Tapeless Thermal Web Splicing for Continuous Production

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Solution Overview

Problem

Conventional splice boxes require tape for forming splices between rolls, leading to limited strength and manual labor, are not compatible with robotic automation, and cause interruptions in the manufacturing process.

Innovation Solution

A system and method for forming a tapeless splice bond between rolls using a thermal bonding apparatus with a knife cutting system and ultrasonic system, allowing for robotic automation and continuous operation without interruptions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If tape is used to form a splice between rolls, then the splicing process can be performed, but the splice strength is limited and manual labor is required

Engineering Contradiction:

Improvesplice bond strengthVSAvoidmanual labor requirement

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent replaces the mechanical tape-based splicing system with a thermal bonding system that uses heat and pressure to fuse the web material directly. The thermal bonding apparatus applies heated rollers or plates to melt and fuse the thermoplastic material in the web, creating a strong splice bond without requiring tape application by manual labor.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the bonding mechanism from mechanical adhesion (tape) to thermal fusion. By controlling temperature, pressure, and time parameters of the thermal bonding process, the system achieves stronger splice bonds while enabling automated operation. The thermoplastic material's phase change from solid to molten state and back enables the bonding process.

Inventive Principle:

Principle #35Parameter changes

2Extent of automation

If conventional splice boxes are used, then splicing can be performed, but they are not compatible with robotic automation

Engineering Contradiction:

Improverobotic automation compatibilityVSAvoidmanual operation requirement

Core Design Contradiction:

Extent of automationVSEase of operation

Solution Approach 1:

The patent replaces manual operations with an automated thermal bonding system that can be integrated into robotic workflows. The system uses programmable control to automatically position the web, apply heat and pressure, and complete the splicing process without human intervention, making it compatible with robotic automation while eliminating manual labor requirements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If conventional splicing methods are used, then rolls can be connected, but interruptions occur in the manufacturing process

Engineering Contradiction:

Improvecontinuous operation capabilityVSAvoidmanufacturing line interruption

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent enables continuous splicing operations by using thermal bonding that can be performed quickly and reliably on-the-fly during manufacturing. The process maintains web tension and continues production without stopping the manufacturing line, eliminating interruptions and maximizing productivity throughout the manufacturing process.

Inventive Principle:

Principle #20Continuity of useful action

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

The system creates a stronger splice bond by overlapping and fusing rolls under tension, eliminating the need for tape and manual labor, and ensuring continuous operation of the manufacturing line.

Implementation Method 1

both portions overlapping each other are simultaneously fused and cut. In some embodiments, the fusion and cutting action occurs by a thermal bonding apparatus

Methodology Applied

Scientific EffectThermal bonding: Heating

Implementation Method 2

an ultrasonic system comprised of a Sonotrode (horn) and an anvil

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Data Source

PatentUS20250332036A1System and method for forming a tapeless splice bond

Publication Date: 2025.10.30 PROCTER & GAMBLE CO

AI summary

A method is presented for providing a continuous web to an absorbent article manufacturing line. The method includes conveying a first roll of material through a splice box. The method also includes providing a second roll of the material extending into the splice box. The method also includes sensing upcoming expiration of the first roll of material. The method also includes using a first and second vacuum to hold a respective first portion of the first roll and a second portion of the second roll against first and second components of a thermal welding apparatus. The method also includes forming a thermal weld at the splice location between the first and second portions. The method also includes cutting the first roll of material upstream of the thermal weld. The method also includes conveying the second roll of material through the splice box without stoppage of the absorbent article manufacturing line.