Single transfer insert placement method and apparatus

An apparatus and method is provided for single transfer insert placement. The apparatus receives continuous web material and cuts a discrete section or pad from the web. The pad is then supported on a single transfer surface. The single transfer surface then may spin the supported pad to a desired angle and provide the pad to a receiving surface at a desired interval.

BACKGROUND OF THE INVENTION

This invention relates to a method and apparatus for receiving and cutting a continuous web, and transferring articles, or inserts, such as absorbent pads cut from the web in the manufacture of disposable absorbent articles such as diapers, incontinence control garments or female sanitary pads as they advance along a production line.

In the production and manufacture of disposable products such as sanitary napkins or pants-type diapers, it frequently becomes necessary to manufacture a component of the product in one orientation, and then to spin that component part to a predetermined angle, which is suitably oriented for use in another step in the production process. Various devices have been developed for this purpose and are known to those experienced in the industry. Examples of such apparatus are those described in U.S. Pat. Nos. 4,726,876, 4,880,102, and 5,025,910.

As mentioned above, a typical article or web to be reoriented by the apparatus of this invention is an absorbent pad. Past devices normally cut a received web to form the pad prior to placement on a transfer mechanism. Cutting the web to form the pad prior to placement on the transfer mechanism requires a separate step between the cutting process and transfer process. Therefore, it is desirable to have an apparatus for receiving a continuous web onto a transfer mechanism prior to cutting the web into discrete pads, cutting a section from the web thereby forming a pad, spinning the pad to a predetermined angle, and transferring the pad for placement on a receiving surface, thereby eliminating the requirement of a separate transfer step between the cutting and transferring step.

In addition to requiring spin, the web may be provided at one velocity and a pad may be cut from the web at a cut pitch. However, the cut pitch is likely a different spacing interval than the desired placement pitch on a receiving surface. In the case of a diaper, for example, the pad may be an absorbent insert to be placed on a fluid impervious chassis. Therefore, the web may be cut at a cut pitch, X, and the receiving pitch, or distance between consecutive chasses at the receiving surface may be represented as Y, where Y is comprised of a chassis trailing edge, an interval space, and a subsequent chassis leading edge. Therefore, it is desirable to compensate for the difference between the cut pitch, X, and the receive pitch, Y. Re-pitching is known in the art, but prior art device techniques tend to cause excessive wear on the devices due to the momentum changes that are required.

Hence, the art would benefit from an apparatus which is capable of receiving a continuous web at one velocity and cutting a section from the web at a first pitch to create a pad, which is transferred, oriented and properly spaced to a desired receiving pitch for placement on a receiving surface, while at the same time reducing wear on the devices.

SUMMARY OF THE INVENTION

Briefly, in accordance with a preferred embodiment thereof, provided are an apparatus and a method for receiving a continuous web, separating a section from the web thereby forming a pad, spinning the pad to a predetermined angle, and changing the spacing between neighboring pads while transferring the pad to a receiving surface.

In a preferred embodiment of the present invention, the apparatus generally includes a transfer mechanism and a cutter. The transfer mechanism comprises a plurality of pucks rotatably driven about a transfer axis. The cutter comprises an anvil roller and a plurality of knife blades rotatably driven about a knife blade axis. The transfer axis and knife blade axis are offset, so as to allow modification of the circumferential spacing between neighboring pucks. The pucks are each supported by a puck support. Each puck is coupled to a spin cam and a pitch cam. As the puck rotates about the transfer axis, the cams alter the position of the puck. The spin cam alters puck motion about a puck spin axis which is generally perpendicular to the transfer axis. The pitch cam alters the relative circumferential spacing of adjacent pucks.

A single transfer placement method according to the present invention includes the following steps:1. Receiving a continuous web.2. Cutting a discrete section from the continuous web, thereby forming a pad, wherein the pad is supported by a first surface; and3. Transporting the pad on the first surface to a receiving surface.

Additionally the transporting step may incorporate the following steps:1. Spinning the first surface to a predetermined angle; and2. Changing the speed of the first surface.

DETAILED DESCRIPTION

Turning now to the drawings,FIG. 1illustrates a front elevation view of a first embodiment 1 of an apparatus according to the present invention. The apparatus1preferably includes a transfer mechanism3and a cutter5.

Referring, in addition toFIG. 1, toFIGS. 2 and 3, the transfer mechanism3includes a plurality of pucks301. Each puck301has a leading edge302and a trailing edge304and is coupled to a puck support303, which is ultimately rotated by a puck wheel305about a puck transfer axis306, which is a major axis of rotation, through a transfer path4. As used throughout the description of the preferred embodiment, “rotate” and its variants refer to the movement of an entire puck301and puck support303assembly about the transfer axis306, while “spin” and its variants refer to the radial spin of a puck301about a puck spin axis312, which is substantially perpendicular to the puck transfer axis306. The puck wheel305is driven preferably by a substantially operationally constant rotational force provided by a shaft314coupled to a motor307.

The puck support303is coupled to the puck wheel305by a primary pitch linkage310and a secondary pitch linkage311. The primary pitch linkage310preferably includes three attachment points; a puck wheel anchor313, a pitch cam follower anchor315, and a secondary linkage anchor317. The puck wheel anchor313couples the primary pitch linkage310to a predetermined location on the puck wheel305. The puck wheel anchor313serves as a minor rotation axis about which the primary pitch linkage310rotates, thereby causing, in cooperation with the secondary pitch linkage311, the associated puck301to change its position in relation to the major axis of rotation, the puck transfer axis306. The pitch cam follower anchor315couples the primary pitch linkage310to a pitch cam follower329. Finally, the secondary linkage anchor317couples the primary pitch linkage310to the secondary pitch linkage311. The secondary pitch linkage311preferably provides a substantially linear link coupled near one end to the primary pitch linkage310and near the other end to the puck support303.

To facilitate position modification of the pucks301, the apparatus1also includes a cam plate320situated about the transfer axis306. The cam plate320is preferably a stationary plate having at least two raceways therein or thereon, a spin cam race321and a pitch cam race323. The spin cam race321is preferably provided around the outside edge of the cam plate320. To achieve desired spin of the pucks301, a spin cam follower325, which is preferably a roller bearing, is in sliding or rolling communication with the spin cam race321. A spin linkage327couples the puck301to the spin cam follower325. While the spin cam race321is depicted as providing a ninety degree puck rotation, positioning of the spin cam race321is generally determined by the desired spin angle of the puck301.

In addition to aiding puck spin, the cam plate320assists the pitch change, or altered circumferential puck spacing. The pitch change is accomplished by using the pitch cam follower329, which is preferably a roller bearing, in sliding or rolling communication with the pitch cam race323. Located preferably near a radial distal edge308of the puck wheel305is a pair of pitch rails309, which allow controlled circumferential displacement of the pucks301. The pitch rails309are preferably fastened to the puck wheel305. The puck support303is provided with rail guides318, which are slidably disposed on the pair of pitch rails309.

The pitch cam race323is formed, preferably on a face of the cam plate320, to effect a desired pitch change. Although different designs could be employed, where the pitch cam race323is situated further from the puck transfer axis306, the velocity of the puck301will be higher than where the pitch cam race323is positioned nearer the transfer axis306. As described in this preferred embodiment, the maximum pitch change, therefore, is generally determined by the shape of the pitch cam race323and the combined length from the primary pitch linkage310of the puck wheel anchor313to the secondary pitch linkage311end which is coupled to the puck support303.

The cutter5is best described with reference toFIGS. 1 and 3. The cutter5preferably comprises an anvil roller501having an anvil surface503, and a knife wheel505. The knife wheel505includes a plurality of knife blades507radially disposed about a knife wheel axis506. The knife wheel505preferably has fewer blades507than the number of rotator pucks301provided on the transfer mechanism3. The fewer number of blades507provided allows a greater offset508between the knife wheel axis506and the puck transfer axis306. The eccentric offset508causes a virtual withdrawal of the knife blades507to allow more space to achieve desired pitch change. Alternatively, an anvil wheel having a plurality of anvils could be substituted for the knife wheel505and a knife roller having a knife blade could be substituted for the anvil roller501.

As seen inFIG. 4A, the apparatus1may also include a manifold330to allow fluid communication between a vacuum source and the pucks301at certain positions. The manifold330is preferably comprised of a vacuum port322, a stationary vacuum manifold324and a rotating vacuum manifold326. The vacuum port322preferably provides vacuum connection point, which may be standard or custom. The port322provides a support structure and an aperture332to allow vacuum pressure to be drawn through the port322. The stationary vacuum manifold324is generally a fixed plate having at least one vacuum groove334formed therethrough at a predetermined location. The vacuum groove334is stationary and in fluid communication with the vacuum port aperture332. The rotating vacuum manifold326is generally a rotating plate preferably having a face in slidable relation to the puck supports303. The rotating manifold326includes at least one aperture336to allow, when in fluid communication with the aperture334in the stationary manifold324, a vacuum to be drawn through the vacuum port322, the stationary manifold324, the rotating manifold326, the puck support303and the puck301.

FIG. 4Bprovides an alternate stationary vacuum manifold333. This embodiment333preferably includes a vacuum port322coupled to a vacuum source and interfaces to a rotating vacuum manifold, such as the rotating vacuum manifold326inFIG. 4AorFIG. 19. The vacuum port322preferably provides vacuum connection point, which may be standard or custom. The port322provides a support structure and an aperture332to allow vacuum pressure to be drawn through the port322. The stationary vacuum manifold333is generally a fixed plate having at least one, but preferably two vacuum grooves334formed at predetermined locations. The vacuum grooves334are in fluid communication with the vacuum port aperture332. The manifold333also preferably includes an ejection port335including an ejection aperture337, which may be adapted to be coupled to a compressed air source (not shown). The ejection port335is preferably in fluid communication with an ejection groove339, which may be an extension of one of the vacuum grooves334, but separated therefrom by a vacuum plug341. The vacuum plug341may be selectively placeable but is preferably stationarily held in one of said vacuum grooves334. In this way, vacuum may be drawn through the vacuum grooves334and compressed air may be forced through the ejection port335and into the ejection groove339. As the rotating manifold326rotates in a first direction343, a pair of manifold apertures336may each encounter a vacuum groove334, perhaps substantially simultaneously. However, it may be desirable to remove vacuum from one of the apertures336and then force air through that same aperture336in opposite direction to the vacuum to aid in the transfer of a pad11to a receiving surface25. For instance, it may be desirable to maintain vacuum on the trailing edge of a puck301while forcing a pad11off of the puck301leading edge with compressed air provided through the ejection aperture337and ejection groove339.

Although the terms “circumferential” and “rotation” are used to describe the transfer movement of the pucks301, it is to be understood that the invention is not limited to applications utilizing a circular motion. For instance, rather than be driven by a puck wheel305rotated by a motor307, the pucks301may be coupled to a chain drive (not shown) or something similar. The travel path of the pucks301may then be defined by the shape of an employed cam plate320or by the path of any supporting pitch rails309used.

All of the components of the apparatus1are either generally well known in the art, such as the roller bearings preferred for the cam followers, or can readily be made of standard materials. For example, the knife blades507and anvil roll501may be made of well known materials such as common tool steels. The supporting and rotating structures, such as the puck supports303, linkages, wheels, etc., may be made of suitable aluminum. The pucks301are formed from any desirable material, but a lightweight material is preferred, such as nylon.

The operation of the present apparatus1will be described next with reference toFIGS. 5-15, inclusive. Generally, the apparatus1receives a continuous web10, separates a section from the continuous web10to form an insert or pad11, spins the pad11to a predetermined angle, and changes the pitch between consecutive pads11. While the operation of the apparatus1is described with reference to a single puck301aand a single knife blade507a, it is to be understood that the operation of the remaining pucks301and knife blades507is at least substantially similar. Furthermore, although the operation is described with reference, inFIGS. 8-15, to discrete puck positions P1-P8, it is to be understood that the operation is preferably generally continuous. The discrete positions aid in illustrating the operations being performed.

FIGS. 5 and 6depict a puck velocity profile, as each puck301rotates through various portions of its travel path. With reference also toFIG. 1, the puck transfer mechanism3rotates about the puck transfer axis306at a relatively constant velocity VS. When a puck301receives continuous web material10, the puck301may be moving at a substantially constant first velocity V1. A pad11is then cut from the continuous web10. To create the pad11, a first cut402is made proximate the leading puck edge302and a second cut404is made proximate the trailing puck edge304. Just after a pad11is cut from the web material10, the puck301may be accelerated406to prevent any collision with the subsequent neighboring puck301and may be decelerated408thereafter back to a substantially constant velocity410, which may be the first velocity V1. Sometime after the trailing edge cut404and prior to placement416of the pad11on a receiving surface25, the puck301spins to a desired angle and the velocity of the puck301may change412to achieve a desirable predetermined circumferential spacing. Upon or after reaching a substantially constant414second velocity V2, the pad11is placed416on the receiving surface25. After pad placement416, the puck301is decelerated418to a substantially constant420first velocity V1and is spun back to a web-receiving orientation. The process then begins anew.

During periods of acceleration and deceleration, the pucks301change position relative to the major axis of rotation, the puck transfer axis306. This can best be seen by reference toFIG. 7. A first reference point430represents a point on the shaft (314onFIGS. 2 and 3) spinning about the puck transfer axis306at the relatively constant velocity VS during operation of the device1. A second reference point432represents a position of a puck301. While the shaft reference430may be rotating about the puck transfer axis306at a constant velocity, the position of the puck reference432with respect to the shaft314may change a desirable amount, such as an increase of ten degrees or more of rotation during acceleration and a decrease of ten degrees or more of rotation during deceleration. To illustrate, the shaft reference430is generally radially aligned with the puck reference432during times of cutting402,404. At the end408of the first acceleration, the puck reference432has changed position relative to the shaft reference430by a first distance434. At the end410of the first deceleration period, the references430,432are again aligned. Prior to pad placement416, the puck301is again accelerated, and at the end414of the second acceleration the puck reference432has advanced beyond the shaft reference430by a second distance436. The first distance434may be the same as, or different than, the second distance436. Finally, at the end420of the second deceleration period, both references430,432are aligned and ready for another revolution.

FIG. 8shows a representative puck301ain a first position P1. In the first position P1, the puck301areceives continuous web material10traveling in a first direction21at the first velocity. A vacuum is drawn through the vacuum port322, the stationary vacuum manifold324, the rotating vacuum manifold326, the puck support303and the puck301ato support the material10on the puck301asurface. While receiving the web10, the puck301ais traveling about a puck wheel axis306in a second direction23, to which at this point P1the first direction21is preferably substantially tangential. The puck301acontinues to move in the second direction23into a second position P2.

FIG. 9depicts the puck301ain the second position P2. In this position, the puck301ais at the leading edge cut time402ofFIG. 6. Here, the cutter anvil surface503cooperates with a representative knife blade507ato cut the web10proximate the leading edge302aof the puck301a. After receipt of the web10and the cut made near the leading edge302a, the puck301aproceeds to travel in the second direction23past the anvil roller501to a third position P3.

FIG. 10shows the puck301ain the third position P3. In this position P3, the puck301ais at the trailing edge cut time404ofFIG. 6. In this position P3, the cutter anvil surface503cooperates with a knife blade507to cut the web10proximate the trailing edge304aof the puck301ato cut a section11afrom the web10. The section11ais held to the puck301aby the vacuum, which was drawn previously. After the cut made near the trailing edge304a, the puck301aproceeds to travel in the second direction23to a fourth position P4.

FIG. 11shows the puck301ain the fourth position P4. As mentioned previously, it is often desirable to spin the cut section11ato some predetermined angle prior to placement on a receiving surface25. Here, the puck301ais shown while in the midst of a spin. WhileFIG. 11shows the puck301arotating in the fourth position P4, the puck301amay rotate in a third direction17to a desired angle anytime after the trailing edge cut made at the third position P3and before placement onto the receiving surface25.

Besides rotation and spin of the pucks301, the apparatus1may also change the circumferential spacing of the pucks301a; thereby resulting in a placement pitch that is different from the pitch at which the web material10was cut. The eccentric nature of the puck wheel axis and the knife wheel axis506allows the puck301ato drop away from the knife wheel505, thereby providing greater angular movement ability than if a knife blade507remained between consecutive pucks301. The ultimate circumferential spacing of the pucks301at the receiving surface25is a function of a desired placement pitch27and the speed at which the receiving surface25is traveling. In the preferred embodiment, the circumferential spacing is achieved by a desired pitch cam slot323configuration. Upon achieving desired circumferential spacing, the puck301aarrives in a fifth position P5.

The puck301ais shown in the fifth position P5inFIG. 12. In this position P5, the puck301ais at the middle of the placement time416shown inFIG. 6. The puck301ahas been situated at the correct placement pitch or distance27with respect to the puck301that preceded it301a. At this pitch or distance27, the section11ais transferred to the receiving surface25. At the time of placement, the vacuum that was drawn through the puck support303and puck301amay be removed from at least a portion of the puck301a, thereby allowing a smooth transfer of the cut insert11afrom the puck301ato the receiving surface25. The vacuum may remain active through the stationary vacuum manifold324and the rotating vacuum manifold326to assist in supporting subsequent sections11in place on later neighboring pucks301. After placing the section11aonto the receiving surface25, the puck301acontinues in the second direction23to a sixth position P6.

FIG. 13shows the puck301ain the sixth position P6. The puck301ais shown as having released the cut section11aonto the receiving surface25. The puck301acontinues to move in the second direction23to a seventh position.

FIG. 14depicts the seventh position P7of the puck301a. If the puck301aand pad11awere rotated after cutting to some predetermined angle prior to placement on the receiving surface25, the puck301amay need to be adjusted to a web-receiving orientation. WhileFIG. 14shows the puck301aspinning in the seventh position P7, the puck301amay spin in a fourth direction19anytime after the section11ahas been placed on the receiving surface25and before the continuous web10is received. The fourth direction19may be the same as the third direction17or different.

Finally, the puck301ais shown in the eighth position P8inFIG. 15. The eighth position P8is substantially similar to the first position P1, except that the knife blade507ahas now advanced a number of positions ahead of the puck301a. The number of positions advanced is a function of the difference between the number of pucks301and the number of knife blades507. In this operating example, there are nine pucks301and eight knife blades507. Therefore, in the eighth position P8, the knife blade507ahas advanced one position ahead of its position in the first position P1.

FIG. 16depicts an alternative embodiment200of a cam plate320according to the present invention. The cam plate200preferably includes a spin cam race321and at least one pitch cam race202, such as that formed by a first edge202aand a second edge202b, which are preferably concentric. This cam plate embodiment200, however, more preferably includes a second cam race204, which may be nested within the first202and formed by a third edge204aand a fourth edge204b, which are preferably concentric. Thus, a single replacement cam plate200may be used on different systems utilizing different static cam race profiles, thus reducing the number of spare parts that must be warehoused. Additionally, as further described below, a single cam plate200may provide added flexibility to a single machine if used in conjunction with pitch cam follower cartridges600.

FIG. 17AandFIG. 17Bshow the use of the preferred cam plate200installed in a system according to the present invention and used in conjunction with pitch cam follower cartridges600.FIG. 17Ashows pitch cam follower cartridges600having a first pitch cam follower629sized and adapted to follow the first pitch cam race202in the cam plate200.FIG. 17Bshows pitch cam follower cartridges600having a second pitch cam follower631sized and adapted to follow the second pitch cam race204in the cam plate200. While it will generally be desirable to utilize the same pitch cam race202or204to control the pitch of all pucks301in a given system, the invention does not preclude the use of the first pitch cam follower629with a first puck301and the second pitch cam follower631with a second puck on the same system. Furthermore, although only two pitch cam races202,204are disclosed, it is to be understood that further nesting of pitch cam races is possible, thus providing three or more nested cam profiles.

FIG. 18Ais a perspective view of a preferred pitch cam follower cartridge600. The preferred pitch cam follower cartridge600has a cartridge housing602having a first side604and a second side606, each side having at least one but preferably a plurality of mounting flanges608. The mounting flanges608on the first side604of a first cartridge600may be interlaceable with the mounting flanges608provided on the second side606of a second cartridge600. Pivotally mounted to the cartridge housing602by a puck wheel anchor313is a primary pitch cam linkage310. The pitch cam linkage310supports a pitch cam follower329, such as the pitch cam follower629shown inFIG. 17A, and provides a site for a secondary linkage anchor317.

FIG. 18Bis a perspective partial assembly view of a preferred pitch cam follower cartridge600being installed on a preferred puck wheel305. A plurality of fasteners620is provided to mechanically couple the pitch cam follower cartridges600to the puck wheel305. The fasteners620may be threaded fasteners adapted to extend through the mounting flanges608on the cartridge housing602and cooperate with threaded apertures622on the puck wheel305to support the cartridge600on the wheel305.

FIG. 19is a perspective view of a preferred method of rotating a vacuum manifold326. A drive pulley650is driven by a vacuum manifold drive shaft652and an endless belt654is placed about the drive pulley650and the vacuum manifold326. An idler pulley656may be used to maintain desired tension of the belt654. In this way, the rotating vacuum manifold326may be placed at variable positions relative to the main puck wheel305. Such independent drive, may be advantageous for certain applications, such as offering size change flexibility.

FIG. 20is a perspective view of a preferred puck support303according to the present invention. The puck support303comprises a puck support head700having a puck support surface702. Extending through the puck support surface702is at least one, but preferably a plurality of vacuum apertures704a-h. The puck support head700also preferably includes a bearing aperture710that extends through the head700at least substantially perpendicular to the puck support surface702. Further, the puck support303is provided with rail interface arms712, which preferably receive the rail guides318to interface with the pitch rails309. The vacuum apertures704a-hare in fluid communication with a vacuum chamber338that runs from the puck support head700through a puck support base706by way of vacuum pipes708a,708b. While the puck support303may have a single vacuum chamber338, the puck support303is preferably provided with two vacuum chambers338a,338b. In this way, multiple apertures704a-dmay communicate with a first vacuum chamber338a, which may be termed the leading vacuum chamber338a. Further, multiple apertures704e-hmay communicate with a second vacuum chamber338b, which may be termed the trailing vacuum chamber338b. In operation, the cooperation of the puck support base706with the rotating vacuum manifold326and the stationary vacuum manifold324may desirably draw a vacuum through the leading vacuum chamber338abefore the vacuum is drawn through the trailing vacuum chamber338bfor receiving the continuous web10. Additionally, the vacuum may be drawn for a longer period on the trailing vacuum chamber338bafter the vacuum has been removed from the leading vacuum chamber338awhen placing the cut pad11on the receiving surface25.

FIG. 21provides a first embodiment800of a preferred puck301according to the present invention. The puck800has a puck body802having a first web surface804, a support surface806preferably oppositely disposed from the web surface804, and a bearing shaft808depending from the support surface806. The bearing shaft808is adapted to be rotatably supported by the puck support303, such as being rotatably held in the bearing aperture710in the puck support head700. The puck body802includes a vacuum chamber (not shown) within the body802. Communicating fluidly with the vacuum chamber are preferably a plurality of web vacuum holes810extending through the web surface804and a plurality of support vacuum holes (not shown) extending through the support surface806. The web vacuum holes810are provided about the web surface804, and may be evenly spaced and provided near the perimeter of the web surface804. The support vacuum holes provide a means for drawing a vacuum through the web vacuum holes810and the vacuum chamber in the puck body802. Preferably, the support vacuum holes are mateable and adapted to cooperate with the vacuum apertures704extending into the puck support303. By imparting a force to the bearing shaft808, the puck301may be spun from a web-receiving orientation801to a web-placement orientation803. Such force may be applied to the bearing shaft808by way of the spin linkage327that is coupled to the spin cam follower325, which is disposed at least partially in the spin cam race321. Though any web-placement orientation803angle may be desirable, the depicted angle805is ninety degrees from the web-receiving orientation801.

FIG. 22A,FIG. 22BandFIG. 23provide a second embodiment850of a preferred puck301according to the present invention. The puck850has a puck body852having a first web surface854, a support surface856preferably oppositely disposed from the web surface854, and a bearing shaft858depending from the support surface856. The bearing shaft858is adapted to be rotatably supported by the puck support303, such as being rotatably held in the bearing aperture710in the puck support head700. The puck body852includes a vacuum chamber (not shown) within the body852. Communicating fluidly with the vacuum chamber are preferably a plurality of web vacuum holes860extending through the web surface854and a plurality of support vacuum holes862extending through the support surface856. The web vacuum holes860are provided about the first web surface854, and may be evenly spaced and provided near at least a portion of the perimeter of the web surface852. The support vacuum holes862provide a means for drawing a vacuum through the web vacuum holes860and the vacuum chamber in the puck body852. Preferably, the support vacuum holes862are mateable and adapted to cooperate with the vacuum apertures704extending into the puck support303. By imparting a force to the bearing shaft858or other portion of the puck301, the puck301may be spun from a web-receiving orientation851to a web-placement orientation853. Such force may be applied to the bearing shaft858by way of the spin linkage327that is coupled to the spin cam follower325, which is disposed at least partially in the spin cam race321. Though any web placement position853angle may be desirable, the depicted angle855is ninety degrees from the web receiving position801.

In addition to the first web surface854, this embodiment850preferably includes a pair of end web surfaces864, which may be slidably disposed upon a pair of rails866. To effect the slide of the end web surface864, in a generally up-and-out manner, a dish cam868may be provided between a desired puck support303and the puck301. The dish cam868preferably includes at least one cam groove870having a changing radius. Thus, when the puck301is in the web receiving position851, the end web surfaces864are in a first position, preferably nearer the puck body852. As the puck301spins to the web placement position853, an end web cam follower872that is placed in the cam groove870causes the end web surface864to slide along the rails866to a second position, preferably further from the puck body852. The end web surfaces864are also preferably provided with a plurality of web vacuum holes860in fluid communication with an end web vacuum chamber874. The end web vacuum chamber274is preferably in fluid communication with the vacuum chamber (not shown) in the puck body852. Such fluid communication between the end web vacuum chamber274and puck body852vacuum chamber may be provided by one or more vacuum bellows876.

FIG. 24andFIG. 25depict a second embodiment 2 of an apparatus according to the present invention. Generally, in this embodiment 2, the pitch cam arrangement of the first embodiment has been replaced by a plurality of servo drives880, each of which may control the relative circumferential movement of a puck301relative to the main puck wheel305, to which the servo drives880are preferably mounted. The servo drives880preferably have a rotatable shaft882that may be coupled to the primary pitch linkage310to enable such control. The servo drives880preferably have a first electrical terminal884and a second electrical terminal886, wherein the first electrical terminal884of a first servo drive880is electrically coupled to the second electrical terminal886of a second servo drive880and the second electrical terminal886of the first servo drive880is electrically coupled to the first electrical terminal of a third servo drive880. Thus, the electrical connections may be provided by a plurality of electrical wires888in a daisy chain format. The servo drives880are preferably controlled by and communicatively coupled to a servo drive controller (not shown). Such communicative coupling may be provided by a slip ring890and a plurality of electrical wires (not shown). An example of servo drives880and a servo drive controller may be found in the Rexroth IndraDrive® Mi Drive System provided by Bosch Rexroth Corporation of Hoffman Estates, Ill.

FIG. 26,FIG. 27andFIG. 28provide a second preferred velocity profile and associated puck positioning of an apparatus according to the present invention. This profile may be referred to as an accel-to-place profile. With reference also toFIG. 1, the puck transfer mechanism3rotates about the puck transfer axis306at a relatively constant system velocity VS. When a puck301receives continuous web material10, the puck301is moving at a first velocity, which may be the system velocity VS. A pad11is then cut from the continuous web10. To create the pad11, a first cut902is made proximate the leading puck edge302and a second cut904is made proximate the trailing puck edge304. Just after a pad11is cut from the web material10, the puck301may be accelerated906to prevent any collision with the subsequent neighboring puck301and may be decelerated908thereafter. Sometime after the trailing edge cut904and prior to placement912of the pad11on a receiving surface25, the puck301spins to a desired angle and the velocity of the puck301may change910to achieve a desirable predetermined spacing. Upon or after reaching a velocity or relative spacing, the pad11is placed912on the receiving surface25. After pad placement912, the puck301may be decelerated and then accelerated914in preparation for the next rotation. The process then begins anew.

During periods of acceleration and deceleration, the pucks301change position relative to the major axis of rotation, the puck transfer axis306. This can best be seen by reference toFIG. 28. A first reference point430represents a point on the shaft (314onFIGS. 2 and 3) spinning about the puck transfer axis306at the relatively constant velocity VS during operation of the device1. A second reference point432represents a position of a puck301. While the shaft reference430may be rotating about the puck transfer axis306at a relatively constant velocity, the position of the puck reference432with respect to the shaft314may change a desirable amount, such as an increase of ten degrees or more of rotation during acceleration and a decrease of ten degrees or more of rotation during deceleration. To illustrate, the shaft reference430is generally radially aligned with the puck reference432during times of cutting902,904. At the end908of the first acceleration, the puck reference432has changed position relative to the shaft reference430by a first distance924. At the end910of the first deceleration period, the puck reference432has changed position relative to the shaft reference430by a second distance926. Prior to pad placement912, the puck301is again accelerated, and at the end of the second acceleration the puck reference432has advanced beyond the shaft reference430by a third distance928. At the end914of the second deceleration period, the puck reference432has changed position relative to the shaft reference430by a fourth distance929. The first distance924, second distance926, third distance928and fourth distance929may be the same or different. By the time it is ready for the same puck301to proceed through the process again, however, both references430,432are aligned and ready for another revolution.

FIG. 29,FIG. 30andFIG. 31provide a third preferred velocity profile and associated puck positioning of an apparatus according to the present invention. This profile may be referred to as a decel-to-place profile. With reference also toFIG. 1, the puck transfer mechanism3rotates about the puck transfer axis306at a relatively constant system velocity VS. When a puck301receives continuous web material10, the puck301is moving at a first velocity, which may be the system velocity VS. A pad11is then cut from the continuous web10. To create the pad11, a first cut932is made proximate the leading puck edge302and a second cut934is made proximate the trailing puck edge304. Just after a pad11is cut from the web material10, the puck301may be accelerated936to prevent any collision with the subsequent neighboring puck301and may be decelerated408thereafter. Sometime after the trailing edge cut934and prior to placement946of the pad11on a receiving surface25, the puck301spins to a desired angle and the velocity of the puck301may change944to achieve a desirable predetermined spacing. Upon or after reaching a velocity or relative spacing, the pad11is placed946on the receiving surface25. After pad placement946, the puck301may be accelerated948and then decelerated950in preparation for the next rotation. The process then begins anew.

During periods of acceleration and deceleration, the pucks301change position relative to the major axis of rotation, the puck transfer axis306. This can best be seen by reference toFIG. 31. A first reference point430represents a point on the shaft (314onFIGS. 2 and 3) spinning about the puck transfer axis306at the relatively constant velocity VS during operation of the device1. A second reference point432represents a position of a puck301. While the shaft reference430may be rotating about the puck transfer axis306at a relatively constant velocity, the position of the puck reference432with respect to the shaft314may change a desirable amount, such as an increase of ten degrees or more of rotation during acceleration and a decrease of ten degrees or more of rotation during deceleration. To illustrate, the shaft reference430is generally radially aligned with the puck reference432during times of cutting932,934. At the end940of a first acceleration, the puck reference432has changed position relative to the shaft reference430by a first distance964. At the end410of the first deceleration period, the puck reference432has changed position relative to the shaft reference430by a second distance436. Prior to pad placement946, the puck301may be decelerated, and at the end of the second acceleration the puck reference432has advanced beyond the shaft reference430by a third distance438. At the end414of the second deceleration period, the puck reference432has changed position relative to the shaft reference430by a fourth distance436. The first distance434, second distance436, third distance438and fourth distance439may be the same or different. By the time it is ready for the same puck301to proceed through the process again, both references430,432are aligned and ready for another revolution.

The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, the details may be changed without departing from the invention, which is defined by the claims.