Apparatus and methods for transporting webs of material

Abstract

Provided are methods and apparatus for transporting either an entire web or discrete components of disposable products. The invention is a means of conveying the web or diaper components down the machine using mechanical forces to grip the nonwoven web and transfer it from one belt or roll to another without or reducing added vacuum. There is a carrier nonwoven web that goes down the length of the machine and other substrates are added on top of this. Methods and apparatus are disclosed to provide sufficient gripping to allow transport of diaper components through the fabrication process. Securing and releasing forces are supplied so that the components can be retained at some points and released at others.

1 - 7 . (canceled) 
     
     
         8 . A system for conveying a web material, the system comprising:
 a transfer apparatus comprising a material surface for moving the web material along a transfer path;   wherein the transfer apparatus comprises a plurality of spikes that extend or selectively extend through or outwardly from the material surface to engage the web material.   
     
     
         9 . The system of  claim 8  wherein the transfer apparatus comprises a conveyor belt from which the plurality of spikes extend outwardly from the material surface to engage the web material. 
     
     
         10 . The system of  claim 9  wherein the plurality of spikes comprise unidirectional spikes slanted in a machine direction in which the conveyor belt moves the web material. 
     
     
         11 . The system of  claim 9  wherein the plurality of spikes comprise bidirectional spikes including first spikes slanted in a machine direction in which the conveyor belt moves the web material and second spikes slanted in a direction opposite the machine direction. 
     
     
         12 . The system of  claim 8  wherein the transfer apparatus comprises:
 a first conveyor belt comprising the material surface moving the web material along the transfer path; and 
 a second conveyor belt positioned on a side of the first conveyor belt opposite the material surface, wherein the second conveyor belt includes the plurality of spikes, with the plurality of spikes extending up towards the first conveyor belt. 
 
     
     
         13 . The system of  claim 12  wherein a first portion of the first conveyor belt and a first portion of the second conveyor belt are positioned adjacent each other, such that the plurality of spikes on the second conveyor belt extend through the first conveyor belt, and wherein a second portion of the second conveyor belt moves away from a second portion of the first conveyor belt so as to be is spaced apart therefrom, such that the plurality of spikes on the second conveyor belt are removed from the first conveyor belt and do not extend therethrough. 
     
     
         14 . The system of  claim 13  wherein the second conveyor belt decelerates as compared to the first conveyor belt, so as to cause the plurality of spikes to be removed from the first conveyor belt. 
     
     
         15 . The system of  claim 8  wherein the transfer apparatus comprises a cylindrical drum from which the plurality of spikes extend outwardly to engage the web material. 
     
     
         16 . The system of  claim 15  wherein the plurality of spikes comprise unidirectional spikes slanted in a machine direction in which the cylindrical drum moves the web material. 
     
     
         17 . The system of  claim 15  wherein the plurality of spikes comprise bidirectional spikes including first spikes slanted in a machine direction in which the cylindrical drum moves the web material and second spikes slanted in a direction opposite the machine direction. 
     
     
         18 . The system of  claim 8  wherein the transfer apparatus comprises:
 an outer cylindrical drum comprising the material surface moving the web material along the transfer path, the outer cylindrical drum comprising a plurality of openings formed therein; and 
 an inner cylindrical drum positioned within the outer cylindrical drum, wherein the inner cylindrical drum includes the plurality of spikes, with the plurality of spikes extending out through the plurality of openings in the outer cylindrical drum. 
 
     
     
         19 . The system of  claim 18  wherein a speed of the inner cylindrical drum is adjustable so as to change an angle of the plurality of spikes that extend out through the plurality of openings in the outer cylindrical drum, with the plurality of spikes selectively engaging and releasing the web material based on the angle thereof. 
     
     
         20 . The system of  claim 8  wherein the web material comprises a nonwoven web material that is either a continuous web or discrete items. 
     
     
         21 . The system of  claim 8  wherein the spikes engage the web material to convey the material along the transfer path without using a vacuum drawn through the material surface. 
     
     
         22 . A method for conveying a web material, the method comprising:
 supplying a web material;   transporting the web material in a machine direction along a transfer path via a transfer apparatus, the web material contacting a material surface of the transfer apparatus; and   selectively securing the web material to the material surface of the transfer apparatus via a plurality of spikes that extend or selectively extend through or outwardly from the material surface to engage the web material.   
     
     
         23 . The method of  claim 22  wherein transporting the web material via the transfer apparatus comprises transporting the web material on a first conveyor belt comprising the material surface; and
 wherein selectively securing the web material to the material surface comprises positioning a second conveyor belt including the plurality of spikes relative to the first conveyor belt such that the plurality of spikes selectively protrude through the first conveyor belt. 
 
     
     
         24 . The method of  claim 23  wherein positioning the second conveyor belt comprises:
 positioning the second conveyor belt in a first position relative to the first conveyor belt along a first portion of the first and second conveyor belts, with the plurality of spikes protruding through the first conveyor belt when the second conveyor belt is in the first position; and 
 positioning the second conveyor belt in a second position relative to the first conveyor belt along a second portion of the first and second conveyor belts, with the plurality of spikes being removed from the first conveyor belt when the second conveyor belt is in the second position. 
 
     
     
         25 . The method of  claim 23  further comprising decelerating the second conveyor belt as compared to the first conveyor belt, so as to cause the plurality of spikes to be removed from the first conveyor belt. 
     
     
         26 . The method of  claim 22  wherein transporting the web material via the transfer apparatus comprises transporting the web material on an outer cylindrical drum comprising the material surface, the outer cylindrical drum comprising a plurality of openings formed therein; and
 wherein selectively securing the web material to the material surface comprises positioning an inner cylindrical drum including the plurality of spikes within the outer cylindrical drum such that the plurality of spikes protrude through the outer cylindrical drum. 
 
     
     
         27 . The method of  claim 26  wherein selectively securing the web material to the material surface comprises adjusting a speed of the inner cylindrical drum relative to a speed of the outer cylindrical drum so as to change an angle of the plurality of spikes that extend out through the plurality of openings in the outer cylindrical drum, with the plurality of spikes selectively engaging and releasing the web material based on the angle thereof.