Method and apparatus for forming a butt splice

Abstract

A method and apparatus is disclosed for forming a zero-speed, butt splice to join together a web from a new roll of material to a web which is from an expiring roll of material and which should be run, at a relatively high speed, through a web processing operation, such as a disposable diaper manufacturing line, under relatively constant, relatively low tension along a predetermined path of travel that includes a running web festoon means having floating dancer rollers and the running web processing operation. To form the butt splice, the leading end of the new web is trimmed by moving one knife wheel assembly along the cutting edge of an anvil. A piece of tape is applied to the leading end so that a portion of the tape projects downstream from that end. The expiring web is held against the anvil and trimmed along the same cutting edge of the anvil. The trailing end of the expiring roll is also simultaneously adhered to the downstream portion of the tape. Only the portion of the expiring roll adjacent to the anvil is momentarily stopped while the expiring web is trimmed and adhered to the leading end of the new roll. The stoppage is sufficiently short so that downstream portions of the expiring web can, in the interim, be withdrawn from the festoon means so that web continues to run, at its relatively high speed and under it relatively constant, relatively low tension, through the web processing operation.