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.

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.

Apparatus for attaching discrete segments together to form a continuous web include a first segment transfer device adapted to receive a first continuous web at a first pick-up location and to release a first discrete segment cut from the first web at an application location. The first segment transfer device has a first speed profile. A second segment transfer device is adapted to receive a second continuous web at a second pick-up location and to release a second discrete segment cut from the second web at the application location such that the second discrete segment is attached to the first discrete segment. The second segment transfer device has a second speed profile that is different than the first speed profile.

Methods and apparatuses for moving and/or transferring discrete articles are described. In particular, the methods and apparatuses relate to flexible arrangements to move and/or transfer discrete articles that vary in size and/or shape with minimal to no change in equipment.

An apparatus includes a transfer mechanism that transfers discrete articles to a receiving member. The transfer mechanism includes a plurality of transfer pucks that carry discrete articles thereon. Each of the transfer pucks includes a puck body with an article carrying surface having vacuum holes formed therein to retain the discrete article thereon via a vacuum. The article carrying surface includes a central region and at least one side region adjacent the central region, the side region aligned lengthwise along the puck body. Each of the transfer pucks also includes one or more resilient puck inserts positioned about a portion of a perimeter of the transfer puck, with each puck insert engaged with the puck body in a respective side region. The puck inserts are sized to protrude above the article carrying surface and are depressible inward toward the article carrying surface upon an application of force thereto.

An apparatus and method is provided for single transfer insert placement. The apparatus receives continuous web material and cuts a discrete section or pad from the web. The pad is then supported on a single transfer surface. The single transfer surface then may spin the supported pad to a desired angle and provide the pad to a receiving surface at a desired interval. The web material can be cut to different insert lengths and the placement location varied.

An apparatus and method is provided for single transfer insert placement. The apparatus receives continuous web material and cuts a discrete section or pad from the web. The pad is then supported on a single transfer surface. The single transfer surface then may spin the supported pad to a desired angle and provide the pad to a receiving surface at a desired interval. The web material can be cut to different insert lengths and the placement location varied.

A temporary holding section includes bridge portions that span along a shaft direction across respective groove portions of a drum at plural discrete locations around the drum circumferential direction. The temporary holding section can accordingly prevent an outer tape and an inner tape from slipping off into the groove portions, enabling damage to the tapes to be forestalled. The temporary holding section can also precisely determine the presence or absence of a banknote by shining a drum detection light toward the groove portions so as to pass through opening hole portions.

A temporary holding section includes bridge portions that span along a shaft direction across respective groove portions of a drum at plural discrete locations around the drum circumferential direction. The temporary holding section can accordingly prevent an outer tape and an inner tape from slipping off into the groove portions, enabling damage to the tapes to be forestalled. The temporary holding section can also precisely determine the presence or absence of a banknote by shining a drum detection light toward the groove portions so as to pass through opening hole portions.

The present invention provides a method and apparatus for transporting a discrete element. A preferably rotatably driven vacuum commutation zone (or internal vacuum manifold), preferably internal to a preferably independently driven porous vacuum roll or drum is disclosed. The vacuum manifold applies vacuum through pores in the driven porous vacuum roll or puck in order to hold material against an external surface of the vacuum roll or puck. By independently controlling the vacuum commutation zone and the driven porous surface, unique motion profiles of the vacuum commutation zone relative to the driven porous surface can be provided. Micro vacuum commutation port structures are also disclosed.