Variable tension process and apparatus for continuously moving layers

A process for controllably registering a plurality of reference marks of a continuously moving first layer with a plurality of corresponding reference marks of a continuously moving second layer, comprising the steps of:

• providing a continuously moving first layer including a plurality of reference marks selectively positioned thereon,
• providing a continuously moving second layer including a plurality of corresponding reference marks selectively positioned thereon,
• sensing each of the reference marks of one of the continuously moving layers and generating a reference mark signal in response thereto,
• measuring the distance between two successive reference mark signals and generating a repeat corrective control signal in accordance with preprogrammed instructions,
• impressing the continuously moving one layer in response to a generated repeat corrective control signal,
• superimposing the continuously moving layers together,
• sensing a reference mark of the continuously moving one layer and its corresponding reference mark of the continuously moving other layer and generating a placement corrective control signal in accordance with preprogrammed instructions, and
• adjusting the speed of the continuously moving one layer in response to a generated placement corrective control signal to controllably register a reference mark of the continuously moving one layer with its corresponding reference mark on the continuously moving other layer.

An apparatus for controllably registering a plurality of components of a continuously moving first layer with a plurality of components on a continuously moving second layer, comprising:

• means for providing a continuously moving first layer including a plurality of components,
• means for providing a continuously moving second layer including a plurality of components being represented with a respective plurality of reference marks,
• means for sensing each of the reference marks, and means for generating a reference mark signal in response thereto,
• means for measuring the distance between the two successive reference mark signals, and means for generating a repeat corrective control signal in accordance with preprogrammed instructions,
• means for selectively applying pressure to the continuously moving one layer in response to a generated repeat corrective control signal to adjust the distance between two successive reference marks,
• means for superimposing the continuously moving first layer and the continuously moving second layer together,
• means for sensing a reference mark and its corresponding component of the first layer, and means for generating a placement corrective control signal in accordance with preprogrammed instructions, and
• means for adjusting the speed of the continuously moving second layer in response to a generated placement corrective control signal to controllably register a reference mark on the continuously moving second layer with its corresponding component on the continuously moving first layer.

An apparatus for controllably registering a plurality of reference marks of a continuously moving first layer with a plurality of corresponding reference marks of a continuously moving second layer, comprising:

• means for providing a continuously moving first layer including a plurality of reference marks selectively positioned thereon,
• means for providing a continuously moving second layer including a plurality of corresponding reference marks selectively positioned thereon,
• means for sensing each of the reference marks of one of the continuously moving layers and means for generating a reference mark signal in response thereto,
• means for measuring the distance between two successive reference mark signals and means for generating a repeat corrective control signal in accordance with preprogrammed instructions,
• means for impressing the continuously moving one layer in response to a generated repeat corrective control signal,
• means for superimposing the continuously moving layers together,
• means for sensing a reference mark of the continuously moving one layer and its corresponding reference mark of the continuously moving other layer, and means for generating a placement corrective control signal in accordance with preprogrammed instructions, and
• means for adjusting the speed of the continuously moving one layer in response to a generated placement corrective control signal to controllably register a reference mark of the continuously moving one layer with its corresponding reference mark on the continuously moving other layer.