Material application system

Abstract

A system for applying a material to a substrate comprising: a feed section that comprises a feed roll and configured for advancing a material along a predetermined path; a material applicator roll configured to receive the material from the feed roll and apply a cut length of material to a substrate; a knife element located between the feed section and the material applicator roll; and a non-vacuum anvil roll positioned near the knife element, wherein the knife element and the non-vacuum anvil roll are positioned along the path of the material and engage the material to cut the material into the cut length of material for applying to the substrate, and wherein the material contacts the peripheral surface of the non-vacuum anvil roll only at a cut engagement point.

What is claimed is: 
     
         1 . A method for applying a material to a series of substrates, comprising:
 advancing a material from a feed roll through a path between a knife element and a non-vacuum anvil roll;   cutting the material to form cut lengths of material by engaging the knife element with the non-vacuum anvil roll;   introducing the cut lengths of material onto a material applicator roll,   applying the cut lengths of material to the substrates; and   controlling the feed rate and the timing of each cutting of the material so as to register the positions of the cut lengths of material with predetermined locations on the substrates and control the length of each cut length,   wherein the material contacts the peripheral surface of the non-vacuum anvil roll only at a cut engagement point.   
     
     
         2 . The method of  claim 1 , wherein the feed roll is controllable to provide a first peripheral speed, the non-vacuum anvil roll and the knife element are controllable to provide a second peripheral speed, and the material applicator roll is controllable to provide a third peripheral speed. 
     
     
         3 . The method of  claim 1 , wherein the knife element comprises a knife roll. 
     
     
         4 . The method of  claim 1 , wherein the non-vacuum anvil roll does not advance the material. 
     
     
         5 . The method of  claim 1 , wherein the material applicator roll comprises a vacuum roll defining a peripheral surface having a contoured surface, and the method comprises applying a contoured material to the substrates. 
     
     
         6 . The method of  claim 5 , wherein the contoured material is inserted into an opening present in the substrate, or the contoured material is applied over an opening present in the substrate. 
     
     
         7 . The method of  claim 1 , wherein controlling the feed rate of the material is independent of controlling the timing of each cutting.