Method of apparatus for separating a web material

A method of separating a web material having a machine direction and a cross-machine direction co-planar and orthogonal thereto along a line of weakness that is generally parallel to the cross-machine direction of the web material, the method comprising steps of:

• a) providing a bedroll having a circumference and being disposed so that the web material passes around at least a portion of the circumference of the bedroll in the machine direction and wherein the bedroll is disposed generally in the cross-machine direction of the web material and wherein the bedroll further comprises a shell having a circumference, and a bedroll chop off assembly comprising a plurality of web pins and at least three bedroll blades, the plurality of web pins and at least three bedroll blades being disposed in the cross-machine direction, the at least three bedroll blades being further disposed generally parallel each to the others and separated circumferentially by a bedroll blade spacing, the web pins being disposed generally along a line substantially parallel to the at least three bedroll blades, wherein the distal portions of the at least three bedroll blades and the web pins are capable of extending beyond the circumference of the shell of the bedroll,
• b) rotating the bedroll at a first circumferential velocity,
• c) providing a chop off roll disposed proximate and generally parallel to the bedroll, the chop off roll further comprising a first plurality of web pin pads capable of circumferentially interfering with at least some of the web pins, the web pin pads being disposed along a line generally in the cross-machine direction and at least three chop off roll blades disposed generally parallel each to the others, and generally in the cross-machine direction, the at least three chop off roll blades being disposed at a chop off blade spacing, wherein at least one of the at least three chop off roll blades being capable of rotationally meshing with the at least three bedroll blades,
• d) rotating the chop off roll at a second circumferential velocity, said second circumferential velocity being distinct from the first circumferential velocity,
• e) routing the web material between the bedroll and the chop off roll,
• f) penetrating the web material with at least one web pin of the plurality of web pins,
• g) perforating at least a portion of at least one web pin pad with at least one web pin of the plurality of web pins,
• h) rotationally meshing at least two of the at least three chop off roll blades with at least one of the at least three bedroll blades, and,
• i) separating the web material at a line of weakness disposed within the web material.