Machine and process for placing discrete components on a moving web with velocity matched placement and integral bonding

A process for cutting discrete workpieces from a first uncut workpiece web moving at a first slower workpiece web speed and transferring and bonding said cut discrete workpieces to a substrate web moving at a second faster substrate web speed comprising carrying out on a single roller the steps of:

• a) receiving on said roller said first uncut workpiece web and cutting discrete workpieces from said first uncut web on said roller while said roller is moving during a first fraction of each rotation at or near said first slower workpiece web speed and holding said cut discrete workpieces to said roller by vacuum means;
• b) changing the speed of said roller and said discrete workpieces to a first temporary speed different from that of said first workpiece web speed and said second substrate web during a second fraction of each rotation of said roller and then changing the speed of said roller and discrete workpieces to match the speed of said second substrate web during a third fraction of each rotation of said roller;
• c) transferring said discrete workpieces to said second substrate web and bonding said discrete workpieces to said substrate web while said roller is moving for a fourth fraction of each rotation at said second substrate web speed;
• and
• d) changing the speed of said roller to a second temporary speed different than that of said first workpiece web and said second substrate web during a fifth fraction of each rotation of said roller and then changing the speed of said roller and discrete workpieces to match the speed of said second substrate web during a sixth fraction of each rotation of said roller.

A combination roller having a length and an outer working surface, a central shaft portion having a length and an outer surface, and a body portion having a length and an outer surface, said combination roller having integral

• a) cutting anvil apparatus for engaging the cutting edge of a rotary cutter disposed in cooperative working relationship with said combination roller;
• b) vacuum transfer apparatus for receiving and holding a first uncut web of workpieces to the working surface of said combination roller and for cutting said first web into discrete workpieces between said cutting edge of said cooperative rotary cutter and said cutting bar anvil and for holding said discrete workpieces to said working surface and transferring said discrete workpieces to a second substrate web;
• and
• c) ultrasonic bonding anvil apparatus for cooperating with the outer working surface of a rotary ultrasonic horn to thereby create bonds bonding the cut discrete workpieces to the second substrate web.

A machine for cutting discrete workpieces from a first web of uncut workpieces moving at a first speed and transferring and bonding the cut workpieces to a second substrate web of material moving at a second speed, said machine comprising:

• a) a first supply apparatus delivering an uncut web of workpieces at a first component web speed;
• b) a second supply apparatus delivering a second substrate web of material at a second substrate web speed;
• c) at least one vacuum commutator;
• d) at least one ultrasonic horn having a first outer working surface;
• e) a rotary cutter having a length, said rotary cutter having a cutting edge disposed along at least a portion of said length;
• f) a combination roller having a second outer working surface, said second outer working surface of the combination roller being disposed in working relationship with said rotary cutter and with said first outer working surface of said at least one rotary ultrasonic horn, said combination roller having
• i) cutting bar anvil apparatus for engaging the cutting edge of said rotary cutter during rotation of said rotary cutter and said combination roller,
• ii) vacuum transfer apparatus communicating with said at least one vacuum commutator for receiving and holding the first uncut web of workpieces to the working surface of said combination roller for cutting of said first web into discrete workpieces between said cutting edge of said rotary cutter and said cutting bar anvil and for holding said discrete workpieces to said working surface and transferring said discrete workpieces to the second substrate web;
• and
• iii) ultrasonic bonding anvil apparatus cooperating with the first outer working surface of said at least one rotary ultrasonic horn to thereby create bonds bonding the cut discrete workpieces to the second substrate web;
• and
• f) variable speed drive apparatus driving said rotary cutter and said combination roller at said first speed for a first portion of each rotation of said rotary cutter and said combination roller at said second speed for a second portion of each rotation of said rotary cutter and said combination roller.