Apparatus For Splicing Sheet Materials

Abstract

Apparatus for cutting severed end portions of sheet materials along substantially straight lines extending transversely thereof while such sheet materials are held fixed against flat surfaces by suction and thereafter connecting the newly formed ends in abutting and overlapped relationship.

Description

The present invention relates to an apparatus for splicing end portions of sheet materials, such as films, foils, strips or tapes and the like.

In the manufacture of sheet materials as well as during subsequent operations, such as slitting and winding operations, it is often necessary to splice sheet materials to restore a desired continuity, as when such sheet materials are ruptured, or to connect the trailing end of one such sheet material with the leading end of another sheet material.

Splices at which the sheet materials are not accurately aligned with each other in a longitudinal direction and/or which exhibit wrinkles or folds create numerous problems during the collection and/or subsequent use of the spliced materials. Sheet materials having splices of this character are, for example, difficult to wind in roll form and provide distorted wound packages in which wrinkles or folds at the spliced areas are often impressed into adjacent layers. When subsequently employed, for example, with high speed article wrapping or printing equipment, such sheet materials are generally incapable of smooth, continuous travel, with the spliced areas often binding or catching within such equipment and jamming the same or tearing at or adjacent to the areas of splicing. Accordingly, a primary object is to provide a generally new or improved and more satisfactory apparatus for splicing sheet materials.

Another object of this invention is the provision of an improved apparatus for accurately cutting ends of the sheet materials and connecting the same in proper longitudinal alignment with each other.

Still another object is to provide an improved apparatus for connecting sheet materials in abutting or overlapping relationship with a wrinkle-free splice.

These and other objects are accomplished in accordance with the present invention by an apparatus in which, initially, an end section of a first sheet material is fixed by suction against a generally flat surface along longitudinally spaced areas which extend transversely thereof, cut across its entire width inbetween the longitudinally spaced fixed areas, after which the suction on the one cut portion of the sheet material which includes the original end thereof is released while the other portion of such sheet material is retained in fixed position by suction. The one cut portion of such sheet material is then removed and is replaced with an end section of a second sheet material which is disposed in opposing and overlapping relationship with the portion of the first sheet material which has been retained in fixed position. The end of this second sheet material is then fixed by suction against the generally flat surface along an area extending transversely and inwardly of the end thereof, and is cut along its entire width along a line substantially parallel and adjacent to or abutting with the newly formed end of the first sheet material. The portion of this second sheet material, which includes the original end thereof, is removed after which the newly formed ends of the first and second sheet materials are connected to each other.

The newly formed ends of the first and second sheet materials may be connected by applying an adhesive coated tape along the exposed sides thereof while such abutting ends are held fixed against the generally flat surfaces by suction. Preferably, an additional adhesive coated tape is fixed by suction along a path extending across the sheet materials and spaced therefrom with the adhesive coated side of such additional tape facing the sides of the sheet materials opposite the exposed sides thereof. The suction on the newly formed and now connected ends of the sheet materials is then released, after which such ends are moved into alignment with the coated side of this additional tape and pressed against the same. The suction on this additional adhesive tape is then released to complete the splicing operation.

In lieu of the butt splice described above, the newly formed ends of the first and second sheet material may be connected in overlapping relationship. This is achieved by further fixing by suction one of such sheet materials against a generally flat surface along a transversely extending area spaced from its end, followed by release of the suction on the end of this one sheet material and movement of such sheet material, at the area at which it is fixed, to dispose its end into overlapping relationship with the end of the other of such sheet materials. The sheet materials are then connected along one or both of their ends, as by adhesive coated tape or by being heat sealed, while they remain fixed to the generally flat surfaces under suction. Once spliced together, the suction on the sheet materials is, of course, released.

The apparatus of the present invention includes walls which define a pair of elongated, parallel chambers with one wall of each of such chambers having perforations extending therethrough and opening into the respective of such chambers. The chambers are supported in spaced apart, side-by-side relationship with the outer surfaces of the perforated walls being disposed in a common plane. Separate means are provided for selectively evacuating each of the chambers whereby a sheet material may be retained in fixed position against the respective perforated walls thereof by suction. Included also in this apparatus is a cutting blade, means for moving such blade inbetween and substantially parallel to the chambers for severing sheet materials which span such chambers, and means for applying an adhesive coated tape to the severed ends of the sheet materials to connect the same.

Preferably, means are provided for holding the edge portions of the sheet material against the outer surfaces of the chamber perforated walls to prevent the same from being moved or folding over when contacted by the cutting blade. The preferred embodiment of the apparatus also includes walls defining an additional elongated chamber which is supported in substantially parallel but spaced apart relationship with the pair of chambers described above. One wall of this additional chamber also includes perforations which extend therethrough and open into the chamber itself and suction means are provided for evacuating this additional chamber. Means are included for moving this additional chamber relative to the pair of chambers first described, either to place the outer surfaces of the perforated wall thereof substantially in the plane of the pair of chambers or to reciprocate such additional chamber toward and away from the pair of chambers.

The severed ends of the sheet materials may be connected by an adhesive coated tape drawn, for example, from a supply roll supported by a carrier which is movable along a track positioned above the chambers. Alternatively, a heated shoe may be provided for use in connecting the ends of the sheet materials in overlapping relationship.

To adapt the apparatus of the present invention for use in splicing sheet materials of various widths, each of the chambers is provided with means for closing off selected areas of the perforated walls thereof.

While the teachings of the present invention are useful with a variety of sheet materials, the apparatus is hereafter described in detail as employed in splicing the leading and trailing ends of separate rolls of regenerated cellulose films.

In the drawing,

FIG. 1 is a side view of one embodiment of the apparatus of the present invention;

FIG. 2 is a top view of the apparatus shown in FIG. 1;

FIG. 3 is a transverse vertical section taken along the line III--III of FIG. 1;

FIGS. 4, 5 and 6 are diagrammatic views illustrating the operation of the apparatus shown in FIGS. 1-3;

FIGS. 7, 8 and 9 are diagrammatic views illustrating the operation of a modified form of apparatus of the present invention; and

FIG. 10 is a view similar to FIGS. 4, 5 and 6 illustrating the operation of a still further embodiment of the apparatus of the present invention.

Referring to FIGS. 1-3 of the drawing, the apparatus there illustrated includes a pair of laterally spaced, vertical supports 15 and 17 across the top of which is fixed a plate 19. Located above the plate 19 are a pair of like elongated chambers 21 and 23 which are disposed in substantially parallel relationship and which are spaced from each other, as indicated at 25.

As best shown in FIG. 3, each of the chambers 21 and 23 includes an angle member 27, having walls or flanges 29 and 31, and a similar but smaller angle member 33, having walls or flanges 35 and 37. The ends of the flanges 29 of the angle members 27 are fixed to the plate 19 and the flanges 35 and 37 of the angle member 33 are welded or otherwise connected in fluid-tight relationship to the flanges 29 and 31, respectively, of the angle member 27. Plates 39, as shown in FIG. 1, are fixed to the ends of each pair of angle members 27 and 33.

The outer surfaces of the walls or flanges 31 of the angle members 27 are disposed in a common plane and extending through such walls 31 are a series of perforations 41. Conduits 43 and 45 open into the chambers 21 and 23 and are connected to suitable vacuum means, not shown, to facilitate selective evacuation of the respective chambers.

Bearings 47 are attached to the underside of the plate 19 in pairs and rotatably support shafts 49 to which are fixed sprockets 51. An endless chain 53 is laced over the sprockets 51 with cutting blade assemblies 55 being fixed thereto at spaced intervals. The blade assemblies 55 are of like construction, with each including a cutting blade 57, such as a razor blade, which is releasably fixed in a retainer 59, and an angle bracket 61 to which the retainer 59 is fixed and, which in turn, is secured to the chain 53. Movement is imparted to the endless chain 53 from a suitable motor, not shown, through an endless chain 63 which is laced over a sprocket 65 fixed to one of shafts 49.

Fixed across opposite ends of the chambers 21 and 23 are brackets 67, which are appropriately slotted to permit the free passage of the endless chain 53 and the cutting blade assemblies 55 which are fixed thereto. The brackets 67 are each formed with a pintle 69 on which arms 71, preferably of rectangular cross section, are supported for swingable movement in a plane generally parallel to the walls 31 of the chambers 21 and 23. A separate slide block 73 is slidably mounted on the respective arms 71, with each including a locking screw 75 for fixing the same in desired position and a hold-down shoe 77 having a pad 79 of sponge rubber or like material on its free end.

Shields 81 are provided for closing-off selected areas of each of the chamber perforated walls 31. The shields 81 are each disposed between the chamber end plate 39 and the underside of the perforated walls 31 and are guided for sliding movement along such walls by tracks 83.

Supported above the chambers 21 and 23 by suitable means, not shown, is a track 85 along which is adapted to travel a carrier 87. The carrier 87 is designed to rotatably support a roll of adhesive coated tape, as indicated at 89, and includes a resilient pressure arm 91 for guiding and applying the tape in a desired position.

In using the above-described apparatus, for example, in splicing the trailing end of depleted roll of regenerated cellulose film, such as indicated at 93, to the leading end a new supply roll of like film, indicated at 95, the trailing end of the film 93 is first laid across the perforated walls 31 of the chambers 21 and 23, as shown in FIG. 4, after which the chambers are evacuated. At this time the shields 81 are adjusted to close-off those perforations 41 in the chamber walls 31 which lie outwardly of the longitudinal edges of the film 93.

Arms 71 are now swung into positions as shown in FIG. 2 and the hold-down shoes 77 are locked in place with the pads 79 thereon pressing the edges of the film 93 snugly against the outer surfaces of the chamber walls 31. Movement is imparted to the endless chain 53 whereby one of the cutting blades 57 travels through the space 25 between the chambers 21 and 23 to thereby sever the film 93. Preferably, the space 25 between the chambers 21 and 23 is no greater than is necessary for free travel of a cutting blade 57 therethrough.

The hold-down shoes 77 are now released and the arms 71 are swung away from the film 93. With the chamber 21 maintained evacuated, air is admitted into the chamber 23 and the portion of the film 93 on its perforated wall 31 is removed.

As shown in FIG. 5, the leading end of the film 95 is placed over the chamber 23 with its free end overlying the film 93 and with the longitudinal edges of the films 93 and 95 being accurately aligned with each other. Chamber 23 is again evacuated and the arms 71 and hold-down shoes 77 are repositioned over the edges of the film 95 in a manner as heretofore described. The endless chain 53 is now driven to advance one of the cutting blades 57 through the space 25 and thus cut the film 95. The portion of the film 95 overlying the chamber 21 is, of course, not fixed and thus can be removed without disturbing the suction in either the chamber 21 or 23.

Tape 89 is now withdrawn from its supply roll as the carrier 87 is moved along the track 85. With the assistance of the presser arm 91, the adhesive coated side of the tape 89 is laid over the abutting ends of the films 93 and 95, as shown in FIG. 6, to thereby splice the films. The suction acting upon the now spliced films is released.

Where a more secure splice between the films 93 and 95 is necessary or desired, an adhesive coated tape is applied to both sides of the newly formed ends thereof. This can be achieved by providing the apparatus heretofore described with an additional suction chamber 97, as shown in FIGS. 7-9. The chamber 97 includes a perforated wall 99 and, except for vertical reciprocating means 101, is constructed and operates in the same manner as the chambers 21 and 23.

FIG. 7 illustrates the path of the film 93 about guide rolls 103 and 105 with its trailing end ready for splicing to the leading end of the film 95 which has been laced about guide rolls 107, 109 and 111. The trailing end of the film 93 and the leading end of the film 95 are first severed and connected to each other by the tape 89 in a manner as heretofore described.

With the chamber 97 in its lowermost position, an adhesive coated tape 113 is fixed by suction to its perforated wall 99, as shown in FIG. 8, with the adhesive side of such tape being exposed. A track and tape carrier which are together mounted for movement over the chamber 97 may be employed for this purpose or the tape 113 may be applied by hand.

Once the abutting edges of the films 93 and 95 have been connected by the tape 89, the suction acting on such films through the chambers 21 and 23 is released. The now connected films 93 and 95 are retracted to place the abutting ends thereof over the chamber 97 by raising the guide roll 105 and simultaneously lowering the roll 109. The elevating means 101 is actuated to raise the chamber 97 and press the adhesive coated side of the tape 113 over the abutting ends of the films 93 and 95, as shown in FIG. 9. Air is then admitted to the chamber 97 to permit free travel of the spliced films.

With slight modification of the method and apparatus shown in FIGS. 7-9, the films 93 and 95 may be spliced together in overlapping relationship. More particularly, the ends of the films 93 and 95 are trimmed in a manner as heretofore described. While still fixed by suction against the perforated walls 31 of the chambers 21 and 31, the film 95 is still further fixed by suction to the perforated wall 99 of the chamber 97. The suction applied to the film 95 through the chamber 23 is released. As shown in FIG. 10, in this embodiment of the apparatus the chamber 97 is mounted for reciprocation in a horizontal plane and when moved toward the chamber 23, carries the film 95 to overlapping relationship with the film 93.

The chamber 23 is again evacuated and the ends of the films may be connected together by adhesive coated tape, as heretofore described. Alternatively, if the opposing sides of the films 93 and 95 include coatings of heat-sealable material, an electrically heated shoe, such as shown at 115, may be pressed against the overlying ends of such films to bond the same together. All three chambers 21, 23 and 97 are then rendered inactive to facilitate advancement of the spliced films.

Claims

We claim:

1. Apparatus for splicing sheet materials including walls defining a pair of elongated chambers, one wall of each of said chambers having at spaced intervals along the length thereof perforations which open into the respective chambers, means supporting said chambers in fixed, parallel, side-by-side relationship with the chambers spaced from each other to permit passage of a cutting blade therebetween and with the outer surfaces of said perforated walls disposed in a common plane, separate means for selectively evacuating each of said chambers for retaining by suction individual sheet materials in fixed positions against the perforated walls of the respective chambers, means positioned in opposing relationship with said perforated chamber walls for pressing against such perforated walls longitudinal edge portions of a sheet material extending between said chambers, a cutting blade, means for moving said cutting blade inbetween and progressively along said spaced chambers for severing a sheet material extending between and pressed against said chambers, and means for bonding to each other severed ends of sheet materials while they are retained against said chambers by suction.

2. Apparatus as defined in claim 1 wherein said bonding means includes a carrier for applying an adhesive-coated tape against one side of abutting severed ends of sheet materials retained against said pair of chambers, and further including walls defining an additional elongated chamber, means supporting said additional chamber in substantially parallel, spaced relationship with said pair of chambers, one wall of said additional chamber having at spaced intervals along the length thereof perforations which open into said additional chamber, a carrier for applying an adhesive-coated tape onto the perforated wall of said additional chamber with its adhesive-surface exposed means for selectively evacuating said additional chamber for retaining by suction on the perforated wall thereof the adhesive-coated tape applied thereto, and means for reciprocating said additional chamber to periodically position the perforated wall of said additional chamber in the common plane of said pair of chambers for receiving sheet materials after the severed ends thereof have been bonded along one side thereof and applying to such severed ends along the opposite side thereof the adhesive-coated tape which is retained on said additional chamber.

3. Apparatus as defined in claim 1 further including walls defining an additional elongated chamber, means supporting said additional chamber in substantially parallel, spaced relationship with said pair of chambers, one wall of said additional chamber having at spaced intervals along the length thereof perforations which open into said additional chamber, means for selectively evacuating said additional chamber for retaining by suction one sheet material against the perforated wall of said additional chamber and means operative when the adjacent of said pair of chambers is inoperative for reciprocating said additional chamber toward and away from said adjacent chamber to place the severed end of sheet material retained on said additional chamber in overlapping relationship with the severed end of the sheet material retained on the other of said pair of chambers.

4. Apparatus as defined in claim 1 further including means for closing off selected areas of the chamber perforated walls to accommodate sheet materials of different widths.