US3284873A

US3284873A - Web joiner

Info

Publication number: US3284873A
Application number: US346858A
Authority: US
Inventors: George R Noel
Original assignee: Pennsalt Chemical Corp
Current assignee: Pennwalt Corp
Priority date: 1964-02-24
Filing date: 1964-02-24
Publication date: 1966-11-15
Anticipated expiration: 1983-11-15
Also published as: FR1431958A

Description

G. R. NOEL WEB JOINER Nov. 15, 1966 Filed Feb. 24, 1964 Sheets-Sheet 1 v/ Z i d M k IIIIIIIIIIII/ \j/ I 3/ g k3 (3 INVENTOR 1 (\l i GEORGE R. NOEL M k). m

ATTORNEY Nov. 15, 1966 G. R. NOEL 3,284,873

WEB JOINER Filed Feb. 24, 1964 4 Sheets-Sheet 2 I INVENTOR. F 5 GEORGE R. NOEL M a]. m

ATTORNEY G. R. NOEL WEB JOINER Nov. 15, 1966 4 Sheets-Sheet 5 Filed Feb. 24, 1964 INVENTOR.

GEORGE R. NOEL M ATTORNEY United States Patent 3,234,873 WEB JOINER George R. Noel, North 'Wales, Pa., assignor t0 Pennsalt Chemicals Corporation, Philadelphia, Pa., a corporation of Pennsylvania Filed Feb. 24-, 1964, Ser. No. 346,858 13 Claims. (Cl. 29-21.1)

This invention relates to web joining apparatus or web joiners or splicers, as they are commonly called. More particularly it relates to splicers for joining metal sheets in a sheet metal treating line of equipment while the sheets are continuously being introduced into the line from a supply station.

A general object of the invention is to permit the leading portion of a new web, i.e. a metal sheet, which initially is substantially stationary to be joined or spliced to the trailing portion of a preceding web which is moving without shutting down or slowing down the line.

The cleaning, corrosion treating, tinning, annealing, plating, painting and other surface finishing operations on various kinds of metal sheet material is carried out in modern treating lines at rates of several hundred feet per minute. Shutting down of the line to charge new sheets is undesirable and costly. Difiiculties also arise when the end of one piece of material is reached and a new piece of material must be started into the line and be guided through the various intricacies of the various pieces of equipment which are generally installed in a treating line. In order to avoid these difficulties, and to avoid shutting down, it is desirable to join the end of an expiring piece of material to the beginning of the next piece preferably without stopping or slowing down the line. When the ma terial is ordinary steel, welding can be resorted to if the metal is sufficiently thick. And if the metal is copper or brass, brazing may be used. Aluminum welding also can be carried out on alum'mum sheet. However, on thin material, e.g. foils, and on non-metallics, these fusion methods of joining are impractical. Furthermore, material flow must stop.

The web joiner and method hereinafter described do not depend on such fusion methods and permit the mechanical joining of two or more sheets of web, each sheet ranging in thickness from about 0.004 inch to about 0.065 inch, in an instant while the sheets move from a supply station and through the web joiner at a lineal speed of 200 feet or more per minute.

The web joiner of this invention uses a plurality of cutting projections mounted on the periphery of a moving arcuate surface and cooperating with an opposed slotted die plate to shear tabs through and to the rear of the surfaces of interlying, moving overlapped webs moving co-directionally with said arcuate surface and at the same velocity. In the preferred embodiment shown herein, it is essential that the starting or leading end of the second sheet lies on top of the tail or trailing end of the first, or preceding, sheet. The tabs are next bent and folded rearward by foldover means and then are firmly compressed together and against the bottom side of the lower web by pressing means. The folded tabs of the second sheet form recesses within which the tabs of the first sheet are folded. As the first sheet 'moves forward through the joiner and into the treating line, the folded tabs of the first sheet engage the folded tabs of the second sheet in a tightly locked manner so that the second sheet is pulled forward by the movement of the first sheet and the tight joints.

Particularly, the web joining machine comprises a tab cutting station, a tab folding station and a tab pressing station. The cutting station consists of an arcuate toothed section moving co-directionally with the webs at the same 3,284,873 Patented Nov. 15, 1966 velocity as the webs and positioned on one side of the webs, and a corresponding stationary tooth receiving section positioned in tab forming relationship opposite said toothed section on the opposite side of said webs. The toothed section is formed to drive a plurality of tabs outward and rearward from the webs so that the tabs project into the tooth receiving section. The tab folding station consists of a web release and holddown plate and a tab knockover plate between which the projecting tabs pass and are folded rearwardly preparatory to the pressing step. The pressing station includes a pressing section on either side of the webs. The pressing sections cooperate with each other to press the folded tabs against the webs to produce a smooth, tight joint.

More particularly, the cutting station consists of a punch roll positioned opposite a slotted die plate between both of which the webs pass. The punch roll has on its surface a plurality of substantially hexahedral, e.g. cube shaped, cutting projections, hereinafter referred to as teeth. The teeth are spaced in irregular rows extending along the length of the roll and in aligned peripheral rows extending part way around the periphery of the roll. Each peripheral row of teeth essentially has a non-toothed section along an arc of from about to The non-toothed sections of the peripheral rows essentially are aligned relative to each other along the roll so that no tooth on the roll contacts the webs when the center line along the roll of the arcuate surface formed by the aligned non-toothed sections is opposite the webs.

Each tooth has forward and side cutting edges and a non-cutting rearward edge. The teeth are shaped as to width, height and length, so that the set of overlapped tabs which is formed by each tooth as it shears the overlapped sheets will be long enough to provide sufiicient metal to form a strong overlapped backfold and wide enough so that a minimum number of tabs need be formed across the width of the sheets to obtain strong joints, but yet not so wide that the tabs will be too diflicult to bend over, fold and press in the subsequent steps of the operation.

The height of the teeth must be sutficient to permit each tooth to penetrate through the overlapped sheets and to permit the crown and the rear edge of the tooth, as the sides of the tooth shear the sides of each set of tabs, to impinge against the topmost tab and depress the set of overlapped tabs below the lower surface of the lower sheet and to force the tabs downward adequately so that the projecting tabs can be caught and further be folded rearward by a knockover bar or plate positioned between the cutting and pressing stations. The sides of each tooth are set vertically at right angles to the axis of the punch roll and with their opposite planes substantially parallel to each other. The contour of the cutting edge on the face of the tooth, i.e., the front of the tooth relative to the direction of movement, is not critical. A square edge is preferred. The height of each tooth preferably is about the same across the crown. However, so long as the form and dimensions of each tooth fulfill the above requirements, and the teeth are otherwise suitably mechanically designed to withstand the physical stresses of the joining operation, slight variations in height or length of a tooth or between teeth are of no significance. The width of each tooth, however, must be substantially the same in each peripheral row in order that each tooth will be in shearing relationship with its corresponding coacting die plate ribs.

The die plate has a plurality of narrow openings, or slots, extending tangentially adjacent to the roll and spaced in rows along the length of the die plate, with the slots corresponding in widths, number and positions with the widths, number and positions of the corresponding peripheral rows of teeth of the punch roll. The slots must be at least sufficiently long enough to permit the teeth of the punch roll to rotate freely through the slots from rear to front during the sheaing operation. In addition, it is critical that there be sufficient clearance between the rear of each slot and the teeth of the punch in the corresponding peripheral row so that as a tooth makes a cut into the web the cut is made with the forward edge and with the sides of the tooth, but not with the rear edge of the tooth. The rear edge of each tooth preferably is rounded. Moreover, the rear edge of each tooth must clear the rear of its die slot by a distance essentially at least as great as the thickness of the overlapped sheets in a downwardly bent position. This minimum clearance is necessary in order that the tabs will not be severed from the sheets by the back edge of the tooth. Also, the metal forming the rear ends of the slots must be close enough to the teeth to provide a support for the webs in order that the webs are not bulged, drawn, or crumpled by the teeth during the tab forming step. However, each slot at the rear need be no longer than necessary to provide a support against which the attached portion of the tabs can be bent by the tooth. Preferably, the rear of each slot is from about 3" to 5" back from the vertical center line of a diameter punch roll.

The die plate preferably is made and mounted to the apparatus so that it can be adjusted forward or rearward to provide the optimum position for sheets of a particular thickness and for sheets of different rigidity and ductility. Each slot at its forward end must be at least long enough and far enough forward from the teeth in its corresponding peripheral row to permit the teeth to pass upward freely through the slots from rear to front when the punch roll rotates. The ribs between adjacent slots must be wide enough to firmly support the overlapped webs as they are sheared by the teeth of the punch roll. In the embodiment shown in FIGS. 1 and 7, the slots and ribs of the die plate 14 are shown to extend forward beyond the vertical center line of the punch roll 6. However, the die plate at its front end need only have ribs long enough to provide shearing edges at least long enough for the teeth of the punch roll to make shearing contact with the edges of the die ribs at the points of contact of the teeth with the webs and provide support for the webs.

The width of each slot must be sufficient to permit each corresponding peripheral row of teeth to pass freely through the slot. However, it is critical that the width of the slot, in relation to the teeth, be such that a shearing relationship is established between the teeth and the edges of the ribs of the slot, with the side cutting edges of each tooth cooperating with the upper cutting edges of the sides of the ribs between each slot to shear cleanly the sides of a set of tabs immediately after the forward edge of the tabs has been formed by the forward edge of the tooth.

The slots are in the form of openings essentially extending through the die plate. The openings serve to provide an open space through which slivers of metal and broken tabs, if any are formed, can freely fall. In this form the slots prevent jamming of the die plate and breakage of punch roll teeth. This feature of the joiner of this invention represents an important improvement over prior art joiners and results in highly eflicient operating of the joiner at previously unattainable speeds. Moreover, there is no need to shut down for cleanouts, which are costly in that they hold up an entire production line.

The thickness of the die plate, except for strength, is not critical. Accordingly, the die plate should be sturdy enough to withstand the heavy stresses suddenly placed on it when a shearing operation is made on sheets passing through the joiner at several hundred feet per minute. Otherwise, its design should be such that the requirements for the slots and ribs are achieved as detailed above.

The die plate can be made in one piece in which the necessary slots are machined. Preferably, the die plate is made up of a series of plates each having vertical side openings machined on the same side. The series of plates are then assembled and attached side by side on the supporting structure of the joiner below the punch roll, with the side openings, in assembled form, corresponding to the slots in the machined plate embodiment. This arrangement is advantageous in that individual plates can be replaced without replacement of the entire die plate.

The forward ends of the slots can be closed and the front end of the die plate then serves as the tab knockover plate of the tab folding station. Preferably, the forward ends of the slots are left open so that the projecting tabs can move freely through the slots to a separate tab folding station. The tab folding station consists of a knockover bar or plate, against which the projecting tabs impinge and are bent and folded almost flat against the web. An opposing upper web holddown bar or plate cooperates with the knockover bar to hold the webs firmly against the knockover bar during the folding of the tabs. When a separate knockover bar is used, the latter bar preferably has a plurality of narrow openings, or slots, open at the rear and closed at the front, extending tangentially to the roll and spaced in rows along its length, with the slots corresponding in widths, number and positions with the widths, number and positions of the corresponding peripheral rows of teeth of the punch roll and the corresponding slots in the die plate. The sides of the slots serve to guide the sides of the tabs as the tabs are folded rearward, thus providing means by which the tabs are kept from skewing during the folding process. This feature is particularly advantageous when heavy sheet material is being folded. The closed forward ends of the slots, whether in the forward end of the die plate or in a separate knockover bar, preferably are inclined from the bottom to the top of the plate or bar, e.g. at 15 to 60 C., to permit a gradual bending of the overlapped tabs. The upper web holddown bar also serves as a web release plate behind the punch roll.

In still another embodiment, the die plate can be made in the form of an assembly of individual straight-sided plates, each of the width and length of a die rib and supported at its ends by supports running to the frame. The plates are assembled side by side in parallel positions to the form of the die plate with the distance between adjacent plates the same as the width of a slot in-the machined plate. The spaces between the plates serve as the slots. The sides of the plates are provided with cutting edges adjacent the nearest web surface. In this form, the rear support to which the plates are mounted also serves to support the uncut portion of the tabs. The front end of each plate can be supported to the bed of the frame of the machine if the opening between the plates is to be left open, particularly when a separate knockover bar is used. The front end of each plate preferably is supported by a support in the form of a knockover bar running to the sides of the frame.

This arrangement is advantageous in that individual plates can be replaced without replacement of the entire die plate and requires less machining than the indented form of plate.

It is to be understood that the term die plate is intended to Include all forms of the die plates, whether made in one unit or whether made of an assembly of individual plates.

The pressing station preferably consists of a pair of calendering, or pressing, .rolls both of which can be smooth. Preferably, however, one of the calender rolls (the one on the same side of the webs as the punch roll) has a plurality of shallow grooves or recesses formed in the roll and extendingperipherally around the roll and spaced in rows along the axis. The rows of grooves correspond in widths, number and positions with those of the corresponding peripheral rows of teeth of the punch roll. The depths of the grooves should be suflicient to receive the bulges of metal formed in the top of the webs when the tabs are pressed between the other calender roll, which preferably is smooth, and the grooved calender roll.

When the punch roll and die plate are operating, particularly at high speeds, the projecting tabs tend to cling to the recesses in the die plate and particularly the webs tend to cling to the teeth of the punch roll, thu causing a drag on the webs. In order to overcome this clinging and drag it is necessary to have present in the web joiner, immediately after the punch roll and die plate, a web release plate on the side of the webs opposite the die plate and preferably immediately opposite the knockover plate. This web release plate has a plurality of slots or spaces corresponding in widths, number and positions to the corresponding peripheral rows of teeth of the punch roll. The metal between the slots forms fingers which serve to pry the webs free from the punch teeth. As disclosed above, the upper web holddown plate at the folding station can be used for this purpose.

In a particularly preferred embodiment, the front web guide plate and the upper web holddown plate at the folding station are made in the form of a single com'bined unit which is appropriately slotted and curved from rear to front and which passes under the punch roll and over the webs and thus serves three purposes, i.e., guide plate, web release plate and web holddown plate. The slots must be at least wide enough to permit the peripheral rows of teeth to pass through the slots freely, but preferably they are somewhat wider. When using this combined purposes plate, the punch r011 preferably is recessed adequately in the spaces between the peripheral rows of teeth along its axis to clear the ribs of the plate. Alternately, a thin plate is used and the teeth are made sufiiciently long to pass through the combined thickness of the plate and webs and into the die plate slots.

The calender rolls preferably are mounted so that the rolls are movable relative to each other, along the plane of their axes, in order to engage or disengage the plurality of webs. The movement can be done with a combination of cams and springs, or hydraulic pistons, or similar lifting and lowering means acting on one or both roll mountings.

The web joiner machine preferably is provided with a power source for directly driving the calender rolls, the source also preferably being connected to a clutch means for driving the punch roll. vided for stopping the punch and calender rolls. If desired, particularly in small sized joiner machines, the punch roll can be provided with its own drive, brake and control means.

The punch roll teeth preferably are arranged with substantially uniform spacing between teeth along the roll and around the periphery of the roll. The teeth in the rows of teeth along the roll preferably are staggered slightly relative to the teeth in each adjacent row in order to minimize the work load on the joiner, thus permitting the teeth in each row to cut in series rather than all at once.

The total number of teeth is not critical. Sufiicient teeth must, however, be provided to ensure adequate joining, but they should not be so closely spaced together that the webs will be weakened by forming an excessive number of perforations when the tabs are formed. Thus, on an eight inch diameter punch roll from 4 to 8 teeth equally spaced apart along about two-thirds of the periphery of each peripheral row and spaced about an equal distance from the closest tooth in an adjacent peripheral row are preferred.

The webs which are to be joined can be of any convenient or conventional, width, e.g. from 2" to 72" in width. The width of the joiner bed can then be of appropriate size to accommodate the range of web widths expected to be encountered. The array of teeth can be spaced accordingly at any suitable distance, from about 1" to 6" being preferred.

The calender rolls normally will be mounted sufficiently apart so that the non-tabbed webs will pass freely between them without restriction. Preferably, the calender A brake means is also pro- 6 rolls are mounted so that they can be moved together to engage the webs tightly and assist in pulling them through the web joiner when carrying out the pressing operation. In many equipment lines, the web driving means in other sections of the line will be adequate for pulling purposes.

The Web joiner is preferably provided with electrical and pneumatic means for automatically controlling the web joiner in carrying out the splicing operation. The control means preferably cause the calender rolls to close and open at predetermined times. They also cause the punch roll to revolve a predetermined number of revolutions and essentially to stop with the punch roll in standby position, i.e. with the non-toothed surface of the roll opposite the web surfaces. This procedure is necessary in order that the web passing through the joiner during a non-joining phase is not damaged by the teeth of the punch roll. Preferably, the control means are automatically activated, e.g., .by electronic means actuated by the tail end of the first web. Forv example, colored markings can be painted on at least one edge or side of the last to feet of the tail section of the first web. As the first portion of this section passes an electronic color sensing means, the control means hereinafter described are first activated, and when the end of the tail section approaches, are then stopped. At comparatively low speeds, the control means can be manually activated by an operator.

The webs are fed into the web joined from a supply station, e.g. a pair of rolls on a roll stand. As one roll of web is about to expire, the leading end of the second roll of web is positioned in the web joiner on the same side as the punch roll. For example, if thepunch roll is on top, as is shown in FIG. 1, the second web 98a is placed on top of the web 98 which is expiring.

A guide table (no-t shown) is used to align the webs laterally. As the web leaves the joiner, it is processed as desired in the treating line and is taken up on rolls or otherwise disposed of beyond the web joiner machine.

Webs which are joined in the web joiner can be any rolled thin metal plate or strip. However, the webs can also be sheets, plates or strips of other materials which are foldable, such as coated papers and fabrics, woven materials, synthetic plastics and so on.

The invention can be under-stood best from a detailed description of a preferred embodiment of the invention, selected for purposes of illustration and shown in the accompanying drawings, in which:

FIG. 1 is a perspective and somewhat exploded view of the elements of the web joiner in operating position with the supporting frame structure and electrical and pneumatic controls removed for clarity.

FIG. 2 is a cross-sectional schematic diagram showing the punch roll and die plate in pre-cutting position.

FIG. 3 is a cross-sectional schematic diagram showing the punch roll and die plate in cutting position during the first cut.

FIG. 4 is a cross-sectional schematic diagram showing the punch roll and die plate in cutting position near the end of the first revolution, after several cuts have been made, and with cut tabs in various stages of folding and pressing.

FIG. 5 is a combined electrical and pneumatic operating flow diagram.

FIG. 6 is a partial cutaway and cross-sectional view taken along the lines 6-6 of FIG. 3.

FIG. 7 is an enlarged view of the portion enclosed in the dashed triangle in FIG. 4.

FIG. 8 is an enlarged view of the portion enclosed in the dashed rectangle in FIG. 4.

FIG. 9 is an enlarged view of the pressed tab 88 of FIG. I viewed from above.

FIGS. 10, 10a and 10b are plan, elevation and side views, respectively, of a combined web guide, web release and Web holddown plate.

FIGS. 11, 11a and 11b are plan, elevation and side views, respectively, of a die plate made up of a series of indented rib plates assembled in the form of the die plate of FIG. 1.

FIG. 12 is a fragment of a plan view of a die plate composed of a series of indented rib plates assembled in the form of the die plate of FIG. 11 and having the forward end of each rib plate closed to form a knockover bar portion.

FIG. 13 is a fragment of a plan view of a combined die plate and knock-over bar in the form of the die plate of FIG. 1 and having the forward ends of the slots closed substantially in the form of the knockover plate of FIG. 1.

FIG. 14 is a cross-sectional schematic diagram showing the punch roll and die plate in cutting position and in which the combined web guide, web release and web holddown plate of FIG. is used in combination with the combined die plate and knock-over plate of FIG. 13, and in further combination with a pair of opposed flat pressing plates.

Referring to FIG. 1, there are a pair of spaced supporting frame plates 2 and 4 with their center, end and lower sections broken away for clarity. These plates support the following elements: a punch roll 6 which is fixedly mounted on shaft 8, which rotates within bearing 10 set in mounting block 12; a die plate 14 which is adjustably attached to and supported on supports 14a, which are attached to plates 2 and 4; an upper calender roll 22 which is fixedly mounted on shaft 24, which rotates within bearing 26 set in mounting block 28; a lower calender roll 30 which is fixedly mounted on shaft 32, which rotates within bearing 34 set in mounting block 36; a pair of forward guide rolls 38 and 40 fixedly mounted on

shafts

42 and 44, which rotate within

bearings

46 and 48, respectively; a rear guide roll 50 which is fixedly mounted on shaft 52, which rotates within bearing 54; an upper web release and holddown plate 56; a tab knockover plate 58; a front web guide plate 56a; a pair of supports 60 for calender roll depressing rod 60; a cam shaft 62, supported at its ends by bearings 108 in frames 2 and 4; and an air cylinder assembly 64 which has its lower end fastened to the frame 2 and a hinged piston arm 66 securely fastened at its extreme end to cam shaft 62.

The punch roll 6 preferably comprises an assembly of a plurality of spacers 70 alternatingly arranged and keyed axially on shaft 8 with a plurality of axially spaced punch disks 72. Each punch disk 72 has a plurality of cutting teeth 74 arranged as heretofore described.

The die plate 14 preferably comprises a plurality of ribs 76 with cutting edges 76a arranged between a plurality of slots 78 corresponding in widths, number and positions to the plurality of corresponding punch disks 72, said die slots being arranged to permit the side edges of punch teeth 74 to move freely through the slots 78 in shearing relationship with cutting edges 76a as roll 6 rotates, as shown in FIGS. 2, 3, 4 and 6.

The front web guide plate 56a comprises a plurality of ribs 59 and of open-ended slots 59a corresponding in widths, number and positions to the plurality of corresponding punch disks 72.

The upper web release and holddown plate 56 has a plurality of slots 80 likewise corresponding in widths, number and positions to the plurality of punch disks 72.

The tab knockover plate 58 also has a plurality of slots 82 corresponding in widths, number and positions to the plurality of punch disks 72.

The

plates

56 and 58 are formed at the ends of slots 7 80 and 82, respectively, substantially as shown in FIG. 7 at 84 and 86.

The upper calender roll 22 is preferably made in one piece and has a plurality of machined recesses 90 corresponding in widths, number and positions to the plurality of corresponding punch disks 72, said recesses being sufiicient to receive the excess of metal bulge formed during the calendering step, as is shown in FIG. 8 at 88.

The lower calender roll 30 preferably also is made in one piece and is smooth.

Cam shaft 62 has rigidly attached to it a pair of cams 92 which are arranged to engage a pair of calender roll depressing rods 94. A pair of tension springs 96 are arranged on rods 94 between supports 60 and mounting blocks 28 on calender roll 22.

The roll 6 is mounted in the supporting frames 2 and 4 with the mounting blocks 12 secured in a fixed but adjustable position relative to mounting block 20 which supports bearing 18 and driveshaft 16. The punch roll 6 and the die plate 14- are normally spaced apart as shown in FIG. 6 with sufficient space between the rolls to permit at least two thicknesses of web 98 to move freely between the rolls.

Each punch disk 72 has a plurality of cutting teeth 74 arranged part way around the circumference of the disk substantially as shown in FIGS. 2, 3 and 4. The teeth 74 are substantially equally spaced along the toothed section of the circumference and along the roll. The plurality of disks 72 is assembled along with the plurality of spacers 70 on shaft 8 and is appropriately locked on the shaft 8 by keying means so that the teeth 74 form rows along the axis of shaft 8 substantially in a slightly staggered line along the roll. The teeth preferably do not form a straight line along the roll. However, it is essential that when punch roll 6 is in a nonoperating state, the

webs

98 and 98a pass freely between roll 6 and die plate 14.

The tab knockover plate 58 is adjustably mounted in a fixed position with its ends supported by frames 2 and 4. Plate 58 is positioned with its upper surface in the same plane as and level with the upper surface of die plate 14. Plate 58 is further positioned so that the ribs 102 and the slots 82 are in close operating position with die plate 14, as shown in FIG. 7.

The upper web release and holddown plate 56 is adjustably mounted in a fixed position with its ends supported by frames 2 and 4. Plate 56 is positioned with its lower surface in the same plane as and level with the lower surface of punch roll 6. Plate 56 is further positioned so that the slots and web release fingers 109 are in close Web releasing position with punch roll 6, as shown in FIG. 7.

The lower calender roll 30 is mounted in the supporting frames 2 and 4 with the mounting blocks 36 secured in a fixed position. The upper surface of roll 30 is positioned at the same plane as and level with that of die plate 14.

The upper calender roll 22 is mounted so that it is vertically movable in the supporting frames 2 and 4, with the sides of mounting blocks 28 vertically guided within a guide framework, not shown, in frames 2 and 4. The bottoms of blocks 28 rest on springs 106 which tend to urge and hold the assembled upper calender roll 30 upwardly in opposition to springs 96 when roll 30 is in a nonoperating state.

Cam shaft 62 is mounted rotatably by its ends in bearings 108 in the supporting frames 2 and 4. Hinged piston arm 66 is adjustably attached at one end to cam shaft 62 and is positioned to simultaneously rotate the cam shaft 62 and cams 92 in an arc sufiicient to move the cams 92 from a nonpressing position when calender roll 22 is in a raised, nonoperating state to a lowered, pressing position when calender roll 22 is placed in operating state.

Guide rolls 38, 40 and 50 are mounted by their shaft ends and bearings in the supporting frames 2 and 4. The lower forward guide roll 40 is positioned so that its top is in the same plane as and level with that of the top of die plate 14. Upper guide rolls 38 and 50 are positioned so that their lower sides are in the same plane as and level with that of punch roll 6.

The web joiner is provided with a motor 132, FIG. 1, which drives flywheel 136 by means of belt 134. Shaft 142 is directly driven by flywheel 136 and directly turns gear 110 in a counterclockwise direction. Gear 118 meshes into gear 122 causing lower calender 30 and gear 128 to turn clockwise. Gear 128 causes gear 130 and the upper calender roll 22 to turn counterclockwise.

A clutch mechanism 138 and a brake mechanism 140 are provided and are mounted on a hollow shaft 145 supported by bearings 149 and passing over shaft 142. A drive drum 143 is provided and is revolvably mounted around the clutch 138. The drum is fixedly mounted on the flywheel side to shaft 142. A clutch band 139 is provided for causing the drive drum 143 to actuate the clutch 138 and to turn brake mechanism 140' and gear 147 counterclockwise. Gear 147 turns gear 120, which causes gears 112 and 114 to turn counterclockwise and gear 116, shaft 16 and gear 124 to turn clockwise. Gear 124 causes gear 126 and punch roll 6 to turn counterclockwise. The train of gears 147, 121 112, 114, 116, 124 and 126 are designed so that one revolution of gear 147 causes one revolution of gear 26 and the punch roll 6.

The brake mechanism 140 is provided with a brake drum housing 151 and a brake band 141. The housing is fixedly mounted to the frame 4.

Referring to FIGS. 2, 3 and 4, 72 is a punch disk on punch roll 6; 74 is one of the plurality of punch teeth, of which five are shown in the present embodiment; 101) is the non-toothed section between the teeth 74 on disk 72; 98a is the second or upper sheet; 98 is the first or lower sheet; 56 is the upper web release and holddown plate; 56a is the front web guide plate; 58 is the tab knockover plate; 76 is a rib; 78 is a slot; 22 is the upper calender roll; 90 is a machined recess in roll 22; 30 is the lower calender roll; and 8, 16, 24 and 32 are shafts. In FIGS. 3 and 4, 98b are tabs.

Referring to FIG. 5, 1 is a airflow control valve in which an airflow directing core 3 is actuated upwardly by solenoid switch 5 (the core is shown in an actuated position); 3a is an air passage; 3b is an exhaust line from valve 1; 7 is an air valve to airflow control cylinder 9; 11 is a solenoid switch to which valve piston 13 is attached by means of rod 15; 64 is the air cylinder assembly of FIG. 1 in which piston 17 moves within cylinder 19 to advance and retract piston arm 66; 23 is an airflow control cylinder; 25 is a piston which is mounted on piston guide rod 27 and which is moved to an advanced position (shown) when solenoid switch 29 is actuated and which is moved to a retracted position (dotted) when solenoid switch 31 is actuated; 138 is the clutch; 140 is the brake; 142 is the drive shaft from motor 132 to gear 110 which drives the calender rolls 22 and 30 of FIG. 1; 143 is the drive drum; 139 is the clutch band; 151 is the brake drum housing; 141 is the brake band; 145 is the hollow shaft to gear 147 which drives the punch roll 6 and shaft 16 33 is a contact arm on shaft 145; 132 is the electric motor; 35 is a master start-stop switch; 37 is an electrical relay switch; 39 is a cycle selector switch; 41 is a cycle limit switch; 43 is an electrical cycle counting relay switch;

45 is a limit switch; 47 is a limit switch; 49 is an operating cycle starting switch; 51 is an electrical lock-in relay switch; 81 is a lock-in relay line from switch 51 to line 57; 53 is an air bleeder valve; 55, 55a, 55b, 55c, 55d, 55a, 55 and 55g are air lines; and 57, 59, 61, 63, 65, 67, 69, 71, 73, 75, 77, 79 and 81 are electrical lines.

Referring to FIG. 6, 6 is the punch roll; 14 is the die plate; 70s are spacers; 72 is a punch disk; 74 is a punch tooth; 76s are die plate ribs; 98a is the second or upper sheet; 98 is the first or lower sheet; and 98b is a lower tab. The cutting edges are 76a, and 78 is a slot in die plate 14.

Referring to FIG. 7, 14 is the die plate; 14b are the surfaces against which the webs are supported during the shearing of the tabs; 72 is the punch disk; 74 is a tooth on punch disk 72; 74a is tooth 74 in pre-cutting position; 74b is the crown of tooth 74; 76 is the die plate rib; 76a is the shearing edge of die plate rib 76; 56 is the upper web release and holddown plate; 58 is the knockover plate; 104 is a rib of the upper web release and holddown plate 56; 182 is a rib of the knockover plate 58; 84 is the back edge of recess 80 in the upper web release and holddown plate 56 shown in FIG. 1; 86 is the back and foldover edge of recess 82 in the knockover plate 58 shown in FIG. 1; 98b are tabs; 980 are slots left where tabs 98b were cut; and 98d is the approximate point at which the front edges of the tabs 98b are sheared.

Referring to FIG. 8, 22 is the upper calender roll shown in FIG. 1; 38 is the lower calender roll shown in FIG. 1; is a machined recess in roll 22; 98a is the second or u per sheet; 98 is the first or lower sheet; 88 is a calendered tab body; 98b are tabs; and 980 are slots left where tabs 98b were cut out.

Referring to FIG. 9, 98 is the first or lower sheet; 980 is the second or upper sheet; 980 is a slot; and 88 is a calendered tab body.

Referring to FIGS. 10, 10a and 10b, 56b are the holddown portion of the combined web guide, web release and web holddown means 10911; 560 are side supports for 109a which mount to frames 2 and 4 of FIG. 1; 59 are rib plates between slots 80a, which slots correspond to slots 80 of FIG. 1; and 84b are back edges of slots 88a corresponding to back edge 84 of FIG. 7.

Referring to FIGS. 11, 11a and 11b, 14a are side sup ports for the die plate assembly 14b which mount to frames 2 and 4 of FIG. 1; 14c. are support surfaces for

webs

98 and 98a of FIG. 1; 14g are cross-supports for die rib plates 76b which correspond to die rib plates 76 of FIG. 1; 14d are mounts screws for (lie plate ribs 76b; 76a are cutting edges of die plate ribs 76b; and 78a are slots corresponding to slots 78 of FIG. 1.

Referring to FIG. 1'2, 14:: is a combined die plate and knockover plate corresponding to die plate 14 of FIG. 1 and die plate 14b of FIG. 11; 14a is a support for the combined plate 142 which mounts to frame 4 of FIG. 1; 14c are support surfaces for

webs

98 and 98a of FIG. 1; 76a are cutting edges corresponding to cutting edges 76a of FIG. 1; 760 is a die rib plate corresponding to die rib plate 76b of FIG. 11; 78a is a die slot corresponding to slot 78 of FIG. 1; and 86a is a back and foldover edge corresponding to edge 86 of FIG. 7.

Referring to FIG. 13, 14 is a combined die plate and knockover plate corresponding to die plate 14 and knockover plate 58 of FIG. 1; 14a is a support for the combined plate 14 which mounts to frame 4 of FIG. 1; 140 are support surfaces. for

webs

98 and 98a of FIG. 1; 76a are cutting edges corresponding to cutting edges 76a of FIG. 1; 78a is a die slot corresponding to slot 78 of FIG. 1; and 86a is a back and foldover edge corresponding to the edge 86 of FIG. 7.

Referring to FIG. 14, 6 is the punch roll; 8 is a shaft; 72 is a punch disk; 74 is a tooth; 74b is the crown of tooth 74; 100 is the non-toothed section of punch roll 6; 56b is the holddown portion of the combined web guide, web release and web holddown means 109a, shown in detail in FIGS. 10, 10a and 10b; 59 is a rib plate; is a support surface for

webs

98 and 98a; 14 is a combined die plate and knockover plate corresponding to that of FIG. 13; 76b is a die plate rib; 76c is the cutting edge of said rib; 78a is a slot adjacent said rib; 86a is a foldover edge; 98b are tabs; 560 is an upper web holddown and pressing plate; 58b is a lower pressing plate; 80a is a slot; 84a is the back edge of slot 80a; and 86b is a sloped bottom edge of slot 1112a.

The upper web holddown and pressing plate 560 is shown in FIG. 14 as having a solid cross-section running forward from the back edge 84a of slot 80a. In another embodiment, the bottom of plate 56c can be made in a grooved form with grooves similar to grooves 90 of upper calender roll 22, and serving the same purpose, running from the right end of slot 80a forward to the front, or right, end of plate 560 as viewed in FIG. 14.

Operation of the web joiner in a joining operation will now be described. Prior to the joining operation, sheet 98, FIG. 1, is moving freely through the web joiner and resting lightly, if at all, on roll 40, die plate 14, and roll 30. The punch roll 6 is in rest position with the cutting disks 72 FIG. 1 in the position shown in FIG. 2, i.e. with the non-toothed section 180 of each disk 72 opposite web 98a and with teeth 74 in non-engaging position above web 98a. Calender rolls 30 and 32 FIG. 1 are preferably also at rest position, i.e. none are being driven. As sheet 98 nears its end, the operator of the web joiner positions a second sheet 98a FIG. 1 on top of the first sheet 98, FIG. 1 by threading the leading edge of sheet 98a first between

rolls

40 and 38; then under front web guide plate 56a and between the punch roll 6 and die plate 14; then between web release and holddown plate 56 and tab knockover plate 58; and then placing the edge of the sheet 98a slightly past the vertical center line of calender rolls 22 and 30, all as shown in FIG. 1 and FIG. 2. The sheets are held in lateral alignment by guides not shown.

Next, in accordance with the electrical and pneumatic control diagram set out in FIG. 5, the operator initially sets cycle selector switch 39 to a desired cycling program under which punch roll 6 FIG. 1 will make 1 or more complete revolutions, always stopping the punch roll 6 in a position as shown in FIG. 2, so that no punch teeth are in position to contact and possibly damage the moving sheet after each cycle is completed. The number of revolutions made by the punch roll 6 should be adequate to ensure tight joining in an aligned position of

sheets

98 and 98a FIG. 1. From 2 to 10 revolutions will usually be suflicient, although more can be used. From 4 to 8 revolutions are preferably used. For purposes of illustration, it will be assumed that the operator sets selector switch 39 for 2 revolutions. The punch roll, having teeth part way around its circumference on each of the seven disks shown in FIG. 1, then is limited to making a total of 70 perforations and sets of tabs.

Having rechecked the position of sheet 98a relative to sheet 98 FIG. 2, the operator then starts electric motor 132 FIG. 5 by placing master start-stop switch 35 in start position. Operating cycle starting switch 49 is simultaneously placed in ready position by switch 35 through electrical line 57. As motor 132 starts, flywheel 136, shaft 142, gears 110, 122, 128 and 130 and calender rolls 22 and 30 all begin turning an instantaneous tangential speed equal to the lineal speed of web 98. The operator then places switch 49 in operating position. Lock-in relay switch 51 holds the cycle operating circuit in energized condition through

lines

81 and 57.

Simultaneously solenoid switch 5 is actuated, raising core 3 of airflow control valve 1 into operating position as shown in FIG. 5, with exhaust line 3b positioned in line with air line 55g. At the same time, solenoid switch 11 is actuated and through rod 15 moves valve spool 13 from position 13a in airflow control cylinder 9 to the position shown in FIG. 5. Air under a pressure of 60-125 lbs. gauge enters cylinder 9 from air supply line 55. The air pressure passes through air line 55b into air cylinder 19. The air pressure acts upon piston 17 moving it from position 17a to the position shown in FIG, 5. Piston rod 66 which is connected to piston 17 is simultaneously moved to contact position with limit switch 47. Also, as may be better seen in FIG. 1, the hinged arm of piston rod 66 rotates cam shaft 62 counterclockwise causing eccentric cams 92 to press against rods 94 and to move upper calender roll 22 downward against springs 106 to a preset position firmly pressing

sheets

98 and 98a between calender rolls 22 and 30. Sheet 98 continues to move rapidly through the web joiner. Sheet 98a, however, due to slippage, moves hardly at all.

As piston rod 66 contacts limit switch 47, solenoid switch 29 is actuated through line 61, causing piston 25 to move along rod 27 in cylinder 23 from position 25a to the position shown in FIG. 5. Air pressure from line 55 enters cylinder 23 and passes through air line 550 into the clutch 138, actuating the clutch band 139 against drive drum 143, causing shaft 145 to rotate counterclockwise.

Referring now to FIG. 1, rotation of shaft 145 causes rotation of the brake mechanism 140. It also causes gear 147 to turn, placing in operation gears 128, 112, 114, 116, 124, 126. With the gears in operation, shaft 16 turns clockwise and punch roll 6 turns counterclockwise with an instantaneous tangential speed equal to the lineal speed of web 98. The punch teeth 74 begin perforating the sheets and forming the tabs in cooperation with the die plate 14.

Sheets

98 and 98a are pulled through the web joiner by the combination of forces exerted from the pressure from the upper calender roll upon the lower calender roll and the pulling force created by the punch teeth in forming the tabs. When the first set of tabs has been cut, folded back and calendered, the pull of the treating line equipment is additionally exerted on the joined sheets.

Referring now again to FIG. 5, as shaft 145 rotates, contact arm 33 contacts the arm of cycle counting relay switch 43. When the shaft 145, to which gear 147 is directly attached, completes the first of its preset cycle of 2 turn (illustrative cycle), relay switch 43 actuates cycle limit switch 39 through line 75. Switch 39 counts with the relay switch 43, turning its contacts through the preset number of shaft rotations. As the last cycle is completed and the shaft 145 completes its 2nd rotation, switch 39 actuates solenoid switch 41 through line 73. Switch 41 actuates solenoid switch 31 through line 65 causing piston 25 to move along rod 27 to position 25a in piston 23. Air pressure then is vented from line 550 by an exhaust vent not shown releasing clutch band 139. Air pressure is simultaneously applied through line 55d to brake 140, actuating the brake band 141 against brake drum housing 151, and causing shaft 145 to stop rotation at once in a preset position. This stops rotation of the punch roll 6 in its proper position as shown in FIG. 2.

Meanwhile, switch 41 also actuates relay switch 37 through line 59. Switch 37 through line 71 throws startstop switch 35 into stop position, turning off motor 132 through line 69. The calender rolls 22 and 30 continue to roll briefly under inertia. As switch 35 goes into stop position, flow of electricity is cut off in line 57, turning olf switch 49. With switch 49 turned off, switches 11 and 5 are also deactivated. Piston 13 is then free to move back to position 13a in cylinder 9. With switch 5 turned off, core 3 moves down, permitting passage 3a to align itself with

air lines

55 and 55g. Air pressure from line 55 passes through line 55a into air bleeder valve 53 and then through line 55 air passage 3a and line 55g into air valve 7. From air valve 7 the air pressure enters cylinder 9, forcing piston 13 to position 13a, thus shutting 01f direct air pressure from line 55 to air cylinder 9 and directing air pressure through line 55a into cylinder 19 to force piston 17 into position 17a. An air vent, not shown, relieves backpressure in the

air cylinders

9 and 19.

As piston 17 moves to position 17a, piston rod 66 is retracted. This causes cam shaft 62 and earns 92 to rotate clockwise, releasing the pressure on rods 94, permitting springs 106 to raise the upper calender roll 22 from contact with sheet 9811. See FIG. 1.

Also, as piston rod 66 retracts, it resets switch 47. Then as the contact on piston rod 66 moves over limit switch 45, it actuates switch 45 through line 63 to energize cycle counting relay switch 43 into a reset position.

The web joiner is then ready for the next joining operation.

The air pressure from line 55 continues to be applied to brake band 141 through air cylinder 23 and line 55d until the piston 25' again moves from position 25a to the posi- 13 tion shown in FIG. 5. This prevents the punch roll 6 of the web joiner from being moved from the position shown in FIG. 2, with the teeth 74 of punch roll 6 clearing the sheet 98a.

The perforating and pressing operation may be best understood by referring to FIGS. 2, 3, 4, 6, 7, 8 and 9.

FIG. 2 shows the cutting disk 72 of the punch roll 6 at the start of a cutting cycle. FIG. 3 shows the double thickness of

sheets

98 and 98a being pierced by cutting tooth 74 of cutting disk 72 with the tab 98b extending into slot 78 and bent down on the shoulder at the junction of rib 76 and slot 78.

The piercing or cutting step is better shown in FIG. 6, taken along the lines 66 of FIG, 3, and in FIG. 7. The cutting tooth 74 is shown cutting through

sheets

98a and 98 on three sides, bending tabs 98b down into slot 7 between ribs 76.

FIG. 4 shows the fifth set of tabs 98b being cut by tooth 74 of cutting disk 72. It shows the fourth set of tabs 98b in the process of being folded back by the knockover plate 58.

The cutting and folding steps can be more clearly understood by referring to FIG. 7. In FIG. 7, at the left, 74a depicts tooth 74 at the start of the shearing step in which the tabs 98b are formed. As disk 72 rotates counterclockwise and the

webs

98 and 98a move linearly from left to right through the joiner, with the webs supported on die plate 14 by supporting surfaces 14b, the front edge of tooth 74 pierces

webs

98a and 98, respectively, when the webs are about at position 98d, forming the front edges of tabs 98b. The sides of tooth 74 then continue shearing

webs

98a and 98 in cooperation with cutting edges 76a of die plate 14, while the webs move linearly through the joiner at the same lineal speed as the tangential speed of disk 72. As tooth 74 passes through

webs

98a and 98, the crown of the tooth 74b gradually forces tabs 98b to a downwardly projecting position, as shown. Tooth 74 then continues its passage from rear to front through and out of slot 78.

Ribs

102 and 109

release sheets

98 and 98a from contact with punch roll 6 and disk 72 thus freeing the tabs 98b. Tabs 98b then move into slot 82. As the

sheets

98 and 98a advance against the knockover plate 58, the tabs 98b impinge against the foldover edge 86 and are folded rearward. The upper web release and holddown plate 56 and the knockover plate 58 are each adjustable and are set so that the folded tabs 98b can pass substantially unrestricted between the two plates. In FIG. 7, 98c are slots in the sides of

sheets

98 and 98a, showing where the tabs have been cut away.

Referring again now to FIG. 4, the third set of tabs 98b is shown midway between the

plates

56 and 58 and the calender rolls 22 and 3. As can be seen, the tabs are not yet completely pressed against the bottom of sheet 98. The completion of the pressing takes place between the calender rolls 22 and 30. As can be seen, the tabs are tabs 98b is shown being pressed.

This latter step can be better understood from FIG. 8 where the tabs 9817 are shown being pressed between the smooth surface of lower calender roll 30 and the recess 99 of upper calender roll 22. The excess of metal from the tabs 98b is thus pressed into the surface of

sheets

98 and 98a, making the lower surface of sheet 98 substantially smooth and free of ridges which might unduly lift the joined sheet as it passes through a subsequent treating line.

Sheets

98 and 98a are shown to be tightly pressed together and in effect moving as a unit.

Referring again to FIG. 4, the folded over, calendered first set of tabs 88 is shown to the right of the calender rolls 22 and 30.

FIG. 9 shows the plan view of one set of tabs 88 and the opening 980 where the tabs have been cut from

sheets

98 and 98a.

White the punch roll 6 and calender roll 22 have been shown on the upper part of the joiner and the die plate 14 and calenderroll 30 on the bottom part, the rolls and die plate can be transposed so that the punch roll 6 and calender roll 22 are on the bottom and roll 30 and the die plate are on top. The positions of

plates

56 and 58 should then be interchanged so that the knockover plate 58 is on top. Then sheet 98a would be fed into the web joiner underneath sheet 98. The tabs 98b would then be cut from the bottom of the sheets and folded upward and rearward and be calendered substantially as already described. This arrangement and method of operation of the web joiner may be preferred for certain operations where it is more convenient to feed the second sheet 98a from underneath sheet 98.

Also, to facilitate maintenance and inspection of the punch roll 6 and die plate 14, means, e.g. springs and cams such as are used with the calender rolls or hydraulic pistons, can be provided for readily releasing and raising punch roll 6 so that access can be had to the space between roll 6 and die plate 14, e.g. in the event that the cutting edges 76a require sharpening. For example, sets of springs can be placed between bearing blocks 12 and 20 which will raise roll 6 when bearing blocks 12 are unlocked from position in frames 2 and 4.

Also, although roll 6 has been disclosed as being made up of. a plurality of spacers and disks, the roll can be made in one piece. For example, the punch roll 6 can be made of one piece into which cutting teeth 74 are individually inserted as by screwing, wedging, welding, or locking into place with bolts.

The joining operation, for pulling purposes, is substantially complete when the tabs 93b have been folded back between the

plates

56 and 58 since the pulling forward of the lower sheet 98 necessarily will pull along upper sheet 98a. Nevertheless, the pressing step is essential in a high speed line in order to prevent the sheets from pulling apart through whiplash or under inertia in the event that the forward section of the treating line is suddenly slowed down before the rear section is slowed.

When joining easily folded materials such as light gauge aluminum or copper, the pressing step can sometimes be carried out by use of one or more knockover plates 58 spaced at successively closer settings in cooperation with one or more upper web holddown plates 56, so that the final setting is about equal to that between the calender rolls during the pressing step. The calendering rolls then would not be necessary. However, in such an embodiment where the calender rolls are not used, means may need to be provided to move the

sheets

98 and 98a through the web joiner. In most cases the treating line will cause sufficient movement of the sheet 98 so that no auxiliary means will be needed. If the line is not able to move the

sheets

98 and 98a sufliciently, a set of drive rolls similar to the calender rolls 22 and 30 can be used in conjunction with the web joiner. However, in the latter case, the upper roll would not need to be recessed nor would the rolls need to act as calenders, provided a sufficient number of knockover plates were used to ensure a secure joint, i.e. one which will not pull apart in event of whiplash or inertia.

It is intended to cover all changes and modifications of this invention substantially as disclosed herein including such changes which do not depart from the spirit and scope thereof. The invention can be used to join dissimilar materials as well as similar materials. Also, it can be used to join more than one new web to a preceding web or plurality of webs by overlapping the leading ends of the new webs upon each other and the tail end or ends of the preceding web or webs, up to the capacity of the punch roll to cut, the tab bending station to bend and the pressing station to press the multiplicity of tabs. Furthermore, webs of different thicknesses can be spliced together by the web joiner. While the joiner is intended principally for use in connection with metal treating lines, it can also be used in other fields of services, such as printing, laminating, strip forming and the like, i.e. wherever it is advantageous to join the leading end of a roll of material to the tail end of a preceding roll under continuous operating conditions.

What is claimed is:

1. In a machine for joining in overlapping relationship a plurality of overlapped webs of foldable material, at least one of said webs initially being substantially stationary and at least one of said webs initially moving linearly through said machine at high speed relative to the bed of the machine, comprising tab cutting means for producing in said overlapped webs a plurality of partial perforations with projecting tabs retained adjacent said perforations at the rear of said perforations relative to the direction of movement of the webs;

tab folding means for acting upon said projecting tabs to fold them rearward from said direction of movement;

tab pressing means for pressing said tabs against said webs; the improvement wherein said tab cutting means consists essentially of a punch roll supported at its ends by the frame of said machine and adjacent to one of the flat surfaces of the webs and having a plurality of substantially hexahedral teeth projecting from its surface and spaced in staggered rows extending along the roll and spaced in aligned peripheral rows in a toothed section extending part away around the periphery of the roll,

with an essentially non-toothed section in the remaining part of the periphery of each peripheral row, said non-toothed sections essentially being aligned relative to each other along the roll so that no tooth in the roll contacts the webs when the center line along the roll of the composite arcuate surface of said sections is opposite said webs, said teeth each having forward and side cutting edges and a non-cutting rearward edge; and a die plate substantially coplanar with the flat surfaces of said webs and adjacent thereto on the opposite side of said webs and opposite said punch roll and having parallel alternating slots and ribs running from front to rear of said plate with cutting edges along the sides of said ribs opposite the side cutting edges of said teeth,

said slots corresponding in widths, number and positions to the widths, number and positions of corresponding peripheral rows of said teeth and providing openings through said die plate, said slots being positioned to permit said peripheral rows of teeth to pass into and out of said slots from rear to front in shearing relationship with the cutting edges of said ribs when said punch roll rotates and to permit the die plate at the rear of the slots to support the rearward portion of the tabs in non-shearing relationship with said teeth; said machine including drive means for turning said punch roll codirectionally with said moving web and for providing said roll with an instantaneous tangential velocity equal to the lineal velocity of the moving web, and means for stopping the rotation of the punch roll at the end of a predetermined number of revolutions when the nontoothed section is opposite a flat surface of the joined webs with no tooth contacting said surface.

2. In the machine according to claim 1, a combined guide web release and web holddown means positioned between the punch roll and the die plate and extending from a position ahead of the roll to a position sufiiciently after the roll to permit the web holddown portion of said means to cooperate with a knockover means lying in the plane of said die plate and adjacent thereto, said combined means consisting essentially of a slotted plate supported at its side edges by the frame of said machine and being closed at its front and rear edges and having a plurality of ribs and slots running from said front to rear edges, said slots corresponding in number and positions to those of the peripheral rows of teeth on said punch roll and providing openings through said plate at least sufliciently wide enough to permit said teeth to rotate freely through the-slots, said plate being sufficiently thin to permit said teeth to pass unobstructed simultaneously through said plate and a plurality of webs lying on said die plate and into shearing relationship with said die plate.

3. In the machine according to claim 1, a die plate assembly comprising a plurality of rib plates having cutting edges and assembled to the form of said die plate, said rib plates each consisting of a plate supported at its front and rear ends by cross supports running to the frame of said machine, each plate having running from front to rear a straight edge and a parallel indented edge, each of said edges having a cutting edge, each of said indented edges being in the form of a cutaway indentation having the width of a corresponding row of peripheral teeth on said punch roll and running from top to bottom of said plate, said indentation being long enough to permit said teeth to pass into and out of said indentation and having its rearward end positioned to permit the die plate at the rear of the indentation to support the rearward portion of the tabs in non-shearing relationship with said teeth, each of said plates being assembled and secured to said cross supports with its straight edge immediately adjacent to the indented edge of the next adjacent plate on one side and with its indented edge immediately adjacent to the straight edge of the next adjacent plate on the other side, said assembled plates pro viding cutting edges having shearing relationship to the teeth of said punch roll.

4. In the machine according to claim 1, a combined die plate and tab folding means, said combined means consisting essentially of a die plate according to claim 1 wherein the forward ends of the slots are closed thereby forming a tab folding means against which the projecting tabs impinge and are folded rearwardly during the forward movement of the webs through the machine.

5. In the machine according to claim 3, a die plate assembly wherein the forward end of each indentation is closed thereby forming a tab folding means against which the projecting tabs impinge and are folded rearwardly during the forward movement of the webs through the machine.

6. In the machine according to claim 1, combined tab folding and tab pressing means consisting essentially of a plurality of pairs of stationary opposed plates supported at their ends by the frame of said machine and positioned parallel to said punch roll adjacent the surfaces of said webs with one member of .each pair above and the other member below said webs and with each successive pair spaced at progressively closer folding and pressing distances relative to the preceding pair.

7. In the machine according to claim 1, a non-toothed section in each row of peripheral teeth on the punch roll, said section extending for about to of the periphery of said row.

8. A machine according to claim 1 in which the die plate is adjustable vertically and horizontally with reference to the positions of the teeth in the peripheral rows.

9. A machine according to claim 1 in which the folding means includes a knockover means bearing slots spaced along its length on its tab engaging side, said slots corresponding in widths, number and positions to the peripheral rows of teeth along said punch roll, and having ribs adjacent and parallel to the sides of said slots, said slots and ribs cooperating to guide the sides of the tabs within said slots during the folding step.

10. A machine according to claim 1 in which the punch roll is vertically adjustable with reference to the surface of the die plate and the slots thereof.

11. A machine according to claim 1 in which the drive means are actuated and stopped by automatic means actuated by a forward portion and a rearward portion respectively of the tail section of the moving web as it passes into the machine.

12. In the machine according to claim 2, a combined die plate and tab folding means, said combined means consisting essentially of a die plate according to claim 1 wherein the forward ends of the slots are closed thereby forming a tab folding means against which the projecting tabs impinge and are folded rearwardly during the forward movement of the webs through the machine.

13. In the machine according to claim 12, tab pressing means consisting essentially of at least one pair of stationary opposed plates supported at their ends by the frame of said machine and positioned parallel to said punch roll in pressing relationship adjacent the surfaces of said webs with one member of a pair above and the other member below said web surfaces and with the distance between said members greater at the tab entering edges than at the tab leaving edges, said distance at the tab leaving edges of the last pair being about equal to twice the combined thickness of the plurality of webs.

References Cited by the Examiner UNITED STATES PATENTS 2,002,554 5/1935 Townley 2921.1 2,945,462 7/1960 Obersuer 113-1 3,060,945 10/ 1962 Spenle 29-21.1 3,129,489 4/1964 Nelson 29-211 CHARLES W. LANHAM, Primary Examiner.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent Noc 3,284,873 November 15, 1966 George Ra Noel It is hereby certified that error appears in the above numbered patent requiring correction and that the said Letters Patent should read as corrected below.

Column 3, line 4, for "sheaing" read shearing column 6, line 28, for "web joined" read web joiner column 13, line 52, for "rolls 22 and 3." read rolls 22 and

30e lines

55 and 56, for "As can be seen, the tabs are tabs 98b is shown being pressed." read In FIG. 4, the second set of tabs 98b is shown being pressed, column 15, line 28, for "part away" read part way Signed and sealed this 12th day of September 1967.

(SEAL) Attest:

ERNEST W. SWIDER EDWARD J. BRENNER Attesting Officer Commissioner of Patents

Claims

1. IN A MACHINE FOR JOINING IN OVERLAPPING RELATIONSHIP A PLURALITY OF OVERLAPPED WEBS OF FOLDABLE MATERIAL, AT LEAST ONE OF SAID WEBS INITIALLY BEING SUBSTANTIALLY STATIONARY AND AT LEAST ONE OF SAID WEBS INITIALLY MOVING LINEARLY THROUGH SAID MACHINE AT HIGH SPEED RELATIVE TO THE BED OF THE MACHINE, COMPRISING TAB CUTTING MEANS FOR PRODUCING IN SAID OVERLAPPED WEBS A PLURALITY OF PARTIAL PERFORATIONS WITH PROJECTING TABS RETAINED ADJACENT SAID PERFORATIONS AT THE REAR OF SAID PERFORATIONS RELATIVE TO THE DIRECTION OF MOVEMENT OF THE WEBS; TAB FOLDING MEANS FOR ACTING UPON SAID PROJECTION TABS TO FOLD THEM REARWARD FROM SAID DIRECTION OF MOVEMENT; TAB PRESSING MEANS FOR PRESSING SAID TABS AGAINST SAID WEBS; THE IMPROVEMENT WHEREIN SAID TAB CUTTING MEANS CONSISTS ESSENTIALLY OF A PUNCH ROLL SUPPORTED AT ITS ENDS BY THE FRAME OF SAID MACHINE AND ADJACENT TO ONE OF THE FLAT SURFACES OF THE WEBS AND HAVING A PLURALITY OF SUBSTANTIALLY HEXAHEDRAL TEETH PROJECTING FROM ITS SURFACE AND SPACED IN STAGGERED ROWS EXTENDING ALONG THE ROLL AND SPACED IN ALIGNED PERIPHERAL ROWS IN A TOOTHED SECTION EXTENDING PART WAY AROUND THE PERIPHERY OF THE ROLL, WITH AN ESSENTIALLY NON-TOOTHED SECTION IN THE REMAINING PART OF THE PERIPHERY OF EACH PERIPHERAL ROW, SAID NON-TOOTHED SECTIONS ESSENTIALLY BEING ALIGNED RELATIVE TO EACH OTHER ALONG THE ROLL SO THAT NO TOOTH IN THE ROLL CONTACTS THE WEBS WHEN THE CENTER LINE ALONG THE ROLL OF THE COMPOSITE ARCUATE SURFACE OF SAID SECTIONS IS OPPOSITE SAID WEBS, SAID TEETH EACH HAVING FORWARD AND SIDE CUTTING EDGES AND A NON-CUTTING REARWARD EDGE; AND A DIE PLATE SUBSTANTIALLY COPLANAR WITH THE FLAT SURFACES OF SAID WEBS AND ADJACENT THERETO ON THE OPPOSITE SIDE OF SAID WEBS AND OPPOSITE SAID PUNCH ROLL AND HAVING PARALLEL ALTERNATING SLOTS AND RIBS RUNNING FROM FRONT TO REAR OF SAID PLATE WITH CUTTING EDGES ALONG THE SIDES OF SAID RIBS OPPOSITE THE SIDE CUTTING EDGES OF SAID TEETH, SAID SLOTS CORRESPONDING IN WIDTHS, NUMBER AND POSITIONS TO THE WIDTHS, NUMBER AND POSITIONS OF CORRESPONDING PERIPHERAL ROWS OF SAID TEETH AND PROVIDING OPENINGS THROUGH SAID DIE PLATE, SAID SLOTS BEING POSITIONED TO PERMIT SAID PERIPHERAL ROWS OF TEETH TO PASS INTO AND OUT OF SAID SLOTS FROM REAR TO FRONT IN SHEARING RELATIONSHIP WITH THE CUTTING EDGES OF SAID RIBS WHEN SAID PUNCH ROLL ROTATES AND TO PERMIT THE DIE PLATE AT THE REAR OF THE SLOTS TO SUPPORT THE REARWARD PORTION OF THE TABS IN NON-SHEARING RELATIONSHIP WITH SAID TEETH; SAID MACHINE INCLUDING DRIVE FOR TURNING SAID PUNCH ROLL CODIRECTIONALLY WITH SAID MOVING WEB AND FOR PROVIDING SAID ROLL WITH AN INSTANSTANEOUS TANGENTIAL VELOCITY EQUAL TO THE LINEAL VELOCITY OF THE MOVING WEB, AND MEANS FOR STOPPING THE ROTATION OF THE PUNCH ROLL AT THE END OF A PREDETERMINED NUMBER OF REVOLUTIONS WHEN THE NONTOOTHED SECTION IS OPPOSITE A FLAT SURFACE OF THE JOINED WEBS WITH NO TOOTH CONTACTING SAID SURFACE.