Apparatus and method for splicing material rolls

A web splicing apparatus is disclosed that includes a web unwinding unit configured to hold a running web material roll and a new web material roll and to unwind webbing from the running web material roll and a web splicing unit operable with the web unwinding unit to selectively splice the webbing of the running web material roll with webbing of the new web material roll. The web splicing unit further includes a cutting assembly configured to selectively sever the webbing of the running web material roll, a web deflection device, an actuator system configured to linearly translate the web deflection device in a first direction and a second direction opposite the first direction, and a locking mechanism operable in a locked state and an unlocked state to selectively prohibit and enable movement of the web deflection device in the first direction and the second direction.

BACKGROUND OF THE INVENTION

The present invention relates generally to an apparatus and method for making disposable garments and, more specifically, to an apparatus and method for the splicing of material rolls that provide the webbing used in the manufacture of a disposable garment assembly or absorbent sanitary product.

Generally, disposable garment assemblies or absorbent sanitary products such as diapers comprise an absorbent insert or patch and a chassis that, when worn, supports the insert proximate a wearer's body. Additionally, diapers may include other various patches, such as tape tab patches, reusable fasteners, and the like. The raw materials used in forming a representative insert are typically cellulose pulp, tissue paper, poly, nonwoven web, acquisition, and elastic, although application specific materials are sometimes utilized.

Typically, most of the raw materials used in the insert and/or chassis—such as web materials—are provided in roll form and unwound and applied in a continuously fed fashion. Usage and application of the web to a disposable garment assembly thus involves the unwinding of a roll of web material. In the prior art, web unwinding units exist that provide for the unwinding of a first or running web roll of material and for the positioning of a second or new roll of material that may be spliced with the running web roll as the running web roll nears expiration. At or near the expiration of the running web roll of web material, the web material on the running web roll is spliced with the web material on the new web roll—with the engagement of the web material on the new web roll occurring by splicing the webbing exiting the unwinding running web roll thereto. After splicing the web materials, the running web roll expires and the new web roll is unwound to continue feeding webbing into the disposable garment assembly.

In existing systems and methods for performing such splicing of material rolls, the splicing is performed using an arm assembly having a first end and a second end. The arm assembly is positioned downstream of a web unwinding unit that includes a first spindle and a second spindle, with webbing material being unwound from a running web roll that rotates about a first spindle while a new web roll is present on the second spindle. The arm assembly possesses rollers for which the webbing traverses along towards the disposable garment assembly. At a point in time, dependent on the amount of webbing material on the running (and now expiring) web roll, the arm assembly pivots or rotates about the first end, such that the second end of the arm assembly moves towards the web unwinding unit. The new web roll is in close proximity to the second end of the arm assembly when the second end of the arm assembly is pivoted towards the web unwinding unit.

At a point in time, in synchronicity with the rotating new web roll, the second end of the arm assembly accelerates towards the rotating new web roll. The acceleration of the second end of the arm assembly causes the unwinding webbing from the running roll of webbing to contact a predetermined area on the new web roll. The contact causes the webbing that is unwinding from the expiring web roll to break. The downstream section, created on the break of the webbing from the expiring web roll, connects to the downstream section of the new roll of webbing, rotating in the standby position. The new web roll then proceeds to unwind webbing towards the disposable garment assembly, with the arm assembly rotating about the first end to return to the unwind position. The new web roll rotates to the unwind position of the unwinding assembly and, in-turn, the expired web roll is rotated to the standby position. The expired web roll is removed and a subsequent new web roll is provided to the apparatus.

Several limitations or drawbacks are associated with the operation of the prior art arm assembly and web unwinding unit described above. First, the break action of the arm assembly may be overly aggressive when splicing web material from the expiring web roll to the new web roll, thereby causing destabilizing vibrations to reverberate through the apparatus. Second, the arm assembly may undergo a kickback or rebound upon bringing web material from the expiring web roll into contact with web material from the new web roll, thereby preventing a reliable slicing of the materials. Still further, the arm assembly provides for the breaking of webbing from only one web unwinding unit and/or allows for splicing of web rolls in only a single webbing line—i.e., it does not provide for the ability to splice web rolls of multiple webbing lines.

Therefore, a need exists for an apparatus and method that allows for splicing of web rolls in multiple web roll lines. The apparatus and method should perform such splicing in a manner that minimizes and/or accounts for destabilizing vibrations and kickbacks that might be associated with splicing web material from the expiring web roll to the new web roll.

BRIEF DESCRIPTION OF THE INVENTION

In accordance with one aspect of the invention, a web splicing apparatus includes a web unwinding unit configured to hold a running web material roll and a new web material roll and to unwind webbing from the running web material roll. The web splicing apparatus also includes a web splicing unit operable with the web unwinding unit to selectively splice the webbing of the running web material roll with webbing of the new web material roll, with the web splicing unit further comprising a cutting assembly configured to selectively sever the webbing of the running web material roll, a web deflection device, an actuator system configured to linearly translate the web deflection device in a first direction and a second direction opposite the first direction, and a locking mechanism operable in a locked state and an unlocked state to selectively prohibit and enable movement of the web deflection device in the first direction and the second direction.

In accordance with another aspect of the invention, a method for splicing webbing of a running web material roll with webbing of a new web material roll is provided. The method includes positioning a web splicing unit in proximity to the running web material roll and the new web material roll, severing webbing of the running web material roll with a cutting assembly of the web splicing unit, and bringing a web deflection device of the web splicing unit into contact with the new web material roll to cause a section of the webbing of the running web material roll to splice with webbing of the new web material roll. In bringing the web deflection device into contact with the new web material roll, the method further comprises operating a locking mechanism of the web splicing unit to allow movement of the web deflection device in a first direction toward the new web material roll and inhibit movement of the web deflection device in a second direction away from the new web material roll and operating an actuator system of the web splicing unit to cause the web deflection device to move in the first direction, so as to bring the web deflection device into contact with the new web material roll, wherein the locking mechanism prevents movement of the web deflection device in a second direction away the new web material roll to prevent a recoil of the web deflection device away from the new web material roll.

In accordance with yet another aspect of the invention, a web splicing unit operable with a web unwinding unit to enable splicing of webbing of a running web material roll with webbing of a new web material roll is provided. The web splicing unit includes a frame, a cutting assembly configured to sever the webbing of the running web material roll, a carriage apparatus coupled to the frame, the carriage apparatus carrying a web deflection unit, an actuator system configured to linearly translate the web deflection unit along the frame in a first direction and a second direction opposite the first direction, and at least one locking mechanism operable in a locked state and an unlocked state to selectively prohibit and enable movement of the web deflection unit in the first direction and the second direction.

These and other advantages and features will be more readily understood from the following detailed description of preferred embodiments of the invention that is provided in connection with the accompanying drawings.

DETAILED DESCRIPTION

Embodiments of the present invention provide for a method and apparatus for splicing the webbing of material rolls used in the manufacture of a disposable garment assembly or absorbent sanitary product. A web splicing unit is operated to translate one or more web deflection devices thereof relative to webbing of the material rolls, so as to selectively splice webbing from a running material roll that is expiring with the webbing from a new material roll. The web splicing unit is constructed in a manner that creates splices while preventing a kickback or recoil of the web deflection device relative to the new material roll, thereby splicing the webbing in a consistent and reliable manner.

With attention toFIG. 1, a side view of a web splicing apparatus2is illustrated according to an embodiment of the present invention. The web splicing apparatus2includes at least one web unwinding unit4(two web unwinding units in the illustrated embodiment) and a web splicing assembly6in close proximity to one another. The web splicing assembly6splices webbing8that is unwound by the unwinding unit(s)4, in the manner described in detail below. The web unwinding units4may be of a known construction and may each include a web unwinding unit base10in rotational communication with a web unwinding unit mount12about an axis14. In the illustrated embodiment, web unwinding unit mount12includes a first pair of arms16extending from the axis14in opposing directions. A spindle20is located near the apex of each arm16, with a first spindle22located in a first or unwind position24and a second spindle26located in a second or standby position28. A second pair of arms30extend from axis14in opposing directions that are substantially perpendicular to the first pair of arms16. Each respective arm30extends from the axis14to a side, and a second arm roller attachment32is in rotational communication with the side of each second arm30. The running web roll34rotates about the first spindle24and the new web roll36rotates about the second spindle26. Initial operation of the web unwinding unit4provides for the running web roll34in the unwind position24to be unwound, where the unwound webbing8travels substantially about a circumference38of the second arm roller attachment32and toward the web splicing assembly6.

As illustrated inFIG. 1, according to one embodiment, the web splicing apparatus2includes a pair of web unwinding units4—first web unwinding unit40and a second web unwinding unit42—between which the web splicing assembly6is positioned. The first web unwinding unit40and the second web unwinding unit42are preferably positioned a distance44from one another that provides for positioning of web splicing assembly6therebetween and are oriented such that the rotation of the web winding unit mount12of the first web unwinding unit40is at least substantially parallel to the rotation of the web winding unit mount12of the second web unwinding unit42. While web splicing assembly6is described here below as configured/constructed for use with a web splicing apparatus2that includes both a first web unwinding unit40and a second web unwinding unit42, it is recognized that web splicing assembly6could alternatively be configured/constructed for use with a web splicing apparatus2that includes only a single web unwinding unit4.

Referring still toFIG. 1and now also toFIGS. 2 and 3, the web splicing assembly6comprises a base structure46, a rail assembly48, and a web splicing unit50. The base structure46comprises a base structure first side52and an opposite base structure second side54separated by a cavity56, as illustrated inFIG. 3. Positioned in the cavity56is a series of guide rollers62that, according to the illustrated embodiment, includes rollers64,66,68,70, although the series of guide rollers62could include a greater or lesser number of rollers. The base structure46may provide two series of guide rollers62separated at least by a distance74, with each series of guide rollers62corresponding a respective one of the first and second unwinding units40,42.

As illustrated inFIG. 3, the rail assembly48includes a first rail assembly76and a second rail assembly78. The first rail assembly76and second rail assembly78each extends a rail assembly length80(FIG. 1) that is defined by a rail assembly first end82and an oppositely opposed rail assembly second end84, which are in close proximity to the web unwinding unit4. The web splicing unit50is in sliding communication with the first rail assembly76and second rail assembly78and may be translated there along by a splice unit drive85when transitioning between use with the first web unwinding unit40and the second web unwinding unit42. Splice unit drive85may be a motor, pneumatic cylinder, hydraulic cylinder, air cylinder, rack and pinion actuator, and ball screw actuator, or any other known drive/actuating device.

As shown in detail inFIG. 2andFIG. 3, web splicing unit50includes two splicing unit sections, a splicing unit first section or frame86and a splicing unit second section or frame88, that are preferably in slidable communication with the first rail assembly76and second rail assembly78. The web splicing unit50further also includes first guide roller90, a cutting assembly92, web deflection devices94, second guide roller96, and a drive or actuator system98comprising one or more drive units/actuators and preferably two drive units/actuators. Actuator system98may include any known type of drive unit or actuating device, including pneumatic cylinders, hydraulic cylinders, air cylinders, rack and pinion actuators, and ball screw actuators, as non-limiting examples.

In the illustrated embodiment, web deflection devices94are rotary devices configured to bump into and thus deflect webbing8. Web deflection devices94are thus referred to hereinafter as bump rollers94. In alternative embodiments, web deflection devices94may be any alternative structure capable of deflecting webbing8via contact therewith. As one non-limiting example, web deflection devices94may be a non-rotary and non-circular structures such as, for example moveable plates. Likewise, actuator system98is referred to hereafter as bump roll actuators98but may be configured to actuate alternative deflection devices in alternative embodiments.

Each of the splicing unit first section86and splicing unit second section88includes a first web splicing unit end102and an oppositely opposed second web splicing unit end104separated by a splicing unit section body106. Each of the splicing unit sections86,88is configured to slide along the first and second rail assemblies76,78at the second web splicing unit end104thereof.

The first guide roller90is in rotational communication with the splicing unit first end102of the splicing unit first section86and the splicing unit second section88. The first guide roller90has a first guide roller circumference108about which the webbing8travels from the web unwinding unit4and toward the cutting assembly92of the web splicing unit50. A second guide roller96is proximate the second web splicing unit end104and preferably in rotational communication with the splicing unit first section86and the splicing unit second section88. The second guide roller96has a second guide roller circumference130about which the webbing8travels from the bump roller94and towards the base structure46.

Bump rollers94A,94B are in close proximity to the first and second rail assemblies76,78and in close proximity to the splicing unit first and second sections86,88. Preferably a bump roller94A is in close proximity to a splicing unit first side110and a bump roller94B is in in close proximity to a splicing unit second side112. Each bump roller94A,94B extends generally between the splicing unit first section86and the splicing unit second section88and has a length defined by a bump roller first end114and a bump roller second end116. According to one embodiment, the length of each bump roller94may differ. As will be explained in greater detail below, each bump roller94may be selectively translated along a linear path by a bump roller actuator98positioned adjacent each of the bump roller first end114and at the bump roller second end116.

Referring again toFIGS. 2 and 3and to the splicing of the running and new web rolls on the first web unwinding unit40, the cutting assembly92is proximate the path of the webbing8of the running web roll34. In the illustrated embodiment, the cutting assembly92includes a cutting wire126that is fixed to a support axle124. Rotational communication between the support axle124and the first and second splicing unit sections86,88providing for rotation of the at least one cutting wire126. The cutting wire126is preferably attached to the support axle124via a connecting member128. The support axle124rotates the cutting wire126in the direction of the bump roller94at a predetermined time interval. The rotation of the cutting wire126severs the webbing8, separating the webbing8into two sections.

According to alternative embodiments, cutting assembly92may be configured to sever webbing8by alternate means such as via laser, air, water jet, or plasma as non-limiting examples. Cutting assembly92also may be located external to or independent from the mechanical frame components of web splicing unit50in alternative embodiments.

Referring now toFIG. 4-FIG. 14, and with continued reference toFIGS. 1-3, a method for operating the web splicing apparatus2is illustrated, according to an embodiment of the invention.

As illustrated inFIG. 4, webbing8is removed from a running web roll34of a web unwinding unit4,40at a rate of removal132, where the running web roll34is in a unwind position24and a new web roll36is in a standby position28. The webbing8continues from the running web roll34to the series of guide rolls62. The new web roll36is rotated about the second spindle26in the standby position28at an increasing rate of rotational speed134to cooperate with the rate of removal132of the webbing from the running (and now expiring) web roll34. As illustrated inFIG. 5, the new web roll36includes at least one adhesive area136located at a downstream webbing section138of the webbing8contained in the new web roll36.

As illustrated inFIG. 6, a web splicing unit50advances toward the webbing8being unwound from running web roll34in unwind position24, as indicated at140, with such advancement occurring via translation of web splicing unit50along rail assembly48by operation of splice unit drive85(FIG. 1), for example. The web splicing unit50advances toward the webbing unwinding from running web roll34in unwind position24at a determined interval based upon one of or a combination of: weight measurements of the running web roll34, tension measurements of the webbing8removed from the running web roll34, remote camera identification, and/or other forms of machine processing timing measurements. The webbing8continues from the running web roll34to the series of guide rolls62during this time.

As illustrated inFIG. 7, the web splicing unit50continues advancing toward the webbing8and new web roll36, and contacts the webbing8being removed from the running web roll34, as indicated at142. Next, the cutting assembly92is engaged at a predetermined time to rotate the cutting wire126toward and into the webbing8, as indicated at146inFIG. 8. The rotation146of the cutting wire126toward and into the webbing8breaks the webbing8, thereby forming an upstream webbing section148and a downstream webbing section150.

As illustrated inFIG. 9, bump roller actuators98are engaged, as indicated at152. The engagement152of the bump roller actuators98pushes the downstream webbing section150of the webbing8from the running web roll34onto the adhesive area136on new web roll36, so as to affix the downstream webbing section150to the downstream webbing section138of the webbing8contained in the new web roll36. According to one embodiment, activation of the bump roller actuators98depends upon the location of the downstream webbing section150from the running web roll34and the new web roll36to the web splicing unit50. According to another embodiment, the bump roller actuators98are activated independent of the location of the downstream webbing section150from the running web roll34and the new web roll36to the web splicing unit50.

As indicated at154inFIG. 10, webbing8begins unwinding from the new web roll36in the standby position28. As the webbing8is unwound, the downstream webbing section150from the running web roll34is adhered to the new web roll36. The web splicing unit50retracts from the web unwinding unit4,40on which the aforementioned splicing occurred, indicated at156. The upstream webbing section148retracts toward the running web roll34, as indicated at158. The webbing8continues from the new web roll36to the series of guide rolls62.

As indicated inFIG. 11, unwinding154of webbing8from the new web roll36continues while new web roll36rotates about axis14of the web winding unit mount12to move the new web roll36from the standby position28to the unwind position24, as indicated at160. In turn, the running web roll34rotates160from the unwind position24toward the standby position28. As can be seen inFIG. 11, the web splicing unit50is not in contact with the webbing8at this moment in the process.

FIG. 12illustrates completion of the rotation160of the web winding unit mount12, such that the new web roll36resides in the unwind position24and the running web roll now resides in the standby position28. While removal154of the webbing8from the new web roll36continues, the running web roll34is ejected from the first spindle22that is now located at the standby position28, as indicated at162. As can be seen inFIG. 13, removal154of the webbing8from the new web roll36continues with the new web roll36located in the unwind position24, with the webbing8continuing from the new web roll36to the series of guide rolls62.

Referring now toFIG. 14, a first web unwinding unit40and a second web unwinding unit42are illustrated in close communication with the web splicing unit50—with the web splicing unit50translating from a position adjacent the first web unwinding unit40toward the second web unwinding unit42, as indicated at163. In the first web unwinding unit40, removal154of webbing8from the new (and now running) web roll36continues, while a subsequent replacement web roll164replaces the removed running web roll34in the standby position. In the second unwinding unit42, a running web roll120is unwound simultaneously with the unwinding of the new web roll36. The running web roll is located in the unwind position24of the second unwinding unit28, while a new web roll122is rotating in the standby position28of the second unwinding unit28, as indicated at166. The web splicing unit50advances towards the second web unwinding unit42, as indicated at128.

The aspect of the invention described inFIG. 14regarding use of the web splicing unit50with first and second web unwinding units40,42is possible where the web splicing unit50includes a bump roller94A,94B in close proximity to each of the splicing unit first side110and the splicing unit second side112. The bump roller94A interacts with first web unwinding unit40to splice webbing8between running and new web rolls34,36, while the bump roller94B interacts with second web unwinding unit42to splice webbing8between running and new web rolls120,122. The method of operation described above may repeat indefinitely where additional web rolls replace expired or previously spliced web rolls.

Referring now toFIGS. 15-17, the web splicing unit50described above is shown in greater detail according to an exemplary embodiment of the invention. As previously described, web splicing unit50includes first guide roller90, cutting assembly92, bump rollers94, and bump roller actuators98—with the splicing unit50having first splicing unit section or frame86on first end102and second splicing unit section or frame88on second end104.

As illustrated inFIGS. 15-17, web splicing unit50further includes a bump roller carriage apparatus168that, according to an exemplary embodiment, comprises a bump roller carriage on each of first and second ends102,104in which bump rollers94are carried (hereinafter referred to as bump roller carriages168). A support shaft170of each bump roller94is coupled to bump roller carriages168on the first and second ends102,104so as to be secured thereto. Each bump roller carriage168is configured to linearly translate along a track or rail172provided as part of the respective first or second frame86,88, so as to provide for movement of the bump rollers94. The bump roller actuator98provided on each of the first end102and second end104of web splicing unit50operates to selectively translate the bump roller carriage168along track172, such that the bump rollers94carried thereby also translate along therewith. According to embodiments of the invention, the bump roller actuators98may be actuators of any suitable type, including but not limited to an electric motor or a pneumatic cylinder, for example.

With reference still toFIGS. 15-17and now also toFIGS. 7, 9, and 14, translation of the bump roller carriages168as part of operation of web splicing unit50is described in more detail. Splicing of webbing8from a first or running web roll34with a second or new web roll36(at first web unwinding unit40) is discussed with reference toFIGS. 7 and 9. Splicing of webbing8from a fourth or running web roll120with a fifth or new web roll122(at second web unwinding unit42) is discussed with reference toFIG. 14. The direction of travel and amount of travel of the bump roller carriages168in directions D1, D2may be selectively controlled via operation of bump roller actuators98, so as to enable a desired positioning of bump rollers94relative to a web material roll to which a web is to be spliced, such as new web roll36,122(FIGS. 7 and 14). That is, bump roller actuators98may be operated to cause movement of bump roller carriages168in a direction D1or D2along track172, thereby causing bump roller94nearest a new web roll36,122to be brought into contact with the running web roll. As a bump roller94is brought into contact with a new web roll36,122to be spliced with the running web roll34,120(FIGS. 7 and 14), webbing8on the running web roll34,120is cut by cutting wire126of cutting assembly92. The webbing8is then passed from first guide roller90to bump roller94, and comes into contact with the adhesive area136of the webbing8on the new web roll36,122(FIG. 9).

With regard to movement of web splicing unit50and bump rollers94on bump roller carriages168to perform splicing of the webbing8on running web roll34,120with the webbing on new web roll36,122, as explained above and as best illustrated inFIGS. 7 and 14, it is recognized that bringing a bump roller94into contact with the webbing8on new web roll36,122may cause a recoil of the bump roller94away from the new web roll36,122. That is, as bump roller actuators98operate to translate the bump roller carriages168along tracks172and bring a bump roller94into contact with web roll36,122, it is recognized that the driving of bump roller94into new web roll36,122may cause the new web roll36,122to contract/depress inwardly if the webbing is a compliant material. When the bump roller actuators98stop providing force to drive the bump roller carriages168, the new web roll36,122may expand outwardly, thereby generating a force that causes a kickback or recoil of the bump roller carriages168(and bump roller94) in a direction opposite from that in which the bump roller94was being driven/translated. Alternatively, the driving of bump roller94into new web roll36,122may cause the bump roller94to contract/depress inwardly when the new web roll36,122is a firm web material (e.g., poly-based webbing) and the bump roller94is formed of a compliant material. In either embodiment, the bump roller94may thus not be properly positioned to enable splicing of the webbing8from the running web roll34,120to new web roll36,122, as bump roller94may not be positioned close enough to new web roll36,122to cause the webbing8from running web roll34,120to come into contact with new web roll36,122to affix the webbing section150to the adhesive area136of the webbing8on the new web roll36,122.

In order to address the potential for a kickback or recoil of bump roller94away from new web roll36,122, a locking mechanism174is provided as part of each of the first and second frames86,88that may be locked and unlocked to selectively enable movement of the respective bump roller carriages168along track172, as further illustrated inFIGS. 15-17. According to one embodiment, each locking mechanism174comprises a locking bar176, locking pawls (or levers) on opposing ends of the locking bar176(i.e., first locking pawl178and second locking pawl180), and springs182associated with the locking pawls178,180to position the locking pawls in a lock-ready position. A locking actuator184positioned on each of the first and second frames86,88control operations of the respective locking mechanisms146by causing movement of the locking pawls178,180from an angled, lock-ready position to a vertical unlocked position. According to one embodiment, locking actuators184are provided as pneumatic cylinders, but may alternatively be provided as electric motors or other suitable actuating devices. Additionally, it is recognized that rather than comprising locking bar176and locking pawls178,180, locking mechanism174may instead comprise alterative suitable clamping/locking devices, such as a rack with locking pawls on each end, a single turret system, gear teeth, an angled locking component, or the like.

Dependent on the direction of travel desired by bump roller carriages168and bump rollers94, and as illustrated in the example provided inFIG. 17, locking actuator184associated with each locking mechanism174is controlled to force second locking pawl180into a vertical position, thereby allowing for the locking bar176to pass thru it freely in either direction. On the opposite side of locking bar176, spring182pushes on first locking pawl178to maintain it in a “lock ready” state. With locking pawls178,180in these positions—first locking pawl178lock-ready and second locking pawl180vertical—the locking bar176and bump roller carriage168are allowed to travel freely in a first desired direction but bind and lock up in the opposite direction when subject to any recoil caused by the bump roller94hitting the new web roll36,122. After the splice is completed, the locking actuator184of each locking mechanism174operates/actuates in the opposite direction, so as to the allow the locking bar176and bump roller carriage168to travel freely back in the opposite direction, so as to provide for movement of the bump roller carriage168away from the new web roll36,122and prepare the web splicing unit50for a subsequent splicing operation of another new web roll36,122at another web unwinding unit40,28, such as illustrated inFIG. 14.

According to one embodiment, the bump roller carriages168on first and second ends102,104of the web splicing unit50are free to travel and lock independently from one another (via independent operation of bump roller actuators98and locking actuators184on each of the ends102,104) to accommodate a web roll that may be higher on one end than the other. That is, it is recognized that in bringing the web splicing unit50(and bump rollers94thereof) into contact with a new web roll36,122, the face of the web roll may not necessarily be flush/square/planar with the bump roller94based on a curvature of the web roll, etc. The independent locking of bump roller carriages168may enable the web splicing unit50to account for such variability in the web roll and provide for consistent contact between the bump roller94and the web roll. As previously described, each of first and second ends102,104has its own bump roll actuator98and locking actuator184for moving bump roller carriage168and for selectively activating locking mechanism174.

Referring now toFIGS. 18-21, and with continued reference toFIGS. 15-17, a sequence of operational steps is provided that illustrates a process flow according to which web splicing unit50is operated. The web splicing unit50is moved and controlled to provide splicing between web rolls (web rolls24,25or web rolls120,122, as shown inFIGS. 7 and 14) on each of a first web unwinding unit40and a second web unwinding unit42, according to a technique as generally previously described but now explained in further detail here below.

Referring first toFIGS. 18A and 18B, web splicing unit50is first illustrated in a “ready bump left” position/state, where web splicing unit50is positioned proximate a new web roll36(on a first web unwinding unit40) to which webbing8from an expiring web roll (not shown) is to be spliced. In the ready bump left position/state, the locking mechanism174in each of the first and second frames86,88is actuated to a state that provides translation/movement of the bump roller carriages168to the left and toward new web roll36, but prevents movement of the bump roller carriages168back in the opposite direction, so as to prevent a kickback or recoil of the bump roller carriages168as previously described. To bring the web splicing unit50into the ready bump left position/state, the locking actuator184on each of first and second ends102,104is operated to cause the first locking pawl178of the respective locking mechanism174to be moved to an angled, lock-ready position, while the second locking pawl180of each locking mechanism174is maintained in its vertical position. With the locking pawls178,180in these positions, the respective locking bars148and bump roller carriages168are allowed to travel freely to the left but are restricted from moving to the right, with the locking bar176and bump roller94bound and locked up from moving to the right.

Upon bringing the web splicing unit50into the ready bump left position/state, the web splicing unit50is then transferred into the “bump left locked” position/state, as illustrated inFIGS. 19A and 19B. In the bump left locked position/state, the bump roller actuator98on each of first and second ends102,104has been operated to translate the bump roller carriages168(and bump rollers94) toward new web roll36, such that the left bump roller94has been brought into contact with new web roll36. In the bump left locked position/state, the first locking pawl178of each locking mechanism174is retained in the angled, lock-ready position while the second locking pawl180of each locking mechanism174is retained in its vertical position, such that locking bar176and bump roller carriage168are allowed to travel freely to the left but prevented from moving to the right. Accordingly, left bump roller94is “locked” in place against new web roll36to provide for effective splicing of webbing8from an expiring web roll (not shown) with webbing on new web roll36, without the bump roller94being subject to or affected by any recoil caused by the bump roller94hitting the new web roll36.

Upon completion of a splicing operation between webbing8from the expiring web roll with webbing on new web roll36, the locking actuator184on each of first and second ends102,104is operated to cause the second locking pawl180of the respective locking mechanism174to be moved to the angled, lock-ready position and the first locking pawl178of the respective locking mechanism174to be moved to the vertical position, so as to allow the locking bar176and bump roller carriage168to travel freely to the right. The bump roller carriages168of web splicing unit50may thus be moved away from the web roll via operation of bump roller actuators98, with the web splicing unit50then being ready to perform a next splicing operation, either on a first web unwinding unit40or a on a second web unwinding unit42.

Referring now toFIGS. 20A and 20B, web splicing unit50is now illustrated in a “ready bump right” position/state, where web splicing unit50is positioned proximate a new web roll122(on a second web unwinding unit42) to which webbing8from an expiring web roll (not shown) is to be spliced. As described previously, web splicing unit50would be translated along rail assembly48(e.g., driven by splice unit drive85,FIG. 1) to bring it toward new web roll122and into the illustrated position. In the ready bump right position/state, the locking mechanism174in each of the first and second frames86,88is actuated to a state that provides translation/movement of the bump roller carriages168to the right and toward new web roll122, but prevents movement of the bump roller carriages168back in the opposite direction, so as to prevent a kickback or recoil of the bump roller carriages168as previously described. To bring the web splicing unit50into the ready bump right position/state, the locking actuator184on each of first and second ends102,104is operated to cause the second locking pawl180of the respective locking mechanism174to be moved to its angled, lock-ready position, while the first locking pawl178of each locking mechanism174is positioned in its vertical position. With the locking pawls178,180in these positions, the respective locking bars148and bump roller carriages168are allowed to travel freely to the right but are restricted from moving to the left, with the locking bar176and bump roller94bound and locked up from moving to the left.

Upon bringing the web splicing unit50into the ready bump right position/state, the web splicing unit50is then transferred into the “bump right locked” position/state, as illustrated inFIGS. 21A and 21B. In the bump right locked position/state, the bump roller actuator98on each of first and second ends102,104has been operated to translate the bump roller carriages168(and bump rollers94) toward new web roll122, such that the right bump roller94has been brought into contact with new web roll122. In the bump right locked position/state, the second locking pawl180of the each locking mechanism174is in the angled, lock-ready position while the first locking pawl178of each locking mechanism174is retained in its vertical position, such that locking bar176and bump roller carriage168are allowed to travel freely to the right but prevented from moving to the left. Accordingly, right bump roller94is “locked” in place against new web roll122to provide for effective splicing of webbing8from an expiring web roll (not shown) with webbing on new web roll122, without the bump roller94being subject to or affected by any recoil caused by the bump roller94hitting the new web roll122.

Upon completion of a splicing operation between webbing8from the expiring web roll with webbing on new web roll122, the locking actuator184on each of first and second ends102,104is operated to cause the second locking pawl180of the respective locking mechanism174to be moved to the vertical position and the first locking pawl178of the respective locking mechanism174to be moved to the angled, lock-ready position, so as to allow the locking bar176and bump roller carriage168to travel freely to the left. The bump roller carriages168of web splicing unit50may thus be moved away from the new web roll122via operation of bump roller actuators98, with the web splicing unit50then being ready to perform a next splicing operation, either on first web unwinding unit40or on second web unwinding unit42.

Beneficially, embodiments of the invention thus provide a web splicing unit and method of operation thereof that translates one or more bump rollers thereof relative to a webbing of the material rolls, so as to selectively cause the splicing of webbing from a first material roll with the webbing from a second material roll. Operation of the web splicing unit provides for such splicing while preventing a kickback or recoil of the bump roller relative to the material rolls, so as to provide a consistent and reliable splicing of the webbing. Additionally, operation of the web splicing unit provides for the splicing of web rolls in multiple web roll lines.

Therefore, according to one embodiment of the invention, a web splicing apparatus includes a web unwinding unit configured to hold a running web material roll and a new web material roll and to unwind webbing from the running web material roll. The web splicing apparatus also includes a web splicing unit operable with the web unwinding unit to selectively splice the webbing of the running web material roll with webbing of the new web material roll, with the web splicing unit further comprising a cutting assembly configured to selectively sever the webbing of the running web material roll, a web deflection device, an actuator system configured to linearly translate the web deflection device in a first direction and a second direction opposite the first direction, and a locking mechanism operable in a locked state and an unlocked state to selectively prohibit and enable movement of the web deflection device in the first direction and the second direction.

According to another embodiment of the invention, a method for splicing webbing of a running web material roll with webbing of a new web material roll is provided. The method includes positioning a web splicing unit in proximity to the running web material roll and the new web material roll, severing webbing of the running web material roll with a cutting assembly of the web splicing unit, and bringing a web deflection device of the web splicing unit into contact with the new web material roll to cause a section of the webbing of the running web material roll to splice with webbing of the new web material roll. In bringing the web deflection device into contact with the new web material roll, the method further comprises operating a locking mechanism of the web splicing unit to allow movement of the web deflection device in a first direction toward the new web material roll and inhibit movement of the web deflection device in a second direction away from the new web material roll and operating an actuator system of the web splicing unit to cause the web deflection device to move in the first direction, so as to bring the web deflection device into contact with the new web material roll, wherein the locking mechanism prevents movement of the web deflection device in a second direction away the new web material roll to prevent a recoil of the web deflection device away from the new web material roll.

According to yet another embodiment of the invention, a web splicing unit operable with a web unwinding unit to enable splicing of webbing of a running web material roll with webbing of a new web material roll is provided. The web splicing unit includes a frame, a cutting assembly configured to sever the webbing of the running web material roll, a carriage apparatus coupled to the frame, the carriage apparatus carrying a web deflection unit, an actuator system configured to linearly translate the web deflection unit along the frame in a first direction and a second direction opposite the first direction, and at least one locking mechanism operable in a locked state and an unlocked state to selectively prohibit and enable movement of the web deflection unit in the first direction and the second direction.