System and method for cutting and splicing polymeric webs

A method of removing defective portions from a printed polymeric web having a repeating pattern thereon such as that which is used for packaging consumer paper products, comprising:

• (a) moving a portable splicing unit into a position in a production line for a printed polymeric web that is convenient for removing a defective portion of the web;
• (b) overlapping a feed end portion of the printed web with respect to a takeup end portion in an inverted relationship so that like surfaces of the feed end portion of said printed web and said takeup end of said printed web are positioned facing each other;
• (c) securing said overlapped feed end portion and takeup end portions in a position of registration in which the regular spacing of the repeating pattern is preserved from the feed end portion to the takeup end portion;
• (d) welding the secured feed end and takeup end portions together by forming a weld line at which the two portions are fused;
• and
• (e) substantially simultaneously with step (d), cutting through said two web portions at the weld line, whereby the defective portion is removed and a nearly seamless, registered splice is created between the takeup end portion and the feed end portion.

A method of a removing defective portion from a printed polymeric web having a repeating pattern thereon such as that which is used for packaging consumer paper products, comprising:

• (a) identifying a defective portion of the printed polymeric web, thereby defining a feed end portion and a takeup end portion of the printed web to be spliced;
• (b) overlapping the feed end portion with respect to the takeup end portion in an inverted relationship so that like surfaces of the feed end portion of the printed web and the takeup end portion of the printed web are positioned facing each other;
• (c) securing the overlapped feed end portion and takeup end portions in a position of registration in which the regular spacing of the repeating pattern is preserved from the feed end portion to the takeup end portion;
• (d) ultrasonically welding the feed end and takeup end portions together by forming a weld line at which the two portions are fused with an ultrasonic tool;
• and
• (e) using a rotary cutting tool that cooperates with the ultrasonic tool to cut through the two web portions at the weld line, whereby the defective portion is cut out of the web and a nearly seamless, registered splice is created between the takeup end portion and the feed end portion.

A method removing a defective portion from a printed polymeric web having a repeating pattern thereon such as that which is used for packaging consumer paper products, comprising:

• (a) moving a portable splicing unit into a position in a production line for a printed polymeric web that is convenient for removing a defective portion of the web;
• (b) overlapping a feed end portion of the printed web with respect to a takeup end portion in an inverted relationship so that like surfaces of the feed end portion of the printed web and the takeup end of the printed web are positioned facing each other;
• (c) securing the overlapped feed end portion and takeup end portions in a position of registration in which the regular spacing of the repeating pattern is preserved from the feed end portion to the takeup end portion;
• (d) using an ultrasonic tool to weld the secured feed end and takeup portions together by forming a weld line at which the two portions are fused;
• and
• (e) using a rotary tool that cooperates with the ultrasonic tool to cut through the two web portions at the weld line, whereby the defective portion is removed in a nearly seamless, registered splice is created between the takeup end portion and the feed end portion.