Winding Method and Apparatus

A method of winding a layered structure comprising steps of:

• a) rotating a winding drum,
• b) transferring a first web structure from a first lay down station to a first winding station of the winding drum;
• c) contacting the web structure with a winding mandrel;
• d) contacting the web structure with a web assembly hold down element;
• e) winding the web structure by rotating the winding mandrel;
• f) fixing a trailing edge of the web structure relative to the wound structure;
• g) discharging the wound structure from the winding drum.

A winding apparatus comprising:

• a) a winding drum, the winding drum comprising a plurality of winding stations, at least one winding station comprising a web guide track, the web guide track comprising a web transfer surface disposed along a portion of a circumference at a first radius of the winding drum, a first web guide track edge element disposed adjacent to the web transfer surface and defining a step change in the web guide track cross section from the first winding drum radius to a second winding drum radius and a second web guide track edge element disposed adjacent to the first web guide track element and defining a step change in the web guide track cross section from the second winding drum radius to a third winding drum radius, a split winding mandrel, a mandrel drive element and a winding nip element;
• b) a plurality of web lay down stations having tangential contact with a circumference of the winding drum, at least one lay down station comprising a rotary lay down drum;
• c) a web assembly hold down element disposed adjacent to a circumference of the winding drum and extending along a portion of the circumference of the winding drum;
• d) a web assembly tail fixing station disposed along a circumference of the winding drum between the web assembly hold down element and the plurality of web lay down stations;
• e) a wound assembly discharge station comprising a wound assembly removal element disposed adjacent to the circumference of the winding drum;
• and
• f) a web separating station disposed along a circumference after the last lay down station and comprising a web separating element.