Lapless Butt Splice Roll Change for Continuous Web Converting

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Converting and printing machinery faces challenges in seamlessly splicing rolls of material without stopping production, as existing methods either require stopping the machine or involve complex, expensive equipment for precision, leading to issues like material damage, wear, and exposed adhesive gaps.

Innovation Solution

A web splicer system that cuts the outgoing web to create a trailing edge and aligns it with an adhesive strip on a replacement roll, using rollers and pneumatic cylinders to apply adhesive strips on both surfaces for a lapless butt splice, allowing continuous operation without material overlap or gaps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If an accumulator, festoon, or J-box is used to enable continuous operation during roll change, then productivity is improved, but device complexity increases and material damage risk increases

Engineering Contradiction:

Improvecontinuous operation during roll changeVSAvoidadditional space and rollers required

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent extracts the adhesive application function from a complex accumulator system and implements it directly at the splice point using a simple roller that applies adhesive only where needed on the web edges, eliminating the need for large accumulators, festoons, or J-boxes while maintaining continuous operation capability

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces a splicer roller as an intermediary element that applies adhesive between the trailing edge of the outgoing web and the leading edge of the incoming web, enabling seamless splicing without requiring complex material storage and retrieval mechanisms

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If adhesive is applied to both surfaces of the web edges, then manufacturing precision is improved by eliminating gaps and overlaps, but use of energy increases due to additional adhesive application

Engineering Contradiction:

Improvelapless butt splice alignmentVSAvoidadhesive application energy

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The patent applies adhesive to both surfaces of the web edges (excessive action) to ensure complete coverage and eliminate any risk of gaps or overlaps, prioritizing splice precision over minimal adhesive usage. The dual-surface application guarantees that the splice joint is fully bonded regardless of minor alignment variations

Inventive Principle:

Principle #16Partial or excessive action

3Manufacturing precision

If the splicer roller is accelerated to match web speed, then manufacturing precision is improved by ensuring proper adhesive application timing, but use of energy increases due to acceleration requirements

Engineering Contradiction:

Improveadhesive strip application timingVSAvoidsplicer roller acceleration energy

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The patent uses sensors to detect the position and speed of the web material, providing feedback to the splicer roller drive system. This feedback mechanism allows the splicer roller to automatically adjust its speed and acceleration to precisely match the web speed at the moment of adhesive application, ensuring accurate timing while minimizing energy consumption through optimized acceleration profiles

Inventive Principle:

Principle #23Feedback

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables efficient, automatic splicing of web material rolls during production, minimizing production loss and ensuring a seamless transition, reducing material damage and adhesive exposure issues downstream.

Implementation Method 1

a cutting blade configured to cut the outgoing web to create a trailing edge

Methodology Applied

Scientific EffectMechanical cutting:

Implementation Method 2

The bump roller may be arranged proximate to the replacement roll and may be further configured to press the trailing edge of the outgoing web against a first adhesive surface coupled to the replacement web

Methodology Applied

Scientific EffectMechanical pressure:

Implementation Method 3

The splicer roller may additionally be configured to selectively press the second adhesive surface against the leading edge of the replacement web and the trailing edge of the outgoing web

Methodology Applied

Scientific EffectMechanical pressure:

Implementation Method 4

press the trailing edge onto the exposed portion of the adhesive strip... affixing the second adhesive strip over the trailing edge and the leading edge

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS10899568B2Automatic lapless butt material splice

Publication Date: 2021.01.26 NEW ERA CONVERTING MACHINERY INC

AI summary

Devices, methods, and systems for splicing a trailing edge of an outgoing roll with a leading edge of a replacement roll with a lapless butt splice on-the-fly during converting and printing production. A first strip of adhesive tape may be placed partially under the leading edge, such that a portion of the adhesive tape remains exposed beyond the leading edge. The replacement roll may be accelerated to match the speed of the outgoing web's movement, a trailing edge of the outgoing web may be cut free from the outgoing roll, and the trailing edge of the outgoing roll may be positioned over the exposed portion of the adhesive tape. A second strip of adhesive tape may be applied over the leading edge and trailing edge using a splicer roller timed to apply the tape when the edges pass proximate to the splicer roller.