Apparatus for splicing a replacement web to a web having a programmed movement without interrupting such movement

Abstract: Automatic splicing apparatus includes a first supply containing a first web (a1) and a second supply containing a second web (a2). An operable puller (4) is engaged with the first web (a1) for intermittently withdrawing the same from the first supply and moving the first web along a predetermined path in a periodic manner. Cutters (12,12') are provided for establishing a trailing end on the first web and a leading end (Q) on the second web (a2), cutting each web midway of a lenghtwise repeated pattern. The presence of the trailing end in the predetermined path is detected and a splicing station (10) is positioned in the path for butt-splicing the leading edge (Q) of the second web (a2) to the trailing end of the first web (a1) in response to detecting the presence of the trailing edge. The splicing is effected with maintained during one of the dwell periods of the first web without interrupting the step by step operation of the puller (4).

Description: This invention relates to apparatus for splicing a replacement web to a web having a programmed movement without interrupting such movement, such apparatus finding application in connection with automatic packaging equipment. BACKGROUND ART Material used in packaging products is often supplied to a packaging line in webs spooled on reels. At the packaging line, the web is severed into segments that are sequentially applied to packages as the latter pass down the line. The web often contains a repeating pattern, and severing occurs between separate patterns such that each severed segment contains the pattern located at a precise position on the segment. Thus, when a segment is applied to a package, it is aesthetically pleasing because every segment on every package has exactly the same appearance. The depletion of a reel containing a patterned web supplied to high speed automatic packaging equipment requires the trailing edge of the web to be quickly and accurately spliced to the leading edge of a web contained in a replacement reel such that the pattern-pitch is maintained at the splice. GB Patent Specification No A2148856 and DE patent Specification No 3402022 disclose splicing machines wherein the web to which another web is to be spliced is fed continuously through the machine and drive interruption or modification must be effected to effect the splice. In other arrangements, a splice is achieved by manually applying to the joint between the webs, a strip of tape having an adhesive on one surface. The problem with the manual approach is two fold: (1) the manual nature of the splice requires constant supervision of the status of the reel in use and the presence of a worker to effect the splice when needed; and (2) the presence of a pattern on the web requires careful cutting by a worker of the trailing end of the exhausted web and the leading end of the replacement web so that the patterns match. Often, the solution to these problems requires the packaging line to be shut down while a splice is effected in order to ensure that a proper splice is made and the pattern in the replacement web is properly located relative to the pattern in the exhausted web. In UK Patent Specification 2037262, there is disclosed an apparatus for splicing webs. The apparatus operates by holding the trailing end of a spent web in a clamp while the leading end of a fresh web is fed so as to overlap the clamped end of the spent web. An adhesive patch is applied over the overlapping portions of the two webs in order to splice one web to the other, but the splice does not provide a butt joint between the webs. British Patent Specification 2148856 and German Specification 2703356 shows splicing arrangements wherein butting of the end of the spent web and the leading end of the fresh web can be achieved, but such machines are relatively complicated and establish the butting of the webs by cutting through overlapped portions. It is therefore an object of the present invention to provide a new and improved apparatus for ameliorating the problems found in the prior art as discussed above by providing an automatic connection system that ensures a proper splice. The invention also provides a splicing apparatus for belt-shaped material comprising: (a) a splicing station in a conveying passage into which is fed said belt-shaped material; (b) a sticky strip feeding mechanism to feed a sticky strip to said splicing station; (c) a connecting block movable toward a bed upon actuation of said block in the conveying passage; (e) said connecting block having means for releasably holding a strip; and (f) means for actuating the connecting block to adhere a sticky strip held on said block to a trailing edge of the belt-shaped material and to the leading edge of a replacement belt-shaped material when in said predetermined position and means for moving said leading edge along said conveying passage and placing the leading edge at the predetermined position characterised by means for moving the leading edge of the replacement belt shaped material along the said conveying passage to position said leading edge into butting relationship with said trailing edge in said predetermined position prior to adhering said sticky strip. The invention further provides a method of splicing first and second webs characterised in that a pre-cut trailing edge of the first web is positioned in a splicing station as is the pre-cut leading edge of a second web so that the said trailing and leading edges are in abutting contact and whilst so positioned an adhesive splicing strip is applied over the edges to splice same, and wherein the first web is fed through the machine by a drive system on a step by step basis with dwell periods between the steps, and the splicing is effected during one of the dwell periods so that the operation of the drive system is not interrupted by the splicing. BRIEF DESCRIPTION OF THE DRAWINGS An embodiment of the present invention is disclosed in the accompanying drawings wherein: Fig. 1 is a schematic side view of an automatic connection system in accordance with the present invention showing a primary web being furnished to a packaging line; Fig. 2 is a side view, with some parts broken away to facilitate illustration of the invention, showing details of the automatic connection system of Fig. 1 at a stage just prior to the exhaustion of a reel containing the primary web being furnished to the packaging equipment; Fig. 3 is a top view of the apparatus shown in Fig. 2; Fig. 4 is a side view of the apparatus shown in Fig. 2 except showing a transfer member in a position to accept a splice strip from a supply as the leading edge of a replacement web is about to be positioned in abutting relationship to the trailing edge of the primary web; Fig. 5 is a view similar to Fig. 4 but showing the transfer mechanism applying the splice strip to the butt junction between the leading edge of the replacement web and the trailing edge of the primary edge; and Fig. 6 is an enlarged view of the transfer mechanism showing the application of the splice seal to the butt connection between the two webs. BEST MODE FOR CARRYING OUT THE INVENTION Referring now to Fig. 1 of the drawings, reference character a₁ designates a primary web derived from a first web supply such as a reel (not shown) on which the web is spooled which is to form, for example, a seal strip on cigarette package A that is part of a packaging line. Web a₁, after passing through cutter 12 (which is not yet actuated) and guide roller 1, passes between preliminary delivery rolls 2, 2' along a predetermined path that includes splicing station 10. Web a₁ is provided with a plurality of equally spaced transverse slits a' (Fig.3) spaced apart a distance P. Between these slits, a pattern may be printed or otherwise formed on the web at a predetermined location relative to adjacent slits. After passing between main delivery rollers 3, 3', web a₁ is engaged by feed claw 4 for the purpose of intermittently moving the web along the predetermined path in a periodic manner. In this manner, web a₁ is periodically stationary for a predetermined period of time at the splicing station. Downstream of feed claw 4, is cutter 5 which is arranged to cut the web, at the slits, into individual segments. These segments are releasably gripped by roller gripper 7, utilizing suction or the like, for transferring the segments, designated a1' to grip rotor 8. Grip rotor 8 rotates in the direction of the arrow shown in Fig. 1 past adhesive applicator 9 which applies adhesive to the exposed surface of each segment as the latter pass to the applicator. Rotor 8 continues rotating and, in synchronism with a conveyor, applies a segment to each package A passing beneath rotor 8. The present invention is concerned with splicing station 10 whereby replacement web a₂ is spliced to the trailing end of primary web a₁ when the supply of this web is exhausted. The operation of the splicing station is such that a butt joint is formed between the leading edge of replacement web a₂ and the trailing edge of web a₁ where the leading and trailing edges of the respective webs are located exactly one-half pitch from a slit in the respective webs. In this manner, a pattern contained within the pitch between the slits will be located properly on the segment severed by cutter 5 regardless of whether the segment is derived from primary web a₁ or replacement web a₂. Splicing station, which is located in the path traversed by a web a₁ during the course of the intermittent operation of feed claw 4, comprises an articulated member in the form of arm 23 that carries block 20 at one end. Drive lever 24 mounted for pivotal movement about one end has its other end pivotally connected to the other end of arm 23 as shown in Fig. 2. Support lever 25 is pivotally mounted at one end and is pivotally engaged at the other end with arm 23 intermediate block 20 and the pivot connection with drive lever 24. Support rod 27 has slot 27' slidably engaged with a pin rigidly connected to support lever 25 for selectively imparting pivotal movement to the support lever in response to displacement of rod 28' connected to air cylinder 28. Drive lever 24 is rigidly connected to spur gear 26 which is capable of oscillation through a predetermined angle as indicated in Fig. 2 by selective oscillation of another gear that meshes with the spur gear. When rod 28' is in its fully extended position (Fig. 4) and spur gear 26 has been rotated counterclockwise to its maximum position, arm 23 will be raised substantially from anvil 20' (Fig. 4) so that block 20 lies adjacent to guide 19 of splice supply 15. The splice supply includes reel B of splice strips b mounted on carrier web b'. Web b' is unspooled from reel B and passes in contact with guide 19 forming an acute angle as shown in Fig. 4 before being respooled on winder 17 operably connected to motor M. Splice strips b are substrates having adhesive on one face and are releasably attached to carrier web b'. When motor M is powered, and winder 17 moves in a clockwise direction as seen in Fig. 4, carrier web b' is spooled onto the winder as the carrier web is unspooled from reel B. Because of the acute angle through which carrier web b' turns when passing the free end of guide 19, a splice strip b will be peeled from the carrier and will remain in the position shown in chain lines in Fig. 4 when the rotation of motor M ceases. The articulated member comprising arm 23 and block 20 will be in the position shown in Fig. 4 when actuator 28 fully extends rod 28' and pinion 26 is rotated as far anti-clockwise as it will go. In this position, block 20 will be juxtaposed to the splice strip b projecting from web b' as shown in Fig. 4. Associated with block 20 is suction pipe 22 which applies a vacuum to a series of apertures 21 in block 20 thereby releasably gripping splice strip b. In this manner, a splice strip is plucked from carrier web b' in response to the detection of the trailing edge of web a₁. By causing pinion 26 to rotate clockwise to its furtherest position, arm 23 is moved from the position shown in Fig. 4 to the position shown in Fig. 2 wherein block 20 is positioned opposite anvil 20' and spaced therefrom. By simultaneously operating actuator 28 to draw rod 28' inwardly, while at the same time imparting clockwise rotation to spur gear 26, block 20 is pressed toward anvil 20' as shown in Fig. 5. This movement will press splice strip b, releasably held by block 20, into engagement with the webs captured between block 20 and anvil 20' with the adhesive surface on the splice strip facing the captured webs. Thereafter, the vacuum in conduit 22 is released as actuator 28 moves rod 28' upwardly to the position shown in Fig. 2 which effectively moves arm 23 upwardly and spaces block 20 from anvil 20'. In operation, the incipient depletion of web a₁ from its supply may be sensed by detection of a suitable marker applied to the web near its connection to the reel, which is accompanied by the operation of paper holder 11 and cutter 12 for the purpose of severing the trailing portion of web a₁ at a location halfway between adjacent slits a' in this web. This has the effect of establishing the trailing edge of web a₁. This trailing edge is designated by reference character Q (Figs. 5 and 6). In timed relation to the creation of the trailing edge of web a₁, holder 11' and cutter 12' are alos actuated for the purpose of severing the leading portion from replacement web a₂ at a position precisely between adjacent slits a'. This action establishes the leading edge of replacement web a₂. As indicated in Fig. 4, the leading edge of web a₂ is designated by reference character Q'. As feed claw 4 continues to intermittently draw web a₁ through the splicing station, detector 13 eventually detects the trailing edge of this web. Upon detection of the trailing edge of web a₁, web a₂ is drawn from its supply reel into the splice station as indicated in Figs 2 and 4. Because of the precise positioning of web a₁ by reason of the operation of detectors 6, 6¹, the trailing edge of web a₁ will eventually arrive midway of anvil 20¹ and stop because of the intermittent nature of web movement caused by the operation of feed claw 4. While web a₁ is stationary, web a₂ is drawn into the splice station as shown in Fig. 4 until the leading edge thereof abuts the trailing edge of web a₁ as shown in Fig. 6. At that moment, actuator 28 is operated causing block 20 on arm 23 to press half of splice strip b' onto web a₁ and the other half onto web a₂ as the butt joint between the two webs and the splice strip are captured between block 20 and anvil 20' as shown in Figs. 5 and 6. The pressure created by the squeezing of the splice strip against the butt joint between the two webs adheres the seal strip to the butt joint thus effecting a splice between web a₁ and web a₂. Thereafter, actuator 28 is operated to extend support rod upwardly as shown in Fig. 2 and provide clearance for continued movement of the spliced web by the next movement of feed claw 4. Continued operation of feed claw 4 is effective to draw web a₂ from its supply allowing a replacement supply to be substituted for the depleted supply of web a₁. When the supply of web a₂ is exhausted, a trailing edge on this web is established by operation of holder 11' and cutter 12', and a leading edge is established on the new replacement supply by the operation of holder 11 and cutter 12. The detection of the new trailing edge by detector 13' is then used to operate the splice station and enable another splice strip to be removed from carrier web b' in preparation for the next splice. From the above description, it can be appreciated that the present invention provides apparatus for splicing a replacement web to a primary web having a programmed movement without interrupting such movement. That is to say, the intermittent movement of claw 4 continues according to its program is unaffected by the splicing operation that occurs in the interval when the web being pulled by the feed claw is stationary. Moreover, the present invention provides for establishing a butt splice joint precisely midway between a pattern so that half of a pattern is on one web and half of a pattern is on the other web at the splice connection. In this manner, the pattern in the replacement web will be in registration with the pattern in the original web; and only a single pattern need be removed to discard the butt joint when the web is severed by cutter 5. Consequently, the present invention provides considerable labour savings compared with the prior art and also improves the working efficiency and productivity of the packaging line. It is believed that the advantages and improved results furnished by the method and apparatus of the present invention are apparent from the foregoing description of the preferred embodiment of the invention. Various changes and modifications may be made without departing from the invention as described in the claims that follow.

Claims: A splicing apparatus for belt-shaped material comprising: (a) a splicing station (10) in a conveying passage into which is fed said belt-shaped material (a₁); (b) a sticky strip feeding mechanism (15) to feed a sticky strip (b) to said splicing station (10); (c) a connecting block (20) movable towards a bed (20') upon actuation of said block (20) in the conveying passage; (e) said connecting block having means (21) for releasably holding a strip (b); (f) means (24, 23) for actuating the connecting block (20) to adhere a sticky strip (b) held on said block to a trailing edge (Q) of the belt-shaped material (a₁) and to the leading edge (Q') of a replacement belt-shaped material (a₂) when in a predetermined position, and means for moving said leading edge (Q') along the said conveying passage and placing the leading edge (Q') at the predetermined position characterised by means for moving the leading edge (Q') of the replacement belt shaped material (a₂) along the said conveying passage to position said leading edge (Q') into butting relationship with said trailing edge (Q) in said predetermined position prior to adhering said sticky strip (b). An apparatus as set forth in Claim 1, characterised by cutter means (12,12') for cutting each of the belt-shaped materials (a₁ a₂) at a position midway of a pattern that repeats in the lengthwise direction of each belt (a₁ a₂), said connecting block (20) being constructed and arranged to form a butt connection between the leading edge (Q') of the replacement belt (a₂) and the trailing edge (Q) of the other belt (a₁) so that the pattern matches at the butt connection. A method of splicing first and second webs characterised in that a pre-cut trailing edge of the first web is positioned in a splicing station as is the pre-cut leading edge of a second web so that the said trailing and leading edges are in abutting contact and whilst so positioned an adhesive splicing strip is applied over the edges to splice same, and wherein the first web is fed through the machine by a drive system on a step by step basis with dwell periods between the steps, and the splicing is effected during one of the dwell periods so that the operation of the drive system is not interrupted by the splicing.

Inventors: KOSHIBA KENJI, OGATA TAIZO, TAKAHASHI TOYOCHARU, KOSHIBA, KENJI, OGATA, TAIZO, TAKAHASHI, TOYOCHARU, KOSHIBA, KENJI, JAPAN TOBACCO INC., OGATA, TAIZO, TOKYO AUTOMATIC MACHINERY, TAKAHASHI, TOYOCHARU TOKYO AUTOMATIC MACHINERY
Applicants: JAPAN TOBACCO INC, TOKYO AUTOMATIC MACH WORKS, JAPAN TOBACCO INC., TOKYO AUTOMATIC MACHINERY WORKS LIMITED
Application year: 1987
Main classification: B65H19
IPC codes: B65H19