Patent ID: 8910689

Claim:
An apparatus for decreasing downtime in a manufacturing process utilizing a continuous web as a raw material, the apparatus comprising: a first transferring member comprising at least one roll capable of carrying a continuous web from a first zone to a second zone at a first web speed; a second transferring member downstream of the first transferring member, the second transferring member comprising at least one roll capable of carrying the continuous web from the second zone to a third zone at the first web speed; a storage member downstream of the second transferring member which can store a contingent amount of the continuous web and can transfer the continuous web to a fourth zone at the first web speed; a defect detection member capable of detecting a defective portion in the continuous web in the first or second zones; a first engaging member being disposed adjacent to the second transferring member and comprising a first actuation element and a braking element, wherein the first actuation element is adapted to engage the braking element with the at least one roll of the second transferring member; and a second engaging member being disposed between the first transferring member and the second transferring member, member, the second engaging member comprises a second actuation element, a cutting element, and a nip, wherein the second actuation element can cause the cutting element to engage the nip, wherein the cutting element further comprises a first bonding site which is capable of engaging the nip and the continuous web thereby attaching the continuous web proximate to a first end and a second end, wherein the first bonding site is heated such that a thermal bond is created in the continuous web; and a central processing unit in communication with the defect detection member, the first engaging member, and the second engaging member and the second engaging member in a sequence wherein after the detection of the defective portion: (a) the braking element engages the at least one roll of the second transferring member thereby reducing the first web speed in the third zone to a second web speed while the first transferring member continuously carries the continuous web form the first zone to the second zone at the first web speed and carries the defective portion from the first zone to the second zone at the first web speed; and (b) wherein the second engaging member reduces the defective portion by separating a part of the defective portion from the continuous web thereby forming a first end and a second end, wherein the second engaging member splices the first end and the second end of the continuous web together, and wherein the storage member provides a portion of the contingent amount of the continuous web to the fourth zone at the first web speed thereby reducing downtime and minimizing the number of defects in the finished products.