Method and apparatus utilizing servo motors for placing parts onto a moving web

An apparatus for forming parts from a continuously moving web of parts material, receiving the parts traveling at a first speed in a receiving zone, and applying the parts onto a carrier web traveling at a second speed through an application zone, the apparatus comprising:

• a rotatable knife roll for severing a continuously moving web of material to form the parts;
• an independent knife roll driving mechanism for rotating the knife roll, the independent knife roll driving mechanism including a programmable motor coupled to the knife roll via a transmitting mechanism for conveying energy therebetween;
• a bonding anvil roll rotating at a surface speed substantially equal to a velocity of the carrier web;
• at least two rotatable transferring devices for receiving the parts in the receiving zone and transferring the parts onto the bonding anvil roll;
• at least two independent transferring device driving mechanisms for rotating the transferring devices, the independent transferring device driving mechanisms including programmable motors coupled to the transferring devices via transmitting mechanisms for conveying energy therebetween;
• and
• a bonding pattern roll rotating at a surface speed substantially equal to a velocity of the carrier web;
• wherein the independent transferring device driving mechanisms maintain the transferring devices at first surface speeds in the receiving zone as the transferring devices pick up the parts and maintain the transferring devices at second surface speeds as the transferring devices transfer the parts to the bonding anvil roll;
• and
• wherein the bonding anvil roll applies the parts to the carrier web and compresses the parts and the carrier web between the bonding anvil roll and the bonding pattern roll, thereby bonding the parts to the carrier web.

A method for forming parts from a continuously moving web of parts material, receiving the parts traveling at a first speed in a receiving zone, and applying the parts to a carrier traveling at a second speed through an application zone, the method comprising the steps of:

• providing a rotatable knife roll;
• providing an independent knife roll driving mechanism for rotating the knife roll, the independent knife roll driving mechanism including a programmable motor coupled to the knife roll via a transmitting mechanism for conveying energy therebetween;
• rotating the knife roll to sever the continuously moving web of parts material to form the parts;
• providing at least two rotatable transferring devices;
• providing at least two independent driving mechanisms for rotating the transferring devices, the independent driving mechanisms including programmable motors coupled to the transferring devices via transmitting mechanisms for conveying energy therebetween;
• programming the programmable motors coupled to the transferring devices to rotate the transferring devices through the receiving zone at first surface speeds and to rotate the transferring devices through the application zone at second surface speeds;
• and
• rotating the transferring devices through the receiving zone to receive the parts and through the application zone to apply the parts to the carrier.

A method for forming parts from a continuously moving web of parts material, receiving the parts traveling at a first speed in a receiving zone, and applying the parts onto a carrier web traveling at a second speed through an application zone, the method comprising the steps of:

• providing a rotatable knife roll;
• providing an independent knife roll driving mechanism for rotating the knife roll, the independent knife roll driving mechanism including a programmable motor coupled to the knife roll via a transmitting mechanism for conveying energy therebetween;
• rotating the knife roll to sever the continuously moving web of parts material to form the parts;
• providing a bonding anvil roll rotating at a surface speed substantially equal to a velocity of the carrier web;
• providing at least two rotatable transferring devices;
• providing at least two independent transferring device driving mechanisms for rotating the transferring devices, the independent transferring device driving mechanisms including programmable motors coupled to the transferring devices via transmitting mechanisms for conveying energy therebetween;
• programming the programmable motors coupled to the transferring devices to rotate the transferring devices at first surface speeds in the receiving zone as the transferring devices pick up the parts and to rotate the transferring devices at second surface speeds as the transferring devices transfer the parts to the bonding anvil roll;
• rotating the transferring devices to receive the parts in the receiving zone and to transfer the parts onto the bonding anvil roll;
• applying the parts from the bonding anvil roll onto the carrier web;
• providing a bonding pattern roll rotating at a surface speed substantially equal to a velocity of the carrier web;
• and
• compressing the parts and the carrier web between the bonding anvil roll and the bonding pattern roll, thereby bonding the parts to the carrier web.

A method for receiving parts traveling at a first speed and applying the parts to a carrier traveling at a second speed comprising the steps of:

• providing at least two rotatable transferring devices;
• providing at least two independent driving mechanisms for rotating the transferring devices, the independent driving mechanisms including programmable motors coupled to the transferring devices;
• programming the programmable motors to rotate the transferring devices through a receiving zone at first surface speeds to receive the parts and to rotate the transferring devices through an application zone at second surface speeds to apply the parts to the carrier;
• wherein the first surface speed is greater than the second surface speed.