Automatic lapless butt material splice

• US 10,457,512 B2
• Filed: 09/19/2016
• Issued: 10/29/2019
• Est. Priority Date: 09/19/2016
• Status: Active Grant

• Current Assignee: New Era Converting Machinery, Inc.
• Original Assignee: New Era Converting Machinery, Inc.
• Inventors: Pasquale, Robert A.
• Primary Examiner(s): Rivera, William A.
• Application Number:
  US15/269,290
• Publication Number:
  US 20180079614A1
• Time in Patent Office: 1,135 Days
• CPC Class Codes: B65H 19/102 Preparing the leading end of the replacement web before splicing operation; Adhesive arrangements on leading end of replacement web; Tabs and adhesive tapes for splicing
• CPC Class Codes: B65H 19/1821 the replacement web being accelerated or running prior to splicing contact
• CPC Class Codes: B65H 19/1826 taking place at a distance from the replacement roll
• CPC Class Codes: B65H 19/1836 the replacement web being accelerated or running prior to splicing contact
• CPC Class Codes: B65H 21/00 Apparatus for splicing webs during web-roll changing B65H19/00
• CPC Class Codes: B65H 2301/46072 inserted between leading edge and wound web roll
• CPC Class Codes: B65H 2301/46075 by adhesive tab
• CPC Class Codes: B65H 2301/46222 involving double butt splice, i.e. adhesive tape applied on both sides of the article or web portions
• CPC Class Codes: B65H 2301/4631 Adhesive tape
• CPC Class Codes: B65H 2301/46414 by nipping rollers

Abstract

Devices, methods, and systems for splicing a trailing edge of an outgoing roll with a leading edge of a replacement roll with a lapless butt splice on-the-fly during converting and printing production. A first strip of adhesive tape may be placed partially under the leading edge, such that a portion of the adhesive tape remains exposed beyond the leading edge. The replacement roll may be accelerated to match the speed of the outgoing web'"'"'s movement, a trailing edge of the outgoing web may be cut free from the outgoing roll, and the trailing edge of the outgoing roll may be positioned over the exposed portion of the adhesive tape. A second strip of adhesive tape may be applied over the leading edge and trailing edge using a splicer roller timed to apply the tape when the edges pass proximate to the splicer roller.

Claims

1. A web splicer for on-the-fly splicing of an outgoing web with a replacement web arranged about a replacement roll and having a leading edge, the web splicer comprising:

a cutting blade configured to cut the outgoing web to create a trailing edge;

a bump roller rotatable about a central axis and configured to rotate in communication with the outgoing web, the bump roller arranged proximate to the replacement roll and further configured to press the trailing edge of the outgoing web against a first adhesive surface coupled to the replacement web;

a splicer backup roller rotatable about a central axis and configured to rotate in communication with the outgoing web; and

a splicer roller rotatable about a central axis, arranged proximate to the splicer backup roller, and configured to receive a second adhesive surface, the splicer roller configured to selectively press the second adhesive surface against the leading edge of the replacement web and the trailing edge of the outgoing web;

wherein the web splicer produces a web splice having the first adhesive surface arranged on a first side of the splice and extending across both the leading edge of the replacement web and the trailing edge of the outgoing web, and the second adhesive surface arranged on a second side of the splice and extending across both the leading edge of the replacement web and the trailing edge of the outgoing web.

2. The web splicer of claim 1, further comprising a motor communicably coupled to the splicer roller and configured to accelerate the splicer roller to a speed matching the speed of the outgoing web moving across the splicer backup roller.

3. The web splicer of claim 1, further comprising a pneumatic cylinder or a motor, the pneumatic cylinder or motor configured to actuate movement of the cutting blade toward the outgoing web.

4. The web splicer of claim 1, further comprising a pneumatic cylinder or a motor, the pneumatic cylinder or motor configured to actuate movement of at least one of the splicer roller and the splicer backup roller, so as to bring the splicer roller and splicer backup roller proximate to one another to press the second adhesive surface against the leading edge of the replacement web and the trailing edge of the outgoing web.

5. The web splicer of claim 1, further comprising a device for tracking the leading edge of the replacement roll.

6. The web splicer of claim 5, wherein the device comprises a leading edge marker arranged on the replacement roll and having a known relationship to the leading edge.

7. The web splicer of claim 1, further comprising a device for tracking the location of the second adhesive strip.

8. The web splicer of claim 1, wherein the web splicer is configured to form a lapless splice between the outgoing web and the replacement web.

9. The web splicer of claim 1, wherein the web splicer is configured to transition from a first configuration, with the replacement roll in a first position, to a second configuration, with the replacement roll in a second position.

10. A method for splicing a replacement web with an outgoing web on the fly, the method comprising:

accelerating rotation of the replacement roll to match a speed of the outgoing web, the replacement roll having a first adhesive strip affixed to an inner surface of a leading edge of the replacement web, such that a portion of the first adhesive strip remains exposed;

arranging a second adhesive strip on a splicer roller, the splicer roller rotatable about a central axis;

accelerating rotation of the splicer roller to match a speed of the outgoing web;

cutting the outgoing web to form a trailing edge, wherein cutting the outgoing web causes the trailing edge to contact the exposed portion of the first adhesive strip;

pressing the trailing edge onto the first adhesive strip, adjacent to the leading edge; and

affixing the second adhesive strip over the trailing edge and the leading edge via the splicer roller, such that the second adhesive strip contacts both webs.

11. The method of claim 10, wherein pressing the trailing edge onto the first adhesive strip comprises passing the trailing edge, leading edge, and adhesive strip together across a bump roller, wherein the bump roller applies pressure to a surface of the trailing edge.

12. The method of claim 10, wherein affixing the second adhesive strip over the trailing edge and the leading edge via the splicer roller comprises passing the trailing edge and leading edge across a splicer backup roller, and actuating at least one of the splicer roller and the splicer backup roller so as to bring the splicer roller and splicer backup roller proximate to one another to press the second adhesive strip against the leading edge and the trailing edge.

13. The method of claim 10, wherein the method results in a lapless splice between the outgoing web and the replacement web.

14. The method of claim 10, wherein affixing the second adhesive strip over the trailing edge and the leading edge via the splicer roller comprises adjusting a rotational phase of the splicer roller so as to align the second adhesive strip with the first adhesive strip.

15. A system for splicing a replacement web with an outgoing web on the fly, the system comprising:

a plurality of rollers facilitating movement of the outgoing web and replacement web;

a cutting blade configured to cut a trailing edge of the outgoing web;

a web speed sensor sensing the speed of the outgoing web as it moves through the plurality of rollers;

a leading edge sensor sensing a location of a leading edge of the replacement web;

a first splicer sensor sensing a location of a first adhesive strip;

a second splicer sensor sensing a location of a second adhesive strip; and

a controller receiving data from the web speed sensor, leading edge sensor, and splicer sensor, the controller further receiving an initiate splice signal;

wherein, upon receiving the initiate splice signal, the controller operates the plurality of rollers and cutting blade to form, using the first and second adhesive strips, a splice between the trailing edge of the outgoing web and the leading edge of the replacement web, wherein each of the first and second adhesive strips extends across the splice to contact both the trailing edge and the leading edge.

16. The system of claim 15, wherein the splice is a largess splice.

17. The system of claim 15, wherein the controller sends a splice roll drive signal to accelerate rotation of a splicer roller.

18. The system of claim 17, wherein the controller adjusts the speed of the splicer roller based on information received from the web speed sensor.

19. The system of claim 18, wherein the controller adjusts the rotational phase of the splicer roller based on information received from the splicer sensor.

20. The system of claim 19, wherein the controller sends a splice roll trigger signal to actuate the splicer roller.