end 62.

[0031] The replacement roll 6 is shown mounted on the second unwind mandrel 10 with its web 20 extending partially into the splice assembly 2. While the first web 12 is being pulled through the splice assembly 2, an operator or automated system loads the replacement roll 10 and feeds its web 20 to the splice assembly 2 to await its use at the end of the first web 12 on the first roll of material 4. In one example, the operator or automated system feeds the leading end 64 of the replacement supply web 20 to a second pair of input rollers 24, 26 controlled by a controller 54, while the controller 54 may activate a second web sensor 52 to determine when the end 64 of the replacement supply web 20 reaches a starting point 66. The controller 54 may then stop the second pair of input rollers 24, 26 leaving the replacement supply web 20 ready and ready to be spliced ​​at the end of the running web 12.

[0032] While the first running web 12 is being pulled through the splice assembly 2, the controller 54 operates and / or receives signals from the first web sensor 50 regarding the status of the first web 12. As the first web 12 is pulled along the first web support surface 14 beneath the first web sensor 50, the first web sensor 50 senses that the supply from the first roll of material 4 has not yet been exhausted, and the controller 54 continues to pull the first web 12 through the splice assembly 2. However, as shown in FIG. 2, once a terminal or terminating end 62 of the first web 12 passes a detection point 68 within the sensing area of ​​the first web sensor 50, the first web sensor 50 communicates to the controller 54 that the terminating end 62 has been detected.

[0033] In response to detecting the terminating end 62, the controller 54 actuates the second pair of input rollers 24, 26 as shown in FIG. 3 to position the leading end 64 of the replacement feed web 20 adjacent the trailing end 62 of the terminating web 12 in preparation for creating a butt splice. Rather than stopping the pair of output rollers 28, 30 so as not to stop the feeding of the first web 12 to the receiving system 46, the controller 54 uses the second pair of input rollers 24, 26 to accelerate the leading end 64 of the second web 20 from its first starting speed to a speed sufficient to position the leading end 64 of the second web 20 adjacent the trailing end 62 of the first web 12. To assist in the deflection of the leading end 64 of the second web 20 along the inclined surface of the second web support surface 22, the web turning assembly 48 may be actuated by the controller 54 to bias or force the leading end 64 of the second web 20 to follow the inclined surface.

[0034] In one embodiment, the location of the initiation point 66 allows the second web 20 to accelerate from an initial speed of zero to the running speed of the first web 12 such that the ends 62, 64 of the respective webs 12, 20 are properly aligned when the second web 20 reaches the running speed of the first web 12. In another embodiment, the location of the initiation point 66 places the leading end 64 of the second web 20 at a greater distance traveled from the merge point 70 of the first web support surface 14 compared to the detection point 68. In this case, the controller 54 uses the second pair of input rollers 24, 26 to accelerate the leading end 64 of the second web 20 from its initial starting speed of zero to a speed faster than the running speed of the first web 12 until the leading end 64 of the second web 20 catches up with or is sufficiently close to the trailing end 62 of the first web 12, which speed may then be decelerated to match or substantially match the running speed of the first web 12. To prepare for placement of the ends 62, 64 of the first and second webs 12, 20 for the butt splice, the speeds of the respective first and second webs 12, 20 are substantially matched prior to application of the splice fasteners. The speeds of the webs 12, 20 and the locations of the start point 66, detection point 68, and merge point 70 may be known in advance so that the program controlling the controller 54 can operate the splice assembly 2 to properly position the ends 62, 64 of the first and second webs 12, 20 in response to end detection. For example, a delay in acceleration of the replacement web may occur after detection of the respective web ends based on travel times and locations of the detected ending end and the prepared and ready leading end.

[0035] 4, the ends 62, 64 of the first and second webs 12, 20 move along the first web support surface 14 toward the splice fastener applicator 34. In preparation for the ends 62, 64 to arrive within the application zone 72, the controller 54 controls the rotation of the splice fastener applicator 34 so that the splice fastener 42 is in position when the ends 62, 64 arrive. In one embodiment, the ends 62, 64 of the first and second webs 12, 20 are spaced apart by a gap 74 with sufficient tolerance to allow small variations in the position of the ends 62, 64 to be successfully spliced ​​via the splice fastener 42.

[0036] 5, movement of the ends 62, 64 of the first and second webs 12, 20 through the application zone 72 is timed with the rotation of the splice fastener applicator 34 so that the splice fasteners 42 are attached to the ends 62, 64 to form butt joints 76 and join or splice together the first web 12 and second web 20 in a non-overlapping configuration. In this manner, a continuous supply of absorbent web is provided to the receiving system 46 without interrupting operation of the system, and even temporary stoppages in the web supply are avoided.

[0037] 6, the second web 20 is being spliced ​​to a previous running web and is therefore the web being fed to the receiving system 46. Thus, an operator or automated system may load a replacement roll 4 in a manner similar to that described herein and feed it to the splice assembly 2 to prepare a spare web 12 for use in being spliced ​​to the trailing end of the second web 20.

[0038] FIG. 7 illustrates an isometric view of a splice fastener applicator 34 according to an embodiment of the present invention. The fastener application surface 40 of the projection 38 has a plurality of openings 78 formed therein. The openings 78 are coupled to a pressure source 80. As shown in FIGS. 6 and 7, the splice fastener 42 is positioned on the fastener application surface 40 prior to application of the splice fastener 42 (see, e.g., FIGS. 4, 5) and is held in place by a low pressure, such as a vacuum, generated by the pressure source 80 through the openings 78. In one embodiment, the low pressure may be removed while the splice fastener 42 is disposed on the web ends 62, 64 as shown in FIG. 5 to facilitate the release of the splice fastener 42 from the fastener application surface 40. In another embodiment, the pressure source 80 may generate a high pressure to force the splice fastener 42 to be released from the fastener application surface 40 while the splice fastener 42 is disposed on the web ends 62, 64 as shown in FIG. 5.

[0039] FIG. 8 illustrates a splicing assembly 82 according to another embodiment of the present invention. Elements and components common between splice assembly 2 and splice assembly 82 have been described above and will not be repeated for brevity. In contrast to splice assembly 2 shown in FIGS. 1-7, splice assembly 82 of FIG. 8 is configured to detect the placement and position of first and second webs 12, 20 using a single web sensor 84 of one of the types described herein. Through web sensor 84, controller 54 may determine when trailing end 62 of supply roll 4 is detected to begin accelerating leading end 64 of replacement roll 6. Because the single web sensor 84 is located after merge point 70, controller 54 may not know the exact location of start point 66. However, based on the velocity of trailing end 62 and the velocity of leading end 64 and their detection by web sensor 84, controller 54 may calculate any remaining distance leading end 64 needs to predictably travel in order to position adjacent trailing end 62.

[0040] In another embodiment, all or some of the sensors 50, 52, 84 described herein may be used along with any additional sensors to control the webs 12, 20 in preparation for splicing.

[0041] 9, a splice assembly system 86 is shown according to an alternative embodiment including multiple splice assemblies 88, 90 positioned to provide a combined output of multiple webs (e.g., first web 12, second web 20, etc.) to the receiving system 46. While FIG. 9 shows the splice assembly 88 as above the splice assembly 90, other orientations are possible that allow running webs from both splice assemblies 88, 90 to be fed to the receiving system 46, either independently or simultaneously. Additionally, while two splice assemblies 88, 90 are shown, embodiments of the present invention contemplate that three or more splice assemblies may be included to provide additional continuous web feed to downstream processing equipment. In one example, the first and second material rolls 4, 6 of the first splice assembly 88 may be a wood pulp-based product, while the first and second material rolls 4, 6 of the second splice assembly 90 may be a eucalyptus-based or bamboo-based product. Combinations of these materials in predetermined ratios can be used to create fiberized materials ideal for, for example, disposable absorbent products. Based on the properties of each material, such as density, thickness, width, etc., each material may be fed to the receiving system 46 at different speeds to achieve the desired material ratio. Thus, the controller 54 may be programmed to operate the first splice assembly 88 at a first running speed that is different from the running speed of the second splice assembly 90. Other suitable web materials include nonwovens, tapes, cellulose pulp, tissue paper, poly, acquisition, and elastic materials.

[0042] FIG. 10 illustrates a splice assembly 92 according to another embodiment of the present invention. Elements and components common between splice assemblies 2, 82, 88, 90 and splice assembly 92 have been described above and will not be repeated for brevity. In contrast to splice assembly 2 shown in FIGS. 1-7, controller 54 of splice assembly 92 operates to control input rollers 16, 18, 24, 26 to create a lap joint 94, in which a trailing end 62 of a first web 12 and a leading end 64 of a second web 20 are joined or spliced ​​together in an overlapping configuration. Similar to FIG. 4, splice fastener applicator 34 of FIG. 10 is shown to have begun its rotation in preparation for applying splice fastener 42 to lap joint 94.

[0043] With the overlap of the trailing end 62 of the first web 12 and the leading end 64 of the second web 20, other types of web fastenings may be used to join the webs 12, 20 in addition to or instead of the tape used in the splice fastener 42. In one embodiment shown in FIG. 11, the splice assembly 96 includes an adhesive applicator 98 controlled by the controller 54 to apply adhesive to the first web 12 to join the leading or trailing edges 62, 64 of the first web 12 to the respective trailing or leading edges 64, 62 of the second web 20. As shown in FIG. 11, the surface 40 of the projection 38 of the web joiner 32 may be configured to apply pressure or force to the lap joint 94 to press the edges 62, 64 together after the adhesive has been applied. Additionally, the surface 40 may also apply the fastener 42 as described in the previous embodiment.

[0044] In another embodiment shown in FIG. 12, the web joiner 32 of the splice assembly 100 includes a joining device 102 positioned to join the webs 12, 20 together. The joining device 102 can be any known ultrasonic welding system in alternative embodiments, including, by way of non-limiting example, a rotary ultrasonic welding system or a blade ultrasonic welding system. In the illustrated embodiment, the joining device 102 includes a rotating anvil 104 and an ultrasonic fixed blade horn 106, also known as a sonotrode, which cooperate to join (i.e., fuse) the edges 62, 64 of the webs 12, 20 together without adhesives. Alternative embodiments may include multiple fixed blade horns or one or more rotating horns. Ultrasonic emissions of energy from the joining device 102 are focused at specific bond points, and frictional heat fuses the layers of the webs together without the need for consumable adhesives. Although the bonding apparatus 102 is described herein as an ultrasonic bonding assembly that ultrasonically fuses layers of a web, it is contemplated that the techniques described herein may be extended to any other known welding or bonding techniques that fuse two or more layers of material without the use of adhesives, including ultrasonic, heat, or compression techniques, as well as various other forms of welding known in the industry.

[0045] A technical contribution of the disclosed method and apparatus is to provide a controller-implemented technique for creating a butt splice between an end of a terminating web and an end of a trailing web by determining the location of the trailing end of a moving web, positioning a leading end of a replacement web adjacent the trailing end, and controlling a web joiner to create a joint connecting the trailing end to the leading end.

[0046] Thus, according to one embodiment of the present invention, an apparatus for splicing comprises a first web support surface configured to support a moving web thereon and a second web support surface configured to support a replacement web thereon. The first moving web moves in a machine direction. The splicing assembly also comprises a first web sensor and a web joiner. The controller is configured to determine, via the first web sensor, a position of a trailing end of the moving web and, in response to determining the position of the trailing end, position a leading end of the replacement web adjacent the trailing end. The computer is also configured to control the web joiner to create a joint connecting the trailing end to the leading end.

[0047] In accordance with another embodiment of the invention, a method of splicing a first web to a second web includes detecting a position of a trailing edge of a moving web moving in a machine direction and positioning a leading edge of a feed web adjacent the trailing edge. The method also includes actuating a web joiner and creating a joint between the trailing edge and the leading edge via the web joiner to connect the trailing edge of the moving web to the leading edge of the feed web.

[0048] According to yet another embodiment of the present invention, a splicing system includes a first and a second splicing assembly. The first splicing assembly includes first and second support surfaces configured to support respective first and second webs of material thereon and a fastener applicator configured to apply a first fastener to the first and second webs of material. The second splicing assembly includes third and fourth support surfaces configured to support respective third and fourth webs of material thereon and a fastener applicator configured to apply a second fastener to the third and fourth webs of material. The splicing system also includes a web edge detection system, a receiving system configured to receive the first, second, third, and fourth webs of material, and a controller. The controller is configured to control a fastener applicator of the first splicing assembly to determine a location of a trailing end of the first web of material via the web edge detection system, position a leading end of a second web of material adjacent the determined trailing end location of the first web of material, and couple the trailing end of the first web of material to the leading end of the second web of material via the first fastener. The controller is also configured to control a fastener applicator of the first splicing assembly to determine a location of a trailing end of a third web of material via the web edge detection system, position a leading end of a fourth web of material adjacent the determined trailing end location of the third web of material, and couple the trailing end of the third web of material to the leading end of the fourth web of material via the second fastener, and feed the spliced ​​first and second webs of material and the spliced ​​third and fourth webs of material to the receiving system.

[0049] Although the present invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the present invention is not limited to such disclosed embodiments. Rather, the present invention can be modified to incorporate any number of variations, alterations, substitutions, or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the present invention. Moreover, while various embodiments of the present invention have been described, it should be understood that aspects of the present invention may include only some of the described embodiments. Thus, the present invention should not be deemed limited by the foregoing description, but is limited only by the appended claims.

Claims

1. a first web support surface (14) configured to support a moving web (12) thereon; a second web support surface (22) configured to support a replacement web (20) thereon; a first web edge sensor (50, 52, 84); Web Joiner (32) and A controller (54), comprising: determining a position of a trailing edge (62) of the moving web (12) via the first web edge sensor (50, 52, 84); responsive to determining the location of the trailing end (62), accelerating the velocity of the replacement web (20) from an initial velocity to a second velocity faster than the velocity of travel of the moving web (12) without stopping the moving web (12), thereby positioning a leading end (64) of the replacement web (20) adjacent the trailing end (62); a controller (54) configured to control the web joiner (32) to create a joint (76, 94) connecting the rear end (62) to the front end (64); a splicing assembly including:

2. The web joiner (32) includes a splice fastener applicator (34, 44); 2. The splicing assembly of claim 1, wherein the controller (54) is configured to control the web joiner (32) to apply splice fasteners (42) to the trailing end (62) and the leading end (64) while the moving web and replacement web (12, 20) are moving in a machine direction (58).

3. 2. The splicing assembly of claim 1, wherein the controller (54) is configured to control the web joiner (32) to create the joint (76, 94), and further configured to control the web joiner (32) to create a butt joint (76) between the rear end (62) and the front end (64).

4. 2. The splicing assembly of claim 1, wherein the controller (54) is configured to control the web joiner (32) to create the joints (76, 94), and further configured to control the web joiner (32) to create a lap joint (94) between the rear end (62) and the front end (64).

5. The controller (54) further comprises: The splicing assembly of claim 1 , configured to slow the second speed to a speed that matches a speed of travel of the moving web (12).

6. The splicing assembly of claim 2 , wherein the splice fastener (42) comprises a tape.

7. The splice fastener applicator (34, 44) A wheel (36); a projection (38) extending from said wheel (36); Including, The splicing assembly of claim 2, wherein the projection (38) includes a fastener application surface (40) configured to receive the splice fastener (42).

8. 8. The splicing assembly of claim 7, wherein the fastener application surface (40) includes a plurality of openings (78) coupled to a pressure source (80), the pressure source (80) configured to generate a vacuum through the plurality of openings (78).

9. The splicing assembly of claim 1 , wherein the first web edge sensor (50, 52, 84) comprises an optical camera.

10. 1. A method of joining a first web to a second web, comprising the steps of: detecting the position of a trailing edge (62) of a moving web (12) moving in a machine direction (58); positioning a leading edge (66) of a feeder web (20) adjacent the trailing edge (62), said positioning comprising accelerating the feeder web (20) from an initial speed to a second speed faster than the speed of the moving web (12) without stopping the moving web (12); activating a web joiner (32); creating a joint (76, 94) between the trailing edge (62) and the leading edge (66) of the supply web (20) via the web joiner (32) to connect the trailing edge (62) of the moving web (12) to the leading edge (66); A method comprising:

11. the step of actuating the web joiner (32) includes actuating a splice fastener (42); 11. The method of claim 10, wherein the step of creating the joint (76, 94) includes actuating a splice fastener (42) to apply the splice fastener (42) to the trailing edge (62) of the moving web (12) and the leading edge (66) of the supply web (20) to create a butt joint (76) therebetween.

12. the step of actuating the web joiner (32) includes actuating a joining device (102); applying the joint (76, 94) includes bonding, without an adhesive, the trailing edge (62) of the moving web (12) and the leading edge (66) of the supply web (20) to create a lap joint (94); The method of claim 10, wherein the trailing edge (62) of the moving web (12) overlaps the leading edge (66) of the supply web (20).

13. The method of claim 10, further comprising decreasing the second speed to a speed that matches the speed of the moving web (12).

14. A first splicing assembly (2, 82, 88, 90), comprising: first and second support surfaces (14, 22) configured to support respective first and second webs of material (12, 20) thereon; a fastener applicator (34, 44) configured to apply a first fastener (42) to said first and second webs of material (12, 20); A first splicing assembly (2, 82, 88, 90) comprising: A second splicing assembly (2, 82, 88, 90), third and fourth support surfaces (14, 22) configured to support respective third and fourth webs of material (12, 20) thereon; a fastener applicator (34, 44) configured to apply second fasteners (42) to said third and fourth webs of material (12, 20); a second splicing assembly (2, 82, 88, 90) comprising: a web edge detection system (50, 52, 84); a receiving system (46) configured to receive the first, second, third, and fourth webs of material (12, 20); A controller (54), determining a position of a trailing edge (62) of the first web of material (12) via the web edge detection system (50, 52, 84); accelerating the speed of the second web of material (20) from an initial speed to a second speed that is faster than the moving speed of the first web of material (12) without stopping the moving first web of material (12) to position a leading end (64) of the second web of material (20) adjacent to the determined trailing end (62) location of the first web of material (12); controlling a fastener applicator (34, 44) of the first splicing assembly (2, 82, 88, 90) to connect a trailing end (62) of the first web of material (12) to a leading end (64) of the second web of material (20) via the first fastener (42); determining a position of a trailing edge (62) of the third web of material (12) via the web edge detection system (50, 52, 84); accelerating the speed of the fourth web of material (20) from an initial speed to a second speed faster than the moving speed of the third web of material (12) without stopping the moving third web of material (12) to position the leading end (64) of the fourth web of material (20) adjacent the determined trailing end (62) location of the third web of material (12); controlling a fastener applicator (34, 44) of the first splicing assembly (2, 82, 88, 90) to connect the trailing end (62) of the third web of material (12) to the leading end (64) of the fourth web of material (20) via the second fastener (42); a controller (54) configured to supply the joined first and second webs of material (12, 20) and the joined third and fourth webs of material (12, 20) to the receiving system (46); A splicing system (86) comprising:

15. The splicing system (86) of claim 14, wherein the receiving system (46) comprises a fiberizer configured to fiberize the first, second, third, and fourth webs of material (12, 20).

16. The splicing system (86) of claim 14, wherein the first and second webs of material (12, 20) comprise a pulp-based material.

17. The splicing system (86) of claim 16, wherein the third and fourth webs of material (12, 20) comprise one of a eucalyptus-based material and a bamboo-based material.

18. 15. The splicing system (86) of claim 14, wherein the controller (54) is further programmed to supply the spliced ​​first and second webs of material (12, 20) to the receiving system (46) at a different speed than the spliced ​​third and fourth webs of material (12, 20).

19. The splicing system (86) of claim 14, wherein the first and second fasteners (42) comprise tape.

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