Patent ID: 6845283

Claim:
A process for controllably registering a continuously moving first layer with a continuously moving second layer, comprising the steps of: providing a continuously moving first layer having a repeating machine product length represented by a plurality of first repeating reference marks, wherein the first repeating reference marks are in registered relationship with a machine constant reference signal; providing a continuously moving second layer having a repeating initial length greater than the repeating machine product length, the repeating initial length represented by a plurality of second repeating reference marks; sensing each of the second reference marks and generating a reference mark signal in response thereto; measuring the distance between two successive second repeating reference mark signals and generating a repeat corrective control signal in accordance with programmed instructions; passing the second layer through a microcreping device including at least one of a conveyor belt and a roll, wherein the second layer is microcreped as the second layer is transferred onto the first layer to adjust the distance between two successive second reference marks in response to a generated repeat corrective control signal and providing the continuously moving second layer having a repeating final length; sensing a second reference mark of the continuously moving second layer relative to a corresponding machine constant reference signal, and generating a placement corrective control signal in accordance with programmed instructions; adjusting the speed of the continuously moving second layer in response to a generated placement corrective control signal to controllably register a second reference mark on the continuously moving second layer with its corresponding first reference mark on the continuously moving first layer; and superimposing the continuously moving first layer and the continuously moving second layer together.