UV-Cured Butt Splice for Continuous Web Processing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional web splicing methods, such as lap and butt splices, face challenges with material thickness, production time losses, and inadequate adhesion to coated web materials, particularly in continuous web processing operations.
Innovation Solution
An apparatus and method using a UV-curable liquid adhesive applied within a gap between the leading and trailing edges of new and expiring web materials, cured using UV light sources, to form a butt splice without material overlap, allowing continuous web processing without stopping the operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a lap splice is used to join web materials, then the splice can be formed by overlapping the leading edge of the new web over the trailing edge of the expiring web, but this results in an undesirable double thickness of material at the splice location
Solution Approach 1:
Instead of overlapping the web edges (lap splice), the invention inverts the approach by butting the edges together end-to-end. The leading edge of the new web is positioned adjacent to the trailing edge of the expiring web with minimal gap, eliminating the double thickness problem while maintaining ease of formation through automated adhesive application and curing.
Solution Approach 2:
The invention changes the physical state and bonding parameters by using UV-curable adhesive that transitions from liquid to solid state upon UV exposure. This allows the adhesive to flow into and fill the gap between butted web edges, creating a strong bond without material overlap, thus resolving the thickness issue while maintaining ease of manufacture.
2Manufacturing precision
If hand operations are used to achieve a good-quality butt splice with less than one/one thirty-second inch gap, then the splice quality is improved, but the web processing operation must be stopped, resulting in significant loss of production time
Solution Approach 1:
The invention replaces manual hand operations with an automated UV-curing system. A UV-adhesive is applied to the web edge and immediately cured by UV light exposure, eliminating the need for manual positioning and bonding operations. This automation maintains precise gap control (less than one/one thirty-second inch) while allowing continuous web processing without stoppage, thus preserving both precision and productivity.
Solution Approach 2:
The UV-adhesive bonding process enables continuous operation by eliminating the need to stop the web processing line. The adhesive is applied and cured in-line during continuous web movement, maintaining uninterrupted production flow while achieving precise splice quality through automated control systems.
3Productivity
If adhesive tape is used to join butted web ends in a butt splice, then the splice can be formed quickly and accurately, but the adhesive tape undesirably increases the thickness of the splice
Solution Approach 1:
The invention changes from using solid adhesive tape to using liquid UV-curable adhesive that is applied in a thin layer and then cured. This parameter change allows the adhesive to be applied in a controlled thin film that fills the gap between butted edges without adding significant thickness, while maintaining quick formation speed through automated application and immediate UV curing.
4Extent of automation
If adhesive tape is used to form a butt splice, then the splice can be formed automatically, but the adhesive tape may not adequately adhere to certain web materials such as those coated with grease-proof, water-proof, or vapor deposition coatings
Solution Approach 1:
The invention changes from using pressure-sensitive adhesive tape to using UV-curable liquid adhesive. The UV-adhesive maintains its liquid state during application, allowing it to wet and penetrate coating surfaces more effectively. Upon UV curing, it forms a strong bond with coated materials including grease-proof, water-proof, and vapor deposition coatings, thereby improving adhesion reliability while maintaining automated splice formation.
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 solution enables a strong, continuous butt splice that maintains web processing efficiency by eliminating the need for material overlap and ensuring adequate adhesion to various web materials, including coated ones, while minimizing production downtime.
Implementation Method 1
A curable liquid adhesive, such as an ultraviolet (UV)-curable liquid adhesive, is dispensed or applied within the gap, and the liquid adhesive is cured to form the butt splice
Data Source
AI summary
Methods are provided for forming a butt splice to join a first web of material to a second web of material is provided. The first web of material is cut or trimmed to form a first edge. The second web of material is cut or trimmed to form a second edge, and the second edge is positioned with respect to and registered with the first edge to define a gap therebetween. A curable liquid adhesive, such as an ultraviolet (UV)-curable liquid adhesive, is dispensed or applied within the gap, and the liquid adhesive is cured to form the butt splice that joins or splices the first web of material to the second web of material.