Machine and process for placing discrete components on a moving web with velocity matched placement and integral bonding

The present invention provides a combination roller, a machine and process for cutting workpieces from a web moving at a first speed and depositing them on and bonding them to a substrate web moving at a second speed with the functions of cutting, transferring, and bonding all carried out on a single roller. The reduction in roller mass achieved by this roller and machine design permits driving the combination roller at variable speeds by means of a servomotor and servomotor controller. The resulting machine permits electronic rather than machine grade changes as the machine and process are used to produce products having different configurations.

TECHNICAL FIELD 
The present invention relates to a method and apparatus for receiving 
discrete parts of a workpiece traveling at one speed and applying and 
bonding the parts to a web of material moving at a different speed. More 
particularly, the invention concerns a method and apparatus for cutting, 
transporting, and bonding on a single roller, discrete parts from a web of 
material moving at one speed to a web of material moving at a different 
speed. 
BACKGROUND OF THE INVENTION 
Articles such as infant diapers, adult continence diapers, feminine napkins 
and the like have been manufactured generally by processes where discrete 
parts or components of the article are deposited on a continuously moving 
product web. Often, the speed with which the parts or components are 
produced and fed into the process is not the same as the speed of advance 
of the product web itself. In such cases, the speed of production and/or 
deposition of the component parts on the moving web must be varied to 
match the speed of the product web to properly match the parts to the 
moving web without adversely affecting the process or the quality of the 
finished article. 
Several methods for changing the speed of a part or component of material 
for deposition on a continuously moving web are known in the art. One 
method, disclosed in U.S. Pat. Nos. 4,726,876 and 4,767,487 to Tomsovic, 
Jr. employs rollers segmented into sections which are inwardly and 
outwardly moveable in a direction radial to their direction of rotation. 
As the roller rotates, the segments are driven by cam actuating or gearing 
means to move inwardly and outwardly changing the linear surface speed of 
the roller segments as the roller rotates through each revolution. 
U.S. Pat. No. 5,021,111 to Swenson discloses an apparatus in which an 
advancing web of material is fed from a slow moving feed roll to a faster 
moving roller which slips against the web. As components are cut from the 
slower moving web they are free to move with the faster moving "slip" 
roller from which they are then transferred to a web moving at the same 
speed. 
Another method utilizes festoons to reduce the speed of the moving web to 
which the parts or components are to be applied. The continuously moving 
web is temporarily slowed to the speed of the component parts to be 
deposited, with the excess portion of the continuously moving web 
gathering in festoons. While the continuously moving web is slowed to 
match the speed of the component parts, the parts are transferred to the 
web and the speed of the web is then accelerated to gather the festoons 
prior to the next cycle. 
Another method disclosed, for example, in U.S. Pat. No. 5,556,504 to 
Rajala, et al. employs independent segments of a cylindrical surface which 
comprise a portion of an arc of the circumference of the cylindrical 
surface. The individual segments are attached to separate concentric 
shafts and are free to move independently. Each arc surface moves, for a 
fraction of each rotation, at one speed to receive a workpiece component 
and then accelerates forward through an angle of rotation to transfer the 
component to a faster moving web. 
U.S. Pat. No. 5,415,716 discloses a machine in which a first web of 
material is fed from a slower moving feed roller through a system of 
dancer rollers to a pair of pinch rollers which move the web at a faster 
speed. 
The use of electronically controlled servomotors to control and vary the 
velocity of various machine roller components is known in the label-making 
art as illustrated, for example, in U.S. Pat. Nos. 5,380,381 and 5,413,651 
to Otruba. Several patents have suggested the use of servomotors for 
controlling the speed of rollers in machines employed in the fabrication 
of infant and adult incontinence diapers, feminine care products, and the 
like. However, the implementation of such a suggestion has faced a number 
of drawbacks. 
Generally, the mass of rollers required in machines for fabricating such 
articles presents obstacles to the use of servomotors as the driving 
means. The rapid acceleration/deceleration of massive rollers is beyond 
the long-term capability of commercially available servomotors. As a 
result, it has been typical in prior art machines to use mechanical means 
such as those described above or variable gearing arrangements to meet the 
demands of the heavy duty cycle imposed by massive machine rollers. 
The use of servomotor drive means is also problematic when ultrasonic 
bonding is used as the means for bonding the discreet components to the 
moving web. Ultrasonic bonding is a preferable form of bonding components 
of diapers and feminine care products because it avoids the use of 
chemical adhesives with their attendant machine drawbacks. However, in 
machines employing ultrasonic bonding the anvil opposing the ultrasonic 
horn must be of a mass equal to or greater than the mass of the horn 
itself to prevent the resonant coupling of the anvil to the horn. This 
generally imposes a lower limit on the mass of anvil rollers which can be 
employed with ultrasonic bonding. 
Typically in machines in which ultrasonic bonding is employed, the bonding 
horn(s) and its (their) opposed anvils are placed downstream from the 
rollers which cut the discrete workpiece components and mate them to the 
advancing web. This solves one problem, but introduces a second. The mass 
of the cutting and placing rollers can be lowered to enable driving the 
rollers by a servomotor, but the separation of the cutting and placing 
steps from the bonding step becomes problematic. In circumstances where 
the placement of workpiece components on the advancing web must be 
maintained with precision, any movement of the component between the 
placing and bonding steps leads to unacceptable product. 
There is thus a need in the industry for a machine and process for cutting, 
and placing workpiece components from a web moving at one speed onto a 
receiving web moving at a different speed which permits the integration of 
the desirable aspects of servomotor control of machine components, while 
providing for precise registration and ultrasonic bonding of workpiece 
components. 
SUMMARY OF THE INVENTION 
These and other advantages are achieved by the present invention which to 
provides, in its principal embodiment a combination roller having a length 
and an outer working surface, and a central shaft portion having a length 
and an outer surface, and a body portion having a length and an outer 
surface. The combination roller has integral elements of a) a cutting 
anvil apparatus for engaging the cutting edge of a rotary cutter disposed 
in cooperative working relationship with the combination roller; b) a 
vacuum transfer apparatus for receiving and holding a first uncut web of 
workpieces to the working surface of the combination roller for cutting 
the first web into discrete workpieces between the cutting edge of the 
cooperative rotary cutter and the cutting bar anvil and for holding the 
discrete workpieces to the working surface and transferring the discrete 
workpieces to a second substrate web; and c) an ultrasonic bonding anvil 
apparatus for cooperating with the outer working surface of a rotary 
ultrasonic horn to thereby create bonds bonding the cut discrete 
workpieces to the second substrate web. 
In an alternative embodiment, the present invention provides a machine for 
cutting discrete workpieces from a first web of uncut workpieces moving at 
a first speed and transferring and bonding the cut workpieces to a second 
substrate web of material moving at a second speed. The machine comprises 
a) a first supply apparatus delivering an uncut web of workpieces at a 
first component web speed; b) a second supply apparatus delivering a 
second substrate web of material at a second substrate web speed; c) at 
least one vacuum commutator; d) at least one rotary ultrasonic horn having 
an outer working surface; e) a rotary cutter having a length, and having a 
cutting edge disposed along at least a portion of its length; f) a 
combination roller having a second outer working surface being disposed in 
working relationship with the rotary cutter and with the outer working 
surface of the at least one rotary ultrasonic horn. The combination roller 
has the integrated elements of i) a cutting bar anvil apparatus for 
engaging the cutting edge of the rotary cutter during rotation of the 
rotary cutter and the combination roller, ii) a vacuum transfer apparatus 
communicating with the at least one vacuum commutator for receiving and 
holding the first uncut web of workpieces to the working surface of the 
combination roller for cutting of said first web into discrete workpieces 
between the cutting edge of the rotary cutter and the cutting bar anvil 
and for holding the cut discrete workpieces to the working surface and 
transferring them to the second substrate web; and iii) an ultrasonic 
bonding anvil apparatus cooperating with the outer working surface of the 
at least one rotary ultrasonic horn to create bonds bonding the cut 
discrete workpieces to the second substrate web. 
The combination roller and rotary cutter of the machine are driven by a 
variable speed drive apparatus which drives the rotary cutter and the 
combination roller at the first component web speed for a first portion of 
each rotation of the rotary cutter and combination roller at the second 
substrate web speed for a second portion of each rotation of the rotary 
cutter and combination roller. 
The machine of the present invention thus integrates the functions of 
cutting the discrete workplace components, transferring them to a 
receiving substrate web, and bonding them to that substrate web into the 
functions of two main machine elements: a combination roller and a rotary 
cutter. The term "combination roller" is used to describe the roller of 
the machine which combines the functions typically found three separate 
rollers in prior art machines: cutter anvil roller, vacuum transfer 
roller, and bonding anvil roller. 
In a third embodiment, the invention provides a process for cutting 
discrete workpieces from a first uncut workpiece web moving at a first 
workpiece web speed and transferring and bonding the cut discrete 
workpieces to a substrate web moving at a second substrate web speed. The 
process comprises carrying out on a single roller the steps of a) 
receiving on the roller a first uncut workpiece web and cutting discrete 
workpieces from that first uncut web on the roller while the roller is 
moving during a first fraction of its rotation at the speed of the first 
workpiece web and holding the cut discrete workpieces to the roller by 
vacuum means; b) changing the speed of the roller and discrete workpieces 
to match the speed of the second substrate web during a second fraction of 
rotation of the roller; c) transferring said discrete workpieces to the 
second substrate web and bonding the discrete workpieces to the substrate 
web while the roller is moving for a third fraction of its rotation at the 
second substrate web speed; and changing the speed of the roller to 
approach the speed of the first workpiece web during a fourth fraction of 
rotation of the roller. 
By thus considerably shortening the length of the path between the cutting 
of the discrete workpiece components and the placing and bonding of the 
cut components on and to the substrate web, the machine of the present 
invention provides improved precision of component placement on the 
substrate web. 
Moreover, by consolidating the functions typically provided by three 
separate rollers into a single roller, the machine of the present 
invention substantially reduces the mass of machine parts which must be 
driven at variable speeds thus permitting the use, in a particularly 
preferred embodiment, of a servomotor and servomotor controller. This 
permits so-called "electronic grade changes" when the machine is shifted 
from one product to another, rather than requiring massive re-tooling of 
the machine. 
These advantages and features of the invention are made clear by reference 
to the following detailed description of the invention and the 
accompanying Drawing Figures which are a part of this disclosure.

DETAILED DESCRIPTION 
A combination roller of one embodiment of the invention is depicted in FIG. 
1 where the roller is shown as 100. The roller comprises a shaft portion 
102 and a body portion 104. In the embodiment depicted in FIG. 1, 
ultrasonic bonding anvil shoes 112 and 120 are shown flanked by ultrasonic 
bonding anvil hold-down shoes 110, 114, 118 and 122. In a manner described 
in further detail below, the ultrasonic bonding anvil hold-down shoes 110, 
114, 118 and 122 are bolted or otherwise fastened to the body portion 104 
of the combination roller and retain the ultrasonic bonding anvil shoes 
112 and 120 to the roller body portion. 
FIG. 2 shows the shaft 102 and body 104 portions of the roller with the 
ultrasonic bonding anvil shoes and ultrasonic bonding anvil hold-down 
shoes removed. Additional features of the combination roller body may be 
seen including vanes or stand-offs 130, 132, 134, and 136 and holes 138 
for receiving bolts or other fasteners. The body portion of the 
combination roller has an outer surface which defines an intermittent or 
interrupted surface defined by the extremities of the vanes or stand-offs 
130, 132, 134, and 136. While this outer surface may conform to a 
cylindrical, hexagonal, octagonal or other similar shape, it is preferred 
that the outer surface of the body portion of the roller conform to a 
cylinder for ease of fabrication of the ultrasonic bonding anvil and 
ultrasonic bonding anvil hold-down shoes. 
In a particularly preferred embodiment, the body portion of the combination 
roller is fabricated by machining grooves, slots, or channels in a 
cylinder. These grooves, slots, or channels are typified by narrow grooves 
or channels 139 and broader grooves or channels 140 in FIG. 2. The 
grooves, slots, or channels 139 and 140 extend inwardly from the surface 
of the body portion of the roller and extend for at least a portion of the 
length of the body portion of the combination roller. Certain of the vanes 
or stand-offs (for example 134 and 136) are also machined to form slots or 
channels 137 which permit air flow laterally between the longitudinal 
grooves, slots or channels 139 and 140. 
The body 104 and shaft 102 portions of the combination roller may form a 
unitary assembly by machining a single piece, but advantages gained by 
forming the body and shaft portions of the roller as separate pieces make 
unitary fabrication less desirable. Preferred embodiments of the roller 
body are shown is FIGS. 3A and 3B. In FIG. 3A the body portion 104 of the 
combination roller is shown as a single piece with a hollow central core 
153. The core 153 is shown as cylindrical in the embodiment depicted in 
FIGS. 3A and 3B, with key-ways 154 and 156. However, the hollow central 
core 153 can be of any surface shape which conforms to and fits closely 
with the outer surface of the shaft portion 102 of the combination roller. 
The one-piece body portion depicted in FIG. 3A is assembled to the shaft 
portion 102 of the combination roller by sliding the body portion 104 over 
the shaft portion 102 prior to assembling the resulting sub-assembly into 
the machine. 
In FIG. 3B, the body portion 104 of the combination roller is shown, again 
as having a cylindrical hollow core 153 as in FIG. 3A, but with the body 
portion split into two pieces along longitudinal cuts 150 and 152. This 
embodiment has the advantage of permitting affixing the body portion 
pieces to the combination roller shaft portion after the latter has 
already been assembled to the machine. In both the one piece and split, 
two-piece, embodiments of the body portion 104 of the combination roller 
shown in FIGS. 3A and 3B, the body portions are affixed to the shaft 
portion 102 by bolts or other fasteners passing through holes 155 in the 
body portions 104. Both the one piece and split, two-piece, embodiments of 
the body portion 104 may be slideably moved along the shaft portion 102 of 
the roller prior to affixing the body portions 104 to the shaft portion 
102. This permits variations in machine set-up to accommodate different 
product configurations. 
Two alternative embodiments of the assembled body and shaft portions of the 
combination roller of the invention are shown in FIGS. 4A and 4B where 
element 202 represents a cut-away section of the machine frame and 
elements 206 and 208 represent cut-away bearing assemblies for the 
combination roller shafts 102. In FIG. 4A the body portion 104 of the 
combination roller is shown as a single longer section, and in FIG. 4B as 
two shorter separate sections 104A and 104B. It is to be understood that 
in both embodiments shown in FIGS. 4A and 4B that the body portions 104, 
104A and 104B may be each of a single piece or in two or more split pieces 
as discussed above and depicted in FIGS. 3A and 3B. 
Also shown in FIGS. 4A and 4B are end- or cap-plates 220, 222, 224, and 226 
of combination roller body portions 104, 104A, and 104B. These end- or 
cap-plates are bolted or otherwise attached to the ends of the body 
portion 104, 104A and 104B of the combination roller and are provided with 
one or more apertures, each communicating with the grooves, slots, or 
channels 139 and 140 in the body portion mentioned above. 
FIG. 5 depicts the partially assembled roller sub-assembly of the machine 
of the invention incorporating the combination roller described above. In 
FIG. 5, the two-section roller body of FIG. 4B is shown assembled into 
machine frame 202 but without the ultrasonic bonding anvil shoes 112 and 
120 or the ultrasonic bonding anvil hold-down shoes 110, 114, 118, and 122 
of FIG. 1 attached. The sub-assembly also shows a two-section rotary 
cutter comprising rotary cutter shaft 402 and rotary cutter sections 404A 
and 404B. The shaft 102 of the combination roller and the shaft 402 of the 
rotary cutter are driven to contra-rotate by meshed 1:1 gears housed in 
gear-box 204. 
Combination roller shaft 102 turns in machine frame 202 on bearing 
assemblies 206 and 208 and rotary cutter shaft 402 turns in machine frame 
202 on bearing assemblies 210 and 212. 
A rotary ultrasonic bonding horn apparatus 300 comprises two rotary 
ultrasonic bonding horns, of the type disclosed in U.S. Pat. Nos. 
5,707,470 and 5,711,847. The contents of which are incorporated herein by 
reference. The rotary ultrasonic bonding horns are shown as partial 
elements 304 and 306 turning on shaft 302. The two horns are shown opposed 
to combination roller body portions 104A and 104B. In FIG. 5, the outside 
working surface of the rotary ultrasonic bonding horns 304 and 306 are 
shown somewhat spaced-apart respectively from combination roller sections 
104A and 104B. This is because the ultrasonic bonding anvil shoes have 
been omitted from this Figure. As can be seen in the fully assembled 
roller sub-assembly of the machine depicted in FIG. 11, discussed further 
below, the outer surfaces of the installed ultrasonic bonding anvil shoes 
120 and 112 are in close working relationship with the outer surfaces of 
the rotary ultrasonic bonding horns 304 and 306, respectively. 
Vacuum commutators 502 and 506 are shown abutting, respectively, the end- 
or cap-plates 222 and 224 of roller body portion 104A and vacuum 
commutators 510 and 514 similarly abutting the end- or cap-plates 226 and 
222 of roller body portion 104B. When the machine is operating, hoses (not 
shown) attached to vacuum take-off ports 504, 508, 512, and 516 draw air 
out of the vacuum commutators and, in a manner discussed further below, 
out of the channels of the combination roller body portions 104A and 104B. 
Rotary cutter sections 404A and 404B are shown in FIG. 5 with respective 
cutter bars 406A and 406B and rotary cutter bar retainers 4308. 
Rotary ultrasonic bonding horns 304 and 306 can be laterally and slideably 
positioned on shaft 302; vacuum commutators 502, 506, 510, and 514 and 
combination roller body portions 104A and 104B can be laterally and 
slideably positioned on combination roller shaft 102; and rotary cutter 
sections 404A and 404B can be laterally and slideably positions on rotary 
cutter shaft 402 to accommodate products of differing widths. 
The roller sub-assembly of FIG. 5 is shown in top view in FIG. 6, with the 
rotary ultrasonic bonding horn assembly 300 of FIG. 5 removed. The top 
view shows the first and second rotary cutter blade oiler assemblies 602A 
and 602B with rotary cutter blade oiling rollers 604A and 604B. The oiling 
rollers are soft, typically sponge rubber, rollers which contact the 
cutting edge of the rotary cutter bar upon each rotation of the rotary 
cutter and deposit a light coating of oil on the cutter bar edge. Other 
elements of the roller sub-assembly shown in both the top view of FIG. 6 
and the front view of FIG. 5 bear the same reference numerals. 
FIG. 7 shows the end view of the roller sub-assembly of FIGS. 5 and 6 with 
the gear-box cover 204 and the rotary ultrasonic horn assembly 300 of FIG. 
5 removed. FIG. 7 shows the cutter blade oiler roller 604 as well as the 
meshed 1:1 gears 702 and 704 driving, respectively, the combination roller 
shaft 102 and rotary cutter shaft 104. 
FIG. 8 shows in perspective view, vacuum commutator 502 of FIGS. 5 and 6. 
The commutator has a central opening 520 which accommodates the shaft 
portion 104 of the combination roller and a vacuum take-off tube 504. An 
arcuate groove 518 is machined into one face of the commutator 502 which 
arc subtends an angle . The groove continues inside the commutator to 
communicate with the opening 522 in the vacuum take-off tube 504 as can be 
seen in the cross-sectional view of commutator 502 along cut line 9--9 
depicted in FIG. 9. As shown in FIGS. 4 and 5, commutator 502 abuts end- 
or cap-plate 220. As the machine is operated, end- or cap-plate 220 
rotates slideably against vacuum commutator 502. A aperture in end- or 
cap-plate 220 communicates with the slot 518 in commutator 502 during that 
portion of each rotation of the combination roller subtended by the arc . 
During that portion of the rotation where the aperture in end- or 
cap-plate 220 is adjacent to the non-slotted face of vacuum commutator, 
the aperture is closed off and no air can be drawn from the commutator. 
The means by which this mechanism functions to hold cut workpieces to the 
outer working surface of the combination roller will be discussed further 
below. 
The fully assembled roller sub-assembly of one embodiment of the machine of 
the invention is depicted in FIG. 11 which corresponds to the partial 
assembly of FIG. 5. The same elements in both Figures bear the same 
reference numerals. FIG. 11 shows the two sections of the body portion of 
the combination roller with the ultrasonic bonding anvil shoes 120 and 112 
and ultrasonic bonding anvil hold-down shoes 122, 118, 114 and 112 
fastened in place on the roller. It can be seen that, in the fully 
assembled roller sub-assembly of the machine, the outer working surfaces 
of the ultrasonic bonding anvil shoes 120 and 112 are in close working 
relationship with the outer working surfaces of the rotary ultrasonic 
bonding horns 304 and 306, respectively. As both the combination roller 
and the ultrasonic bonding horns contra-rotate with non-bonded materials 
passing between them, the vibratory action of the ultrasonic bonding horns 
working against ultrasonic bonding anvil shoes forms welds or bonds 
between the materials. 
The ultrasonic bonding anvil shoes 120 and 112 and ultrasonic bonding anvil 
hold-down shoes 122, 118, 114 and 112 are depicted in greater detail in 
FIGS. 12-15. Both types of shoes comprise pieces having outer or working 
surfaces which are sections of a cylindrical surface. While the inside 
surfaces of both types of shoes are shown in the embodiments depicted in 
FIGS. 12-15 as also comprising sections of a cylindrical surface, the 
inner surface of the shoes can be of any shape or form which conforms to 
and fits closely with the outer surface of the combination roller body 
portion 104 described above. Thus, when the shoes are affixed to the body 
portion 104 of the combination roller, they form a cylindrical roller 
outer working surface. 
A typical ultrasonic bonding anvil hold-down shoe 122 is shown in FIG. 12 
where vacuum apertures such as 816 are shown forming a pattern in the 
shoe. Bolt or fastener apertures 814 passing through the hold-down shoe 
receive bolts or fasteners for attaching the hold-down shoes to the vanes 
or stand-offs such as 132 and 134 of combination roller body portion 104 
in fastener apertures or holes 138 on the vanes or stand-offs. 
As can be seen in FIG. 12 and the cross-sectional view in FIG. 13, taken 
along cut line 13--13 of FIG. 12, one edge of the anvil hold-down shoes 
122 are provided with a flange 818 which depends outwardly from the shoes 
in the direction of the width of the shoes. The flange 818 of the anvil 
hold-down shoes are inwardly facing flanges. The term "inwardly facing" 
flanges means that the outer or working surface of the anvil hold-down 
shoes are wider than the inner go surface of the shoes. While the 
embodiment depicted in FIGS. 12 and 13 shows an inwardly facing flange 818 
on only one edge of the anvil hold-down shoe 122, the alternative 
embodiment where the hold-down shoe has inwardly facing flanges on both 
edges is also contemplated as falling with the scope of the invention. 
The ultrasonic bonding anvil shoes are represented by ultrasonic bonding 
anvil shoe 120 depicted in FIG. 14 and the cross-sectional view of FIG. 15 
taken along cut line 15--15 of FIG. 14. As with the hold-down shoes 122, 
the ultrasonic bonding anvil shoes 122 are provided with a pattern of 
vacuum apertures 820. In addition, the outer or working surfaces of the 
ultrasonic bonding anvil shoes are provided with a raised pattern of 
stippling, shown as a pattern of dots 822 in the embodiment depicted in 
FIGS. 14 and 15. The pattern may take any form, however, which effectively 
interacts with the working surface of the ultrasonic bonding horn to forms 
bonds between webs of materials passing between the two. The pattern of 
stippling is typically formed in the outer working surface of the 
ultrasonic bonding shoes by machining or chemically etching away a portion 
of the outer surface of the shoes to leave the stippling pattern. 
Initially the outside diameter of the pre-fabricated ultrasonic bonding 
anvil is a few mils (1 mil=0.0254 mm) greater than the outside diameter of 
the hold-down shoes. The pattern of stippling which remains on the 
ultrasonic bonding anvil shoes after machining or etching is thus raised 
slightly above the surface of the anvil hold-down shoes. 
Unlike the anvil hold-down shoes, however, the ultrasonic bonding anvil 
shoes are not provided with bolt or fastener holes or apertures. It has 
been found that when the ultrasonic bonding anvil shoes are, themselves, 
bolted or otherwise attached with fasteners to the combination roller 
body, the vibratory energy of the ultrasonic bonding horns tends to loosen 
or, in some instances, burn out the fasteners. 
Instead, the edges of the ultrasonic bonding anvil shoes are provided with 
flanges 824 and 826 which depend outwardly from the anvils in the 
direction of the width of the anvils. The flanges 824 and 826 are 
outwardly facing by which is meant the inside surface of the ultrasonic 
bonding anvil shoe 120 is wider than the outside surface. The ultrasonic 
bonding anvil shoes are thus held firmly to the outer surface of the body 
portion 104 of the combination roller by flanking each ultrasonic bonding 
anvil shoe with a pair of hold-down shoes and bolting or other wise 
fastening the hold-down shoes to the combination roller body portion 104. 
The cooperative interaction of the inwardly facing flanges on the 
hold-down shoes and the outwardly facing flanges of the ultrasonic bonding 
anvil shoes urges the inside surface of latter against the outside surface 
of the combination roller body portion. In this manner, the ultrasonic 
bonding anvil shoes are held firmly in place on the roller body. Since the 
bolts or fasteners holding the anvil hold-down shoes are thus distanced 
from the rotary ultrasonic bonding horns, the problem alluded to above of 
vibratory loosening or burning off of the bolts or fasteners is 
considerably diminished. 
When the anvil and anvil hold-down shoes are thus affixed to the 
combination roller body, vacuum tubular channels or cavities are formed 
between the inner surfaces of the shoes and the grooves, channels, or 
slots 139 and 140 in the combination roller body portion 104. These 
channels or cavities provide means for drawing air in through the vacuum 
apertures 816 and 820, respectively, in the anvil hold-down shoes 122 and 
the bonding anvil shoes 120. The tubes or channels permit the movement of 
air along the inside the assembled combination roller hub assembly. The 
slots or grooves 137 (cf. FIG. 2) permit lateral movement between adjacent 
channels or tubes in the assembled combination roller. In the manner 
described previously, holes or apertures in end- or cap-plates such as 220 
communicate with these tubular channels and with slot 518 in the vacuum 
commutators 502 (cf. FIG. 8) abutting the end- or cap-plates 220. 
FIG. 16 shows an alternative embodiment of the fully assembled roller 
sub-assembly of the machine of the invention. In FIG. 16, all parts 
correspond to the same parts illustrated in FIG. 11, with the same parts 
in both Figures denoted by the same reference numerals. In FIG. 16, 
however, the underlying roller body is that of FIG. 4A. As a consequence, 
only two vacuum commutators 502 and 514 are required. The two sets of 
anvil shoes and anvil hold-down shoes, 122-120-118 and 114-112-110 in the 
embodiment shown, are separated by a spacer shoe 116. The spacer shoe 116, 
like the anvil hold-down shoes 122, 118, 114 and 112 are provided with 
vacuum apertures and bolt or fastener apertures. Since the spacer shoe is 
flanked by anvil hold-down shoes 118 and 114, it may or may not be 
provided with outwardly facing edge flanges, depending upon whether one or 
both edges of the flanking anvil hold-down shoes are provided with 
inwardly facing flanges. 
This spacer shoe permits the passage through the machine of a wider 
substrate web. To accommodate webs of different widths, it is merely 
necessary to affix the spacer shoe of appropriate width on the combination 
roller body 104 and place the pairs of bonding anvil shoes and anvil 
hold-down shoes 122-120-118 and 114-112-110 on either side and attach them 
to the combination roller body. 
One embodiment of a machine employing the combination roller described 
above is depicted schematically in FIG. 18. The machine 900 is shown in 
perspective view with uncut component webs 910 and 912 and substrate web 
903 being fed through the machine. The webs 910 and 912 of uncut 
components are fed to the machine from supply rollers 909 and 911 and the 
substrate web 903 from supply roller 902 in the conventional manner. 
The uncut component webs 910 and 912 are shown passing over a turning bar 
914 and then over an endless belt conveyor 920 passing over rollers 916 
and 918. In the manner described above, the uncut webs 910 and 912 of 
component material are received, and held by vacuum to, combination roller 
104. As the webs 910 and 912 pass between combination roller 104 and 
rotary cutter 404, the webs are cut into discrete components which are 
held to the combination roller 104 by the vacuum means described above. In 
FIG. 18, one such cut discrete component 906 can be seen held to the outer 
working surface of combination roller 104. 
As the rollers and webs move in the directions indicated by the arrows, the 
cut component 906 is moved into position on the underside of substrate web 
903 where both the component 906 and the substrate web 903 pass between 
rotary ultrasonic bonding horn 306 and an ultrasonic bonding anvil shoe 
attached to, and forming a part of, the outer working surface of 
combination roller 104. The ultrasonic energy generated in the rotary horn 
306 bonds component 906 to the substrate web 903. Simultaneously, a 
similar operation is occurring on the opposite edge of advancing web 903 
with discrete components cut from web 910 by the cooperative action of 
rotary cutter 404, the combination roller 104 and rotary ultrasonic 
bonding horn 304. In FIG. 18, the finished substrate web, now indicated as 
904, shown leaving the machine with bonded components 908 attached. 
Rotary cutter 404 and combination roller 104 are driven by servomotor 922 
which, in turn, is controlled by programmable controller 923. A 
right-angle gear-box 924 and meshed gears contained with gear-box 204 
complete the transmission driving the contra-rotating rotary cutter 404 
and combination roller 104. A separate motor (not shown) turns jack-shaft 
pulley 926 by means of gear-belt 928. The jack shaft 930, with attached 
pulleys 932 and 934 drive the rotary ultrasonic bonding horns 304 and 306 
in the direction of the arrows by means of pulleys 940 and 942 on shaft 
302 and gear-belts 936 and 938. The linear speed of the rotary ultrasonic 
bonding horns 304 and 306 is the same as the speed of the advancing 
substrate web 903. 
The path of the webs through the machine, and the cooperative action of the 
rotary cutter and combination roller cutting anvil bar 106 is better seen 
in the detail view shown in FIG. 19. which is a partial end-view of the 
machine of FIG. 18. In FIG. 19. advancing uncut component web 912 passes 
over endless conveyor belt 920 and is picked up by the vacuum apparatus of 
combination roller 104. The component web 912, held to the outer working 
surface of combination roller 104 then passes through the nip between 
cutter bar 406 and combination roller cutting bar anvil 106 to cut the web 
into discrete workpieces 906. The cut workpiece 906, likewise held to the 
outer working surface of the combination roller 104, is moved into 
position on the underside of substrate web 903 where both the workpiece 
and the substrate web pass between combination roller 104 and rotary 
ultrasonic bonding horn 306. A workpiece component 908, prior in time in 
the process, is shown attached to substrate web 903, leaving the nip 
between the combination roller and ultrasonic bonding horn. 
FIG. 19 shows in detail the function of the rotary cutter, illustrating 
features of the rotary cutter mentioned above. The rotary cutter body has 
been machined to have one or more flats; the embodiment shown in FIG. 19 
shows four such flats, indicated as 416, 418, 420, and 422. The number of 
flats may vary from one to four, with one or three flats being preferred. 
More than four flats is theoretically possible on the rotary cutter, but 
such an arrangement becomes increasingly crowded. 
In FIG. 19, one of these flats, 416, is shown occupied by a cutting bar 
apparatus which comprises a base plate 424, a cutting bar 406, a cutting 
bar retainer 430, and retainer bolt or fastener 428. As can be seen in 
FIG. 19, this arrangement permits the cutting bar 406 to strike the 
cutting anvil bar 106 on the combination roller 104 at an angle. This 
arrangement has two distinct advantages. First, the edge of the cutting 
bar 406 which strikes the cutting anvil bar 106 is only one of four such 
edges on the cutting bar. When this edge becomes dulled or nicked during 
operation of the machine, it is a simple matter of removing the bolts or 
fasteners 428 holding cutting bar retainer 430 and cutting bar 406 and 
turn the cutting bar to begin using a new edge. Second, the cutting bar 
406 strikes the anvil bar at an angle and can thus flex, somewhat in the 
manner of a spring-board or diving board at a swimming pool. This 
eliminates the need for careful or precise placement of the cutting bar on 
the rotary cutter during machine set-up and operation. 
Having described the parts and function of the illustrated embodiment of 
the machine, the method of selectively controlling and varying the speeds 
of the combination roller 104 and rotary cutter 404 will now be described. 
As mentioned previously, the machine of the present invention employs a 
servomotor 922 for driving the shafts 102 and 402 of combination roller 
104 and rotary cutter 404, respectively. Servomotors having the requisite 
torque are commercially available. A suitable servomotor for use in the 
machine of the present invention is available, for example, from the 
Indramat Division of Mannesmann Rexroth, 5150 Prairie Stone Parkway, 
Hoffman Estates, Ill. 60192. The servomotor is controlled by a Model DDS 
or HDS controller which has been programmed in the manner taught by the 
manufacturer using the desired speed profile for a given product. 
Speed profiles for one cycle of a process using the machine of the present 
invention are shown as solid lines in the graph depicted in FIG. 20. The 
vertical axis of the graph represents the linear speed at which the 
combination roller 104 and rotary cutter 404 are turning, and the 
horizontal axis represents time, with the interval between T.sub.0 and 
T.sub.6 representing the time required for one complete rotation of 
combination roller 104 and rotary cutter 404. Speed profiles for the 
combination roller and rotary cutter are represented by the solid lines 
which begin at point B, pass through points C, E, and F, and end at point 
H. Each speed profile comprises four distinct regions: (1) a first 
constant or dwell speed, V.sub.1, represented by the horizontal line BC 
during time interval T.sub.0 to T.sub.1, (2) a period of speed change in 
the interval between T.sub.1 and T.sub.3, (3) a second constant or dwell 
speed, V.sub.2, represented by the horizontal line EF in the time interval 
between T.sub.3 and T.sub.4, and (4) a period of speed change in the 
interval between T.sub.4 and T.sub.6, which returns the speed of the 
combination roller and rotary cutter to the original speed, V.sub.1. 
In the speed profiles represented in FIG. 20, the first speed, V.sub.1, is 
shown as slower than the second speed, V.sub.2. This corresponds to the 
situation depicted in FIG. 18 where workplace webs 910 and 912 are fed 
into the machine of the invention at a first slower speed because the 
components are closely spaced apart from one another on the workpiece 
web(s). In the speed profiles of FIG. 20, the second speed V.sub.2 is 
faster than the first speed, V.sub.1. This also corresponds to the 
situation of FIG. 18 where the substrate web 903 moves at a faster speed 
than the workpiece webs 910 and 912 to space the bonded components further 
apart on the substrate web than they were on the workpiece or component 
web(s). However, it will be apparent to one of ordinary skill in the art 
that the two speeds can be reversed in the machine and process of the 
invention; that is, V.sub.1 can be faster than V.sub.2. In such a 
situation, the workpiece components bonded to the substrate web will be 
spaced more closely together than on the supply workpiece web(s). In 
certain circumstances, this may lead to "shingling" or overlapping of the 
bonded workpiece components on the substrate web, and the machine and 
process of the invention can be used to produce such products, if desired. 
Returning to the speed profiles of FIG. 20, the combination roller and 
rotary cutter speed change occurring in the intervals T.sub.1 to T.sub.3 
and T.sub.4 to T.sub.6 can take on an unlimited number of shapes, a few of 
which have been illustrated in the Figure. The first speed change can 
follow, for example a profile represented by any of the solid lines CDE, 
CD.sub.1 E, CE, CD.sub.2 E, or CD.sub.3 E or any similar variant. 
Likewise, the combination roller and rotary cutter speed change in the 
interval between T.sub.4 and T.sub.6 can follow a profile represented by 
the lines FGH, FG.sub.1 H, FH, FG.sub.2 H, or FG.sub.3 H or any similar 
variant, in a manner independent of the first speed change profile. 
It should be noted that, while the exemplified speed profiles in the speed 
change intervals T.sub.1 -T.sub.3 and T.sub.4 -T.sub.6 are shown as 
rectilinear, the profiles shown in FIG. 20 can also be curvilinear. That 
is to say, speed change profile CDE, shown as a line of acceleration CD 
and a line of deceleration DE, could be represented by a line breaking at 
two, three, or more intermediate points. Following this to its logical 
extreme, the line CDE would be a smooth curve between points C and E 
having a maximum at point D. It is preferred, however, that the speed 
profile in the speed change intervals T.sub.1 -T.sub.3 and T.sub.4 
-T.sub.6 each be defined by a single "break point" to simplify 
determination of the overall speed profile, although, it has been found 
that the majority of cases of cutting and bonding can be accommodated by 
the straight line acceleration CE and deceleration FH. 
It has been found that when the operating speed profile of the machine of 
the invention is measured, programming an idealized rectilinear speed 
profile such as BCDEFGH into the controller for the servomotor results in 
an actual observed speed profile in which regions CDE and FGH are 
curvilinear, while closely following profile the straight lines CDE and 
FGH. This will be readily understood by one of ordinary skill in the 
machine arts, who realizes the difficulty of abrupt changes in motor and 
roller speed such as would be required at points D and G in the idealized 
speed profile. Thus both rectilinear and curvilinear speed profiles for 
the speed change intervals T.sub.1 -T.sub.3 and T.sub.4 -T.sub.6 are 
contemplated as falling within the scope of the invention. 
It is fundamental to the development of the velocity profile that the area 
under the line BCDEFGH (i.e. the integral of the speed profile function 
with respect to time) be set equal to the length of the circumference of 
the combination roller. With this fundamental "rule" set, it is possible 
to develop profiles which utilize the machine to manufacture articles 
having an almost infinite number of component configurations without 
requiring elaborate retooling of the machine. 
That is, as the spacing of the uncut components on the component supply web 
and the required spacing of the components bonded to the substrate web 
differ from one product to another, the roller speeds V.sub.1 and V.sub.2 
must be changed, relative to one another. Such a change results in a 
corresponding change in the area under the speed profile, which would 
ordinarily require an attendant change in the roller circumference (i.e. a 
grade machine change). However, in the machine and process of the present 
invention, as product line changes require changes in the roller speeds 
V.sub.1 and V.sub.2, the total AREA under the speed profile (i.e. the 
machine roller circumference) is kept constant by the simple expedient of 
appropriate adjustment in the speed profile in the speed change intervals 
T.sub.1 -T.sub.3 and T.sub.4 -T.sub.6. The only limitation on this being 
the ability to complete an acceleration or deceleration within the 
allotted time based upon the torque available from the motor driving the 
roller. The required torque is the slope of the acceleration or 
deceleration multiplied by the roller inertia. Also, knowing that the time 
interval T.sub.0 -T.sub.6 represents the time for one complete product 
cycle, and given the available servo motor torque, the maximum machine 
speed (product/second) can be readily calculated. 
As stated earlier, the dwell speeds V.sub.1 and V.sub.2 are determined by 
the spacing of the components on the supply workpiece web and their 
desired spacing when bonded to the substrate web for a particular product 
line. The profile AREA is defined by 1/4, 1/2, 3/4, or 1 rotation of the 
combination roller, and the time interval T.sub.0 -T.sub.6 corresponds to 
the product cycle for each AREA. The profile AREAs are changed to 1, 2, 3, 
or 4 times per roll revolution to better fit product specifications and 
match acceleration to available torque and desired machine speed. 
Therefore, all of the values of V.sub.1, V.sub.2, T.sub.1, T.sub.3, 
T.sub.4, T.sub.6, and the area under speed profile are thus established by 
requirements of the product configuration or machine roller diameters. All 
that remains in determining a speed profile is the determination of the 
"break points" in the speed change intervals. 
Referring to FIG. 20, an "ideal" speed profile is represented by the solid 
line BCEFH. This "ideal" speed profile represents one in which the machine 
is "tailor-made" to the particular product line, that is, a machine in 
which the roller circumference is chosen to be equal to the area bounded 
by a speed profile having two constant dwell speeds equal to the web 
speeds, and periods of smooth, linear acceleration and deceleration. The 
line BC represents the slow dwell speed at which the component web is 
received and cut into components. The solid line CE represents an interval 
of simple linear acceleration to the faster substrate web speed during 
which interval the speed of the combination roller and cut workpiece 
process are changed to meet the faster speed of the advancing substrate 
web. The line EF represents the faster dwell speed during the interval 
where the cut workpiece is bonded to the substrate web. Finally, solid 
line FH represents the interval during which the combination roller speed 
is changed to again match the slow speed of the workpiece or component 
web, thus completing one cycle of the machine operation. 
In this "ideal" situation, the roller circumference would be fixed by the 
length corresponding to the irregular area bounded by the lines joining 
the points ABCEFHL. If one were to use the machine to make a different 
product where the product configuration required moving, for example, 
speed V.sub.2 to a lower value while leaving V.sub.1 at its former value, 
the result would be a decrease in the area bounded by lines joining points 
ABCEFHL. If the speed profile were to remain an "ideal" profile, the area 
under the profile would correspondingly decrease, requiring a decrease in 
the machine roller circumference. The machine of the present invention 
permits a simple "electronic grade change" when moving to the new product 
line rather than requiring such a complicated machine change. The total 
area under the speed profile in the machine and process of the invention 
is kept constant by simply adding area to or subtracting area from the 
area under the "ideal" speed profile as V.sub.2 is moved with respect to 
V.sub.1. 
It is readily apparent to one of ordinary skill in the machine arts that 
matching V.sub.1 to the in-feed product for the ideal time span T.sub.0 
-T.sub.1 is a physical impossibility for a single variable velocity roll 
as described here. In the situation where a workpiece component patch of 
length X is placed on a product of length Y, it is understood that 
component patch X is fed at a rate of one X per one product Y. Since the 
component patch having length X is fed once per product of length Y, and 
the perfect time interval is T.sub.0 -T.sub.6, it is only possible to 
match the in-feed speed (V.sub.1) for a fraction of the in-feed time, and 
therefore T.sub.0 -T.sub.1 must be less than T.sub.0 -T.sub.6. It has been 
found through experimentation with the machine of the present invention 
that matching V.sub.1 is generally only critical during the instant of 
cutting and that the roller speed can be mis-matched from the patch speed 
during the pre-cut in-feed interval. The machine of this invention does, 
however, match the V.sub.2 bonding speed since the V.sub.2 time interval 
T.sub.3 -T.sub.4 is naturally a fraction of the product time cycle T.sub.0 
-T.sub.6. 
It is to be understood that in FIG. 20 and in the discussion which follows, 
the speed V.sub.2, and its graphical representation, line EF, is upwardly 
or downwardly moveable, carrying with it points E and F and the lines 
attached thereto. The various speed profiles shown in FIG. 20 have been 
shown with a common line EF to avoid unnecessarily cluttering the figure. 
In the hypothetical case of speed profile BCDEFGH, the substrate web speed, 
V.sub.2 has been lowered with respect to workpiece web speed V.sub.1. To 
maintain the area under the speed profile constant (to match the fixed 
machine combination roller circumference), "excess" triangular areas 
bounded by lines joining the points CDE and points FGH are added. This 
area is generated by over-accelerating the roller to a speed greater than 
V.sub.2, and decelerating back down to V.sub.2 in the first speed as 
change interval, and over-accelerating the roller to a speed greater than 
V.sub.2, and decelerating back down to V.sub.1 in the second speed change 
interval. 
In another hypothetical example, were the product configuration to require 
raising V.sub.2 with respect to V.sub.1, it would be necessary to subtract 
area from the area under the speed profile. Such a situation is 
represented, for example by speed profile BCD.sub.2 EFG.sub.2 H. In that 
case, the triangular areas CED.sub.2 and FHG.sub.2 would be subtracted 
from the "ideal" profile area to maintain the area constant. In this 
manner, the mechanical features of the machine (roller diameter and 
circumference) may remain unchanged while the servomotor driving the 
roller is re-programmed electronically to accommodate product line 
changes. 
The values of maximum velocity D and G, corresponding to coordinates 
V.sub.max, T.sub.2 and T.sub.3 are determined as illustrated in FIG. 21 
where the initial portion of speed profile BCDEFGH is illustrated. The 
total area under that speed profile is the irregular area bounded by the 
lines jointing points ABCDEFGHL of FIG. 20. If the preferred choice is 
made to divide the excess speed area into equal triangular areas CDE and 
FGH, the area under the triangle CDE, Area.sub.CDE, is equal to: 
EQU Area.sub.CDE =(Roller circumference)/2-Area.sub.CEK -Area.sub.EFJK 
-(Area.sub.ABHL)/2 
Correspondingly, the area under the triangle FGH, Area.sub.FGH, is equal to 
: 
EQU Area.sub.FGH =(Roller circumference)/2-Area.sub.FHJ -(Area.sub.ABHL)/2. 
Once the area of triangle CDE is known, point D is determined as 
illustrated in FIG. 20. Referring to FIG. 21, a right triangle CER is 
constructed on the base line CE which runs between coordinates T.sub.1, 
V.sub.1 and T.sub.3 V.sub.2 by dropping a line perpendicular to line CE 
passing through the coordinate T.sub.3 V.sub.2 (point E) and extending it 
to point R such that its length, Length.sub.WER, is equal to: 
EQU Length.sub.ER =sqrt[(T.sub.3 -T.sub.1).sup.2 (V.sub.2 -V.sub.1).sup.2 ] 
Next, a line ST of slope equal to the slope (acceleration) of line CE is 
then constructed to pass through point R. The point D falling on line ST 
is then determined such that the angles CDQ and QDE are equal. This point 
defines the dotted lines CD and DE and fixes point D which, in turn 
determines V.sub.max and T.sub.2. In a similar manner, the value of 
T.sub.5 is also determined. 
Once the velocity values of V.sub.1, V.sub.2, V.sub.max, and the time 
values T.sub.1, T.sub.2, T.sub.3, T.sub.4, T.sub.5 and T.sub.6 are 
determined for a particular product, a data table of velocity for n points 
along the time axis of the speed profile is generated. The resulting data 
table is used as the data control set for controlling the variable speed 
of the servomotor during each revolution of the machine rollers. For 
example, a data table of roller speed at each 1/2000 revolution is 
constructed. These data are fed into the servomotor controller drive the 
servomotor, combination roller, and rotary cutter to operate at the 
desired speeds. To convert the machine to the production of a new product 
with different configuration, it is merely necessary to generate a new 
data table for that product to drive the servomotor. 
While there has been shown and described the preferred embodiments of the 
machine and process of the present invention, it will be clear to one of 
skill in the art that various modifications in the machine and process can 
be made without departing from the scope of the invention as it is 
described in the appended claims.