SYSTEM AND METHOD FOR FORMING AND APPLYING A MULTIZONE STICKER FOR USE IN MANUFACTURING OF ABSORBENT ARTICLES

Abstract

A method is presented for making a multizone sticker for manufacturing an absorbent article. The method includes unwinding a sticker laminate. The method also includes separating the laminate into a first layer and a second layer, with the first layer including a surface with adhesive and the second layer including a non-stick backing layer. The method also includes treating the first layer with adhesive neutralizing agent to form a first zone with untreated adhesive and a second zone with treated adhesive. The method also includes recombining the first layer and the second layer, with at least a portion of the first zone configured to extend across a leading edge of a roll of material comprising a roll winding direction.

Claims

1. A method for making a sticker for manufacturing an absorbent article, the method comprising: unwinding a sticker laminate; separating the sticker laminate into a first layer and a second layer, wherein the first layer comprises a surface with adhesive and the second layer comprises a non-stick backing layer; treating the first layer with adhesive neutralizing agent to form a first zone comprising untreated adhesive and a second zone comprising treated adhesive; and recombining the first layer and the second layer; wherein at least a portion of the first zone is configured to extend across a leading edge of a roll of material comprising a roll winding direction.

2. The method of claim 1, further comprising die cutting a perimeter defining individual multizone stickers.

3. The method of claim 2, wherein the first layer further comprises a third zone without adhesive, and wherein the perimeter surrounds a portion of the third zone, and wherein the third zone is adjacent to the first zone and is configured to extend away from the first zone opposite the roll winding direction.

4. The method of claim 1, wherein the second zone is adjacent to the first zone and is configured to extend away from the first zone in the roll winding direction.

5. The method of claim 1, further comprising treating the first zone with an adhesive neutralizing agent to form a first portion and a second portion of the first zone, wherein the first portion is configured to adhere to the roll of material with a first level of force and the second portion is configured to adhere to the roll of material with a second level of force, wherein the second level of force is less than the first level of force.

6. The method of claim 5, further comprising die cutting a perimeter defining individual multizone stickers.

7. The method of claim 6, wherein the first layer further comprises a third zone without adhesive, and wherein the perimeter surrounds a portion of the third zone, wherein the third zone is adjacent to the first zone and is configured to extend away from the first zone opposite the roll winding direction.

8. The method of claim 5, wherein the second portion of the first zone is adjacent to the second zone and is configured to extend away from the second zone opposite the roll winding direction.

9. The method of claim 1, further comprising applying additional adhesive to the first zone to form a first portion and a second portion of the first zone, wherein the first portion is configured to adhere to the roll of material with a first level of force and the second portion is configured to adhere to the roll of material with a second level of force, wherein the second level of force is less than the first level of force.

10. The method of claim 1, further comprising applying a substrate to the first zone to form a third zone, wherein an exposed side of the substrate is an adhesive that is weaker than the adhesive of the first zone.

11. A method of preparing material for automated pick up used for manufacturing an absorbent article, the method comprising: providing a roll of material comprising a leading edge, a first side, and a second side axially separated from the first side, the roll of material further comprising an roll winding direction; advancing the multizone sticker in a label making direction across the roll of material, the multizone sticker comprising a first zone and a second zone; and placing the multizone sticker on the roll of material; wherein the first zone of the multizone sticker is placed across the leading edge of the roll of material, and wherein the second zone of the multizone sticker extends from the first zone in the roll winding direction.

12. The method of claim 11, further comprising aligning the multizone sticker to be about centered between the first side and the second side of the roll.

13. The method of claim 11, further comprising attaching the first zone to the roll with an adhesive.

14. The method of claim 11, further comprising separating at least a portion of a carrier web from the rest of the multizone sticker.

15. The method of claim 11, wherein the multizone sticker further comprises first edge and a second edge separated from the first edge in the label making direction, the method further comprising aligning the first edge of the multizone sticker to be about parallel with the first side or the second side of the roll of material.

16. The method of claim 11, further comprising inspecting the multizone sticker on the roll to confirm that the multizone sticker is correctly applied.

17. The method of claim 11, further comprising placing the multizone sticker on the roll of material with a robot.

18. The method of claim 11, further comprising moving the roll of material to align the roll of material with multizone sticker.

19. A multizone sticker for manufacturing an absorbent article, the multizone sticker comprising: a first layer comprising a first zone and a second zone, wherein the first zone is configured to adhere to an outer layer of a roll of material, and wherein the second zone is configured to not adhere to the outer layer of the roll of material; a second layer comprising a third zone configured to adhere to the roll of material; and a fourth zone that is not adhered to the roll of material; wherein the third zone is at least partially radially inward from the first zone or the second zone when the multizone sticker positioned on the roll of material.

20. The multizone sticker of claim 19, wherein the fourth zone is sandwiched between the first zone and the third zone.

21. The multizone sticker of claim 19, wherein the first zone comprises a first adhesive coating and wherein the third zone comprises a second adhesive coating.

22. The multizone sticker of claim 21, wherein the third zone is configured to stay adhered to the roll of material if the second zone is moved radially away from the fourth zone.

23. The multizone sticker of claim 22, wherein the third zone is configured to be positioned into a splice box.

24. The multizone sticker of claim 23, wherein the fourth zone is configured to be removed from the third zone.

25. The multizone sticker of claim 24, wherein the fourth zone is radially inward from the second zone, and wherein there is no adhesive directly between the fourth zone and the second zone.

26. The multizone sticker of claim 19, wherein the second zone is configured to be moved by a robot device.

27. The multizone sticker of claim 26, wherein the robot device comprises a vacuum device.

28. The multizone sticker of claim 26, wherein the robot device comprises a gripper, and the robot device is configured to wind the third zone about the gripper.

29. The multizone sticker of claim 19, wherein the fourth zone is configured to be moved by a gripper of a robot.

30. The multizone sticker of claim 29, wherein the robot is configured to pull the roll of material in order to align the third zone of the sticker within the splice box.

31. The multizone sticker of claim 19, wherein a first portion of the first zone is configured to adhere to the roll of material with a first level of force and a second portion of the first zone is configured to adhere to the roll of material with a second level of force, wherein the second level of force is less than the first level of force.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Many aspects of this disclosure can be better understood with reference to the following figures, which illustrate examples according to various embodiments.

[0010] FIG. 1A is a block diagram that illustrates an example of a system for forming a tapeless splice bond between material of an expiring roll and a new roll, according to various embodiments;

[0011] FIG. 1B is a block diagram that illustrates an example of the system of FIG. 1A upon detection of an upcoming expiration of the expiring roll, according to various embodiments;

[0012] FIG. 1C is a block diagram that illustrates an example of the system of FIG. 1A upon fixing a first portion of the expiring roll adjacent the sonotrode and a second portion of the new roll adjacent the anvil, according to various embodiments;

[0013] FIG. 1D is a block diagram that illustrates an example of the system of FIG. 1A upon forming a splice bond between the first portion of the expiring roll and the second portion of the new roll, according to various embodiments;

[0014] FIG. 2A is a block diagram that illustrates an example of the system of FIG. 1A where outer layers of the new roll are collected downstream of the splice location, according to various embodiments;

[0015] FIG. 2B is a block diagram that illustrates an example of the system of FIG. 1A where the second portion of the new roll is fixed adjacent the anvil, according to various embodiments;

[0016] FIG. 2C is a block diagram that illustrates an example of the system of FIG. 1A where the collected outer layers are cut from the second roll, according to various embodiments;

[0017] FIG. 3A is a side view that illustrates an example of the sonotrode and anvil of the system of FIG. 1C forming the splice bond, according to various embodiments;

[0018] FIG. 3B is a perspective view that illustrates an example of the sonotrode and anvil of the system of FIG. 1C forming the splice bond, according to various embodiments;

[0019] FIG. 3C is a side view that illustrates an example of the splice bond formed between material of the expiring and new rolls in the system of FIG. 1D, according to various embodiments;

[0020] FIG. 3D is a front view that illustrates an example of the splice bond formed between materials of the expiring and new rolls in the system of FIG. 1D, according to various embodiments;

[0021] FIGS. 4A and 4B are front views that illustrate an example of the anvil and adjacent sensors to detect a presence of the leading edge of the new roll in the system of FIG. 1B, according to various embodiments;

[0022] FIGS. 5A and 5B are side views that illustrate an example of the mandrel of the new roll and a vacuum device to automatically pick up the leading edge of the new roll, according to various embodiments;

[0023] FIGS. 5C and 5D are side views that illustrate an example of the mandrel of the new roll and an air blade and mechanical finger to automatically pick up the leading edge of the new roll, according to various embodiments;

[0024] FIG. 5E is a top view of a conventional sticker used to secure a leading edge of a new roll;

[0025] FIG. 5F is a top view that illustrates an example of a multi-zone sticker to secure the leading edge of the new roll and facilitate automated pick up of the leading edge of the new roll;

[0026] FIG. 5G is a cross-sectional view of the multi-zone sticker of FIG. 5F taken along the line 5G-5G;

[0027] FIG. 5H is a top view that illustrates an example of indicia provided on one or more zones of the multi-zone sticker of FIG. 5F;

[0028] FIG. 5I is a top perspective view that illustrates an example of a cantilevered splice box used in the system of FIG. 1A;

[0029] FIG. 5J is a top perspective view that illustrates an example of a non-cantilevered splice box used in the system of FIG. 1A;

[0030] FIG. 5K is a top view of a multizone sticker, according to various configurations;

[0031] FIG. 5L is a side view of a multizone sticker adhered to a roll of material, according to various configurations;

[0032] FIG. 6 is a flowchart that illustrates an example of a method for forming a tapeless splice bond between material of the expiring roll and material of the new roll, according to various embodiments;

[0033] FIG. 7 is a block diagram that illustrates a computer system upon which an embodiment of the invention may be implemented;

[0034] FIG. 8 is a block diagram that illustrates a chip set upon which an embodiment of the invention may be implemented;

[0035] FIG. 9 is a block diagram that illustrates a mobile terminal upon which an embodiment of the invention may be implemented;

[0036] FIG. 10 is a perspective view of a bundle of rolls of webs of material wrapped in a film and with a sacrificial material positioned intermediate the film and the webs, according to various configurations;

[0037] FIG. 11 is a flowchart that illustrates an example of a method of forming a multizone sticker, according to various configurations;

[0038] FIG. 12 is a top view of a multizone sticker, according to various configurations;

[0039] FIG. 13 is a top view of an array of multizone stickers on a laminate, according to various configurations;

[0040] FIG. 14 is a flowchart that illustrates an example of a method of forming a multizone sticker, according to various configurations;

[0041] FIG. 15 is a top view of an array of multizone stickers on a laminate, according to various configurations;

[0042] FIG. 16A is a side view of a multizone sticker including a splice tape section, according to various configurations;

[0043] FIG. 16B is a side view of a multizone sticker including a splice tape section on a roll of material, according to various configurations;

[0044] FIG. 17A is a side view showing a system for positioning material from a new roll to a splice box, according to various configurations;

[0045] FIG. 17B is a side view of the system of FIG. 17A with the roll of material reoriented;

[0046] FIG. 17C is a side view of the system of FIG. 17B including a robot peeling a top layer of a multizone sticker from a splice tape section of the multizone sticker;

[0047] FIG. 17D is a side view of the system of FIG. 17C with the splice tape section moved near a splice box;

[0048] FIG. 17E is a side view of the system of FIG. 17D with a fourth zone of the multizone sticker removed from the third zone of the multizone sticker;

[0049] FIG. 17F is a side view of the system of FIG. 17E with the third zone of the multizone sticker positioned inside the splice box, according to various configurations;

[0050] FIG. 17G is a side view of the system of FIG. 17F with the outer layers of the roll of material wound around a gripper separated from the rest of the web of material;

[0051] FIG. 18 is a flowchart that illustrates an example of a method of positioning material from a new roll into a splice box, according to various configurations;

[0052] FIG. 19 is a side view of a multizone sticker aligned on a roll of material, according to various configurations;

[0053] FIG. 20A is a schematic of a system for forming for forming a multizone sticker, according to various configurations;

[0054] FIG. 20B is a schematic of an adhesive neutralizing location, according to various configurations;

[0055] FIG. 21A is a schematic of a system for forming for forming a multizone sticker, according to various configurations;

[0056] FIG. 21B is a schematic of an adhesive neutralizing location, according to various configurations; and

[0057] FIG. 22 is a flowchart that illustrates an example of a method for placing a multizone sticker on a roll of material, according to various configurations.

[0058] It should be understood that the various embodiments are not limited to the examples illustrated in the figures.

DETAILED DESCRIPTION

Introduction and Definitions

[0059] This disclosure is written to describe the invention to a person having ordinary skill in the art, who will understand that this disclosure is not limited to the specific examples or embodiments described. The examples and embodiments are single instances of the invention which will make a much larger scope apparent to the person having ordinary skill in the art. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by the person having ordinary skill in the art. It is also to be understood that the terminology used herein is for the purpose of describing examples and embodiments only, and is not intended to be limiting, since the scope of the present disclosure will be limited only by the appended claims.

[0060] All the features disclosed in this specification (including any accompanying claims, abstract, and drawings) may be replaced by alternative features serving the same, equivalent, or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. The examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to the person having ordinary skill in the art and are to be included within the spirit and purview of this application. Many variations and modifications may be made to the embodiments of the disclosure without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure. For example, unless otherwise indicated, the present disclosure is not limited to particular materials, reagents, reaction materials, manufacturing processes, or the like, as such can vary. It is also to be understood that the terminology used herein is for purposes of describing particular embodiments only and is not intended to be limiting. It is also possible in the present disclosure that steps can be executed in different sequence where this is logically possible.

[0061] All numeric values are herein assumed to be modified by the term about, whether or not explicitly indicated. The term about generally refers to a range of numbers that one of skill in the art would consider equivalent to the recited value (for example, having the same function or result). In many instances, the term about may include numbers that are rounded to the nearest significant figure.

[0062] In everyday usage, indefinite articles (like a or an) precede countable nouns and noncountable nouns almost never take indefinite articles. It must be noted, therefore, that, as used in this specification and in the claims that follow, the singular forms a, an, and the include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a support includes a plurality of supports. Particularly when a single countable noun is listed as an element in a claim, this specification will generally use a phrase such as a single. For example, a single support.

[0063] Unless otherwise specified, all percentages indicating the amount of a component in a composition represent a percent by weight of the component based on the total weight of the composition. The term mol percent or mole percent generally refers to the percentage that the moles of a particular component are of the total moles that are in a mixture. The sum of the mole fractions for each component in a solution is equal to 1.

[0064] Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit (unless the context clearly dictates otherwise), between the upper and lower limit of that range, and any other stated or intervening value in that stated range, is encompassed within the disclosure. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges and are also encompassed within the disclosure, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the disclosure.

[0065] In this specification and in the claims that follow, reference will be made to a number of terms that shall be defined to have the following meanings unless a contrary intention is apparent.

[0066] Absorbent article refers to devices that absorb and contain liquid, and more specifically, refers to devices that are placed against or in proximity to the body of the wearer to absorb and to contain various exudates discharged from the body.

[0067] Machine direction (MD) refers to the direction of material flow through a process. In addition, relative placement and movement of material can be described as flowing in the machine direction through a process from upstream in the process to downstream in the process.

[0068] Cross direction (CD) refers to a direction that is generally perpendicular to the machine direction.

System for Forming a Splice Bond

[0069] A system for forming a splice bond between an expiring roll of material and a new roll of material in an absorbent article manufacturing line will now be discussed. FIG. 1A is a block diagram that illustrates an example of a system 100 for forming a tapeless splice bond between material of an expiring roll and a new roll, according to various embodiments. In one embodiment, the material of the expiring roll is a first web or an expiring web 130 that has a tailing edge (not shown) and the material of new roll is a second web or new web 140 that has a leading edge 141.

[0070] Although some related art methods and devices are disclosed that form a tapeless splice bond between an expiring roll of material and a new roll of material, such as WO 2024/34461A1 to Zuiko (Zuiko hereafter), this related art method and device also features notable drawbacks. For example, Zuiko requires that the manufacturing line be shut down during the splicing process, which severely impacts the overall efficiency of the absorbent article manufacturing line. Yet further, Zuiko does not remove outer layers of the new roll of material which may need to be discarded (e.g. due to hygiene and/or routine wear or damage of outer layers of the new roll) prior to the splicing process. Hence, the method of Zuiko potentially forms a splice bond between the material of the expiring roll and damaged material of the outer layers of the new roll.

[0071] The system will now be discussed prior to initiating the splicing process. As shown in FIG. 1A, the expiring web 130 is conveyed from a first mandrel 101, through a splice box 102 in a machine direction (MD) 132, over an undriven roll 113 and to a second mandrel 105 to an absorbent article manufacturing line 149. In one example embodiment, the first mandrel 101 has a first motor 104 and the second mandrel 105 has a second motor 108. The first motor 104 is configured to rotate the first mandrel 101 in either a clockwise or counterclockwise direction. In one example embodiment, clockwise rotation of the first mandrel 101 and counterclockwise rotation of the undriven roll 113 causes the expiring web 130 to move through the splice box 102 to the manufacturing line 149. A controller 110 is provided that is communicatively coupled with the motor 104 to send signals to the motor 104 to adjust a magnitude or direction of the rotation speed of the mandrel 101 and thus adjust a magnitude or direction of the rotation speed of the expiring web 130 over the mandrel 101 and undriven roll 113.

[0072] The controller 110 may include a passive generator and safety circuit 111. The controller 110 may perform one or more steps of the method 200 discussed with respect to the flowchart of FIG. 6. In some embodiments, the processor or controller 110 is a computer system as described below with reference to FIG. 7, a chip set described below with reference to FIG. 8 or a mobile terminal described below with reference to FIG. 9.

[0073] As further shown in FIG. 1A, in one example embodiment an accumulated portion or splicer buffer system 144 of the expiring web 130 is collected downstream of the splice box 102. In one embodiment, this splicer buffer system 144 is collected using mandrels that cause the expiring web 130 to form a serpentine path downstream of the splice box 102 and upstream of the absorbent article manufacturing line 149. This splicer buffer system 144 is used to continuously feed the expiring web 130 to the absorbent article manufacturing line 149 in the event that the expiring web 130 is slowed or stopped upstream of the splice box 102. This could occur for various reasons including the method disclosed herein where the expiring web 130 is slowed down and stopped to form a splice bond between the expiring and new web 130, 140. In some embodiments, once the splicing process herein is initiated the value of the splicer buffer system 144 can be increased such that by the time that the expiring web 130 is stopped to form the splice bond the splicer buffer system 144 has increased to a value that is sufficient to ensure no stoppage of the web material to the manufacturing line 149 during the process steps herein.

[0074] As further shown in FIG. 1A, in one embodiment the new web 140 is provided prior to expiration of the expiring web 130, where the new web 140 similarly extends into the splice box 102 in the MD direction 132. As shown in FIG. 1A, in this embodiment the new web 140 is conveyed from a third mandrel 103 to the splice box 102 in the MD direction 132. As with the other mandrel 101, the third mandrel 103 features a motor 106 which is communicatively coupled with the controller 110 which sends signals to the motor 106 to adjust a magnitude or direction of the rotation speed of the mandrel 103 and thus a magnitude or direction of the rotation speed of the new web 140 over the mandrel 103.

[0075] In some embodiments, again referring to FIG. 1A, a visual inspection device 600, such as a camera, may be positioned proximate to the mandrel 103. The visual inspection device 600 may be positioned at any suitable position proximate to the mandrel 103 so that it is configured to detect when one full defect-free revolution of the new web 140 is unwound. As such, instead of initially unwinding a certain number of revolutions (e.g., 10) from the new web 140, only the amount of damaged material may be unwound until a defect free revolution is detected. This can attribute to significant material savings by reducing scrap.

[0076] In some embodiments, the expiring web 130 and the new web 140 are the same material. In an example embodiment, the expiring web 130 and the new web 140 each include a nonwoven material, a film, or a laminate including a nonwoven material and a film. In still another example embodiment, the expiring web 130 or the new web 140 may include a laminate of more than one material. In other embodiments, the expiring web 130 and new web 140 may be different material (e.g. bond cross of different material).

[0077] The control of the new web 140 will now be discussed. In some embodiments, the roll of the new web 140 includes outer layers which are to be removed prior to using the new web 140 in the slicing process disclosed herein. This is due to various reasons (e.g. hygiene) or conditions (e.g. puncture with a forklift) that can routinely cause damage to these outer layers prior to conveying the new web 140 into the splice box 102. In one embodiment, these outer layers are removed manually from the new web 140 prior to moving the leading edge 141 of the new web 140 into the splice box 102 or at least downstream of a splice location (e.g. location of the sonotrode 122 and anvil 124 within the splice box 102) as shown in FIG. 1A. As shown in FIG. 1B, the controller 110 transmits a signal to the motor 106 of the third mandrel 103 to cause the third mandrel 103 to rotate clockwise and thus move the leading edge 141 in an upstream direction (opposite to the MD direction 132). In this embodiment, the controller 110 sends a signal to the motor 106 to stop or slow down rotation of the third mandrel 103 upon detecting that the leading edge 141 is within a threshold distance of the second component (e.g. anvil 124) of the thermal bonding apparatus and/or that a second portion 143 of the new web 140 is adjacent to the second component of the thermal bonding apparatus. As discussed in later embodiments, a sensor (not shown) is positioned to detect the presence of the leading edge 141 within the threshold distance of the second component of the thermal bonding apparatus. This sensor is configured to transmit a signal to the controller 110 after which the controller 110 signals the motor 106 to cease or slow down rotation of the third mandrel 103. The new web 140 features a second clamping mechanism (not shown), such as the vacuum bar 126b, which holds the second portion 143 of the second web 140 against the second component (e.g. anvil 124) of the thermal bonding apparatus, prior to and during the splice bonding step. However, although FIG. 1B depicts that the second portion 143 is spaced apart from the anvil 124, this is for ease of illustration and the second portion 143 would be in contact against the anvil 124 as the leading edge 141 is retracted back in the upstream direction to within the threshold distance of the anvil 124.

[0078] An initial step of the splicing process is now discussed herein, where an upcoming expiration of the expiring web 130 is detected. FIG. 1B is a block diagram that illustrates an example of the system of FIG. 1A upon detection of an upcoming expiration of the expiring web 130, according to various embodiments. In some embodiments, a sensor (not shown) is provided to detect the upcoming expiration of the web 130 and transmit a signal to the controller 110 to indicate the upcoming expiration. In some embodiments, the sensor is on the mandrel 101 of the expiring web 130 (not shown) and detects when a number of remaining layers on the mandrel 101 is below a threshold number. This sensor can detect when a radial thickness of the remaining expiring web 130 on the mandrel 101 falls below a threshold value. In other embodiments, the sensor is an imaging device (e.g. camera) which detects that the radial thickness of the remaining expiring web 130 on the mandrel 101 is less than the threshold value.

[0079] The control of the expiring web 130 will now be discussed after detecting the upcoming expiration. Upon receiving the signal from the sensor indicating the upcoming expiration of the web 130, the controller 110 transmits one or more signals to the motor 104 of the mandrel 101 to slow down the expiring web 130 upstream of the splice box 102. In this embodiment, the controller 110 does not transmit a signal to the motor 108 of the mandrel 105 downstream of the splicer buffer system 144 and thus the speed of the expiring web 130 incident on the manufacturing line 149 remains unchanged. Thus, FIG. 1B depicts that the splicer buffer system 144 of the expiring web 130 has reduced from the splicer buffer system 144 of the expiring web 130 in FIG. 1A prior to detection of the upcoming expiration of the web 130. When the splice bond is to be formed between the webs 130, 140, the controller 101 transmits a signal to the motor 104 to cease rotation of the mandrel 101 such that a first portion 133 of the expiring web 130 is adjacent to a first component (e.g. sonotrode 122) of a thermal welding apparatus in the splice box 102. The thermal welding apparatus of the splice box 102 is used to form a splice bond between the expiring web 130 of the expiring roll and the new web 140 of the new roll.

[0080] Although the previously discussed embodiment teaches that the controller 101 transmits a signal to the motor 104 of the mandrel 101 to slow down the expiring web 130 upon detecting an upcoming expiration, in other embodiments the controller 101 may transmit a signal to the motor 104 of the mandrel 101 to speed up the expiring web 130 upon detecting the upcoming expiration. This may advantageously increase the splicer buffer system 144 from what is depicted in FIG. 1A (e.g. since the speed of the expiring web 130 incident on the manufacturing line 149 remains unchanged).

[0081] Although the previously discussed embodiment teaches that the splicer buffer system 144 of the expiring web 130 is collected downstream of the splice box 102, in other embodiments no splicer buffer system 144 of the expiring web 130 is collected downstream of the splice box 102. In this embodiment, once the upcoming expiration of the web 130 is detected by the sensor, the controller 110 transmits signals to the motor 104 so that the mandrel 101 ceases rotation when the first portion 133 of the expiring web 130 is adjacent to the sonotrode 122. In this embodiment, there is a stoppage in the expiring web 130 to the manufacturing line 149 during the splice process.

[0082] A second step of the splicing process will now be discussed, where the splice bond is formed between the expiring and new webs 130, 140 and excess tails of the expiring and new webs 130, 140 are cut away after forming the splice bond. FIG. 1C is a block diagram that illustrates an example of the system 100 of FIG. 1A upon fixing the first portion 133 of the expiring web 130 adjacent the sonotrode 122 and the second portion 143 of the new web 140 adjacent the anvil 124. In some embodiments, before the detection of the upcoming expiration of the web 130 and before the splice bond is formed between the expiring and new webs 130, 140, a vacuum of the vacuum bar 126b is used to hold the second portion 143 of the new web 140 against the anvil 124. In some embodiments, the vacuum is a fluid pressure and a portion of the fluid pressure is provided through the source of vibration energy. As shown in FIG. 1B, the first portion 133 of the expiring web 130 and the second portion 143 of the new web 140 are in an overlapping configuration in the MD direction 132. This is due to the expiring web 130 extending upstream of the splice location (location of the thermal bonding apparatus) whereas the leading edge 141 being positioned downstream of the splice location. The overlapping configuration of the first and second portions 133, 143 is preferred over a butt splice to survive the web converter up to the reject gate of the splice end of the line. In some embodiments, non-overlapping splices may be too weak, such that the web breaks at splice point and leads to web loss and effort/time lost on production line. Although FIG. 1B depicts the first and second portions 133, 143 spaced apart from the sonotrode 122 and anvil 124, this is for ease of illustration and in some embodiments the first portion 133 and second portion 143 would be in contact against the sonotrode 122 and anvil 124 during the splice bonding step.

[0083] After fixing the first and second portions 133, 143 of the expiring and new webs 130, 140 against the respective first and second components of the thermal bonding apparatus, the first and second components of the thermal bonding apparatus are moved together to form the splice bond. As shown in FIG. 1C, in an embodiment upon sensing that the first and second portions 133, 143 are fixed against the first and second components of the thermal bonding apparatus, the controller 110 transmits a signal to a motor (not shown) to move the first and second components of the thermal bonding apparatus together. In this example embodiment, the motor causes the sonotrode 122 and anvil 124, as well as the vacuum bars 126a, 126b to move together in a direction orthogonal to the MD direction 132. This may be due to the vacuum bar 126a being on the same carriage as the sonotrode 122 and the vacuum bar 126b being on the same carriage as the anvil 124 (e.g. such that they move together with one pneumatic cylinder). The controller 110 then signals the sonotrode 122 and anvil 124 to activate and the splice bond 160 (FIG. 1D) is then formed between the first and second portions 133, 143 of the expiring and new webs 130, 140.

[0084] In some embodiments, the sonotrode 122 includes an ultrasonic converter which converts electrical energy to ultrasonic vibrations. The sonotrode 122 also includes an ultrasonic booster which amplifies the vibrations from the ultrasonic converter to a desired amplitude. The sonotrode 122 also includes an ultrasonic sonotrode or horn (e.g., two options with and without vacuum) which is the part of the sonotrode 122 that that physically oscillates to form the bond 160 between the webs 130, 140. In some embodiments, the anvil 124 is a vacuum anvil that is the part of the thermal bonding apparatus that receives the oscillation and holds the geometry shaped pattern of the bond 160.

[0085] After forming the splice bond 160 between the first and second portions 133, 143 of the expiring and new webs 130, 140, the system cuts excess material from the expiring web 130 (upstream of the splice location) and from the new web 140 (downstream of the splice location). FIG. 1C depicts a cut leading edge 150 from the expiring web 130 by the splice blade 120 upstream of the splice location and thus upstream of the splice bond 160, resulting in a cut trailing edge 131. FIG. 1C similarly depicts a cut tail 152 from the new web 140 by the outer layer blade 128 downstream of the splice location and thus downstream of the splice bond 160. In these embodiments, the controller 110 transmits signals to each of the splice blade 120 and the outer layer blade 128 to automatically cut the respective cut leading edge 150 and tail 152 after forming the splice bond 160. The cutting of the cut leading edge 150 and cut tail 152 advantageously removes undesired web material extended from the splice bond 160. In an example embodiment, the cut leading edge 150 has a length in the range of about 0.01 mm to about 20 mm. In another example embodiment, the cut tail 152 has a length in the range of about 0.01 mm to about 20 mm. In an example embodiment, the tail retraction and removal advantageously prevents issues in downstream conveying of the tail, and this is enabled by a special design of the vacuum bar 126 and ultrasonic sonotrode 122. In some embodiments, the use of the sensors and motors herein resolve to minimize the cut leading edge 150 and cut tail 152 length by eliminating the non-bonded tail to zero. In one example embodiment, the length of the cut tail 152 is minimized by using a vacuum sonotrode 122 or the vacuum bar 126 near the sonotrode 122.

[0086] As further shown in FIG. 1C, due to the continual splicing process, the splicer buffer system 144 of the expiring web 130 has reduced from the previous splicer buffer system 144 (FIG. 1B), 144 (FIG. 1A) during earlier steps in the process. This advantageously ensures continual operation of the manufacturing line 149 during the splicing process. The amount of the initial splicer buffer system 144 (FIG. 1A) is adjusted such that the product of a length of the splicer buffer system 144 and the average speed of the expiring web 130 is less than an estimated stoppage time of the expiring web 130 to perform the splicing process herein.

[0087] Although the previously discussed embodiments discuss that the first component and the second component of the thermal bonding apparatus are respectively the sonotrode 122 and the anvil 124, in other embodiments other types of thermal bonding apparatus components can be used to form the splice bond. In one example embodiment, the first and second components of the thermal bonding apparatus can feature a heat bar or a source of hot fluid.

[0088] The splice bond formed between the expiring and new webs will now be discussed. FIG. 1D is a block diagram that illustrates an example of the system 100 of FIG. 1A upon forming a splice bond 160 between the first portion 133 of the expiring web 130 and the second portion 143 of the new web 140. In some embodiments, the splice bond 160 is a thermal weld at the splice location between the first and second portion 133, 143 of the respective expiring and new webs 130, 140. In one embodiment, the splice bond 160 is not formed by the thermal welding apparatus traversing across the expiring web 130 and the new web 140. In another embodiment, the splice bond 160 is tapeless. In another example embodiment, the splice bond 160 is formed in an amount of time in a range from about 0.1 seconds to about 0.5 seconds. In some embodiments, the formation of the splice bond 160 may include an initial web stabilization step that takes an amount of time between about 0.05 seconds and about 0.1 seconds, followed by a welding step to form the splice bond 160 that takes an amount of time between about 0.1 seconds and about 0.5 seconds and a web cool-off step that takes an amount of time between about 0.05 seconds and about 0.2 seconds. In an example embodiment, a plunge splice is preferred over a traversing splice. Additionally, in an example embodiment, an ultrasonic thermal bonding apparatus (e.g. featuring the sonotrode 122) is preferred over thermal conduction heat (e.g. Hot Wire). The use of the ultrasonic welding apparatus advantageously leads to less accumulated material in the web buffer system and ensures a zero-speed splice can be achieved.

[0089] The system 100 advantageously conveys the new web 140 through the splice box 102, splice bonds the new web 140 to the expiring web 130 and conveys the new web 140 into the absorbent article manufacturing line 149 without stoppage of the absorbent article manufacturing line 149 during the splicing process. This is depicted in FIG. 1D where the splicer buffer system 144 of the expiring web 130 has reduced to zero without any stoppage in the absorbent article manufacturing line 149. It should be noted that the splicer buffer system 144 of the expiring web 130 need not be reduced to zero at the time that the splice bond 160 is formed but instead may be any non-zero value. Additionally, after the splice bond 160 is formed and the new web 140 is conveyed through the splice box 102 and to the absorbent article manufacturing line 149, the new web 140 is accumulated downstream of the splice box 102 to a similar extent as the splicer buffer system 144 of the expiring web 130 in FIG. 1A. This splicer buffer system of the new web 140 can then be used in the event of a future splicing between an expiring web 140 and a new web.

[0090] Although the embodiment of FIGS. 1A and 1B discuss one embodiment where unwanted outer layers of the new web 140 are manually removed, in other embodiments the unwanted outer layers of the new web 140 are automatically removed. FIGS. 2A through 2C discuss a system 100 that is similar to the system 100 of FIGS. 1A through 1D with the exception of the features discussed herein. The automated removal of the unwanted outer layers of the new web 140 increases the production hygiene standards, which include winding the outer layers of material off the new web 140 around a gripper, cutting the excess material using a cutter to separate the outer layers of the new web 140 from the splice tail. In an example embodiment, this could be achieved either by a Splicer mounted Cobot Arm or an AMR Cobot.

[0091] FIG. 2A is a block diagram that illustrates an example of a system 100 where outer layers 162 of the new web 140 are collected downstream of the splice location, according to various embodiments. As shown in FIG. 2A, the system 100 features a fourth mandrel 107 operated by a fourth motor 109. In some embodiments, the fourth mandrel 107 and fourth motor 109 are components of a robot that is moved into the splice box 102 and is used to collect the unwanted outer layers of the new web 140. The dotted line in FIG. 2A indicates unwanted outer layers 162 of the new web 140 which are to be removed prior to splicing the new web 140 to the expiring web 130. In this embodiment, as shown in FIG. 2A the motors 106, 109 are activated by the controller 110 in order to collect the outer layers 162 of the new web 140 on the fourth mandrel 107. The controller 110 activates the motors 106, 109 until the predetermined length of the outer layers 162 are collected on the fourth mandrel 107. FIG. 2B is a block diagram that illustrates the system 100 after the outer layers 162 of the new web 140 are downstream of the splice location and on the fourth mandrel 107. As shown in FIG. 2C, the outer layer blade 128 is then used to cut the outer layers 162 from the new web 140, and thus forming the leading edge 141 that is positioned proximate to and downstream of the anvil 124. The controller 110 then signals the motor 109 to rotate the third mandrel 103 in a clockwise direction to move the leading edge 141 in an upstream direction until the sensor (not shown) detects that it is within the threshold distance of the anvil 124. The new web 140 in the system 100 in FIG. 2C then resembles the new web 140 of the system 100 of FIG. 1B. The next steps of the system 100 in performing the splice bond 160 are similar to the other steps in the system 100 of FIGS. 1B through 1D that were previously discussed. These other steps would include the detection of the upcoming expiration of the expiring web 130 (FIG. 1A) and the control of the speed of the expiring web 130 until the first portion 133 is adjacent to the sonotrode 122.

[0092] FIG. 3A is a side view that illustrates an example of the sonotrode 122 and anvil 124 of the system 100 of FIGS. 1C and 1D forming the splice bond 160, according to various embodiments. FIG. 3B is a perspective view that illustrates an example of the sonotrode 122 and anvil 124 of the system 100 of FIGS. 1C and 1D forming the splice bond 160, according to various embodiments.

[0093] FIG. 3C is a side view that illustrates an example of the splice bond 160 formed between the expiring web 130 and the new web 140 in the system 100 of FIG. 1D, according to various embodiments. FIG. 3D is a front view that illustrates an example of the splice bond 160 formed between the expiring web 130 and the new web 140 in the system 100 of FIG. 1D, according to various embodiments. As shown in FIG. 3D, in some embodiments the expiring web 130 includes, in the CD direction 134, a first side region 135, a second side region 136 and a central region 138 between the first and second side regions 135, 136. The new web 140 similarly includes, in the CD direction 134, a first side region 145, a second side region 146 and a central region 148 between the first and second side regions 145, 146. In some embodiments, the thermal welding apparatus including the sonotrode 122 and the anvil 124 form the splice bond 160 across the first side region 135, second side region 136 portion 135 and central region 138 of the first portion 133 and across the first side region 145, second side region 146 and central region 148 of the second portion 143 at the same time. In an example embodiment, the splice bond 160 is formed using a full width plunge-style sonotrode 122 (e.g., distinguished over known CD traversing anvil splice box designs).

[0094] FIGS. 4A and 4B are front views that illustrate an example of the anvil 124 and adjacent sensors 164, 166 to detect a presence of the leading edge 141 of the new web 140 in the system 100 of FIG. 1B, according to various embodiments. In one embodiment, the anvil 124 of FIGS. 4A and 4B includes an integrated vacuum bar that performs the function of the vacuum bar 126b and features multiple sensors 164, 166 to assist with performing one or more steps by the system. In one example, the multiple sensors 164, 166 are web presence sensors that detect the presence of the web 140 (e.g. leading edge 141) proximate to the anvil 124. In another example, the multiple sensors 164, 166 are embedded optical sensors. In an embodiment, the sensors 164, 166 are communicatively coupled with the controller 110 and transmit signals to the controller 110 based on detecting a presence of the new web 140 (e.g. leading edge 141) at either sensor.

[0095] During a splice preparation process (e.g. prior to detection of the upcoming expiration of web 130), as the new web 140 is directed in the downstream direction, once the bottom web presence sensor 166 detects a presence of the new web 140, the bottom web presence sensor 166 may transmit a signal to the controller 110 which may cause the controller 110 to activate the vacuum (e.g. vacuum bar 126b) of the integrated vacuum bar. This would then cause the new web 140 to adhere to the anvil 124 of the integrated vacuum bar. Although this embodiment discuses an option where the controller 110 automatically activates the vacuum upon detection of the new web 140 by the bottom presence sensor 166, in other embodiments the user may manually activate the vacuum (e.g. pressing a reset button) upon the bottom presence sensor 166 initial detection of the new web 140.

[0096] Additionally, during the splice preparation process, after activation of the vacuum of the integrated vacuum bar to adhere the new web 140 to the anvil 124, the controller 110 may transmit a signal to the motor 106 of the mandrel 103 to move the new web 140 in the upstream direction. Thus, as the new web 140 is adhered to the anvil 124, the mandrel 103 rotates in the clockwise direction and causes the new web 140 to move in the upstream direction as it is adhered to the anvil 124. In one example, this upstream movement of the new web 140 may continue until the top web presence sensor 164 no longer detects the new web 140. This may indicate that the leading edge 141 of the new web 140 is adhered to the anvil 124 or that the leading edge 141 is positioned between the top web presence sensor 164 and the anvil 124. In this embodiment, upon receiving a signal from the top web presence sensor 164 that the new web 140 is no longer detected, the controller 110 may transmit a signal to the motor 106 of the mandrel 103 to slow down and/or stop the mandrel 103 movement in the upstream direction. Although this embodiment discuses an option where the controller 110 automatically causes the new web 140 to move in the upstream direction until the leading edge 141 is adhered to and/or in close proximity to the anvil 124, in other embodiments the user may manually cause the new web 140 to move in the upstream direction (e.g. pressing a reset button) until such time as the leading edge 141 is adhered to and/or in close proximity to the anvil 124, after which the user may manually cause the new web 140 to slow down and/or stop moving in the upstream direction (e.g. pressing a reset button).

[0097] Although the above embodiment discusses the use of two web presence sensors 164, 166, in other embodiments a single web presence sensor may be employed in the integrated vacuum bar. In this embodiment, the vacuum of the integrated vacuum bar may be activated based on the initial detection of the new web 140 by the web presences sensor (as the new web 140 moves in the downstream direction through the splice box 102). In this embodiment, after activation of the vacuum, the controller 110 may transmit a signal to the motor 106 of the mandrel 103 to move the new web 140 in the upstream direction (as the new web 140 is adhered to the anvil 124). Once the single web presence sensor no longer detects the presence of the new web 140, the controller 110 may signal the motor 106 to slow down and/or stop the upstream movement of the new web 140.

[0098] In an example embodiment, when the controller 110 receives a signal from the first sensor 166 indicating no presence of the new web 140 at the first sensor 166 but does receive a signal from the second sensor 164 indicating a presence of the new web 140 at the second sensor 164, this communicates to the controller 110 that the leading edge 141 is positioned within the threshold distance of the anvil 124. In this example embodiment, the controller 110 transmits a signal to the motor 106 of the third mandrel 103 to stop and/or slow down the moving the new web 140 in the upstream direction and thus fix the leading edge 141 at the threshold distance from the anvil 124. As previously discussed herein, upon forming the splice bond 160, the controller 110 may transmit a signal to deactivate the vacuum of the integrated vacuum bar and/or a signal to the outer layer blade 128 to cut the tail 152 of the new web 140 which is based on the extent to which the new web 140 extends from the anvil 124 over the second sensor 164.

[0099] In some embodiments, zero-tail can be achieved by requiring that both sensors 164, 166 do not detect the new web 140 which corresponds to the new web 140 having moved such that the leading edge 141 is within the anvil 124 (e.g. at the boundary between the anvil 124 and the sensor 164). In other embodiments, the sensors 164, 166 are provided along the anvil 124 and thus zero tail can be achieved (e.g. when the new web 140 is cut within the anvil 124 and thus no tail is formed beyond the splice bond 160). In yet another embodiment, the sensors 164, 166 of FIG. 4B can be utilized to achieve zero-tail, where after the sensor 164 detects the new web 140 but the sensor 166 does not detect the new web 140, the controller 110 transmits a signal to the motor 106 of the mandrel 103 to move the new web 140 in the upstream direction by a fixed distance (e.g. the thickness of the sensor 164 in the MD direction 132 and/or the detection range of the sensor 164 in the MD direction 132). Then the leading edge 141 of the new web 140 would be moved to a boundary between the anvil 124 and the sensor 164 and thus the splice bond 160 would be formed with zero-tail downstream of the splice location. In an example embodiment, the sensors 164, 166 are offset in the CD direction 134 which advantageously enhances the accessibility of each sensor (e.g. in the event of repair and/or replacement).

[0100] In an embodiment, the splice box 102 is automated such that the expiring web 130 and/or the new web 140 are guided into the splice box by one or more robots. In one example embodiment, such robots include the aspect of the automated removal of the unwanted outer layers 162 of the new web 140 (FIGS. 2A through 2C). Additionally, as shown in FIG. 5I, in another example embodiment, a cantilevered/side-open splice box 102 design is provided. The cantilevered splice box 102 has a side 156 facing an operator that defines one or more openings 154. These openings 154 align with a movement axis 158 of a robot 169 (e.g. holding the new web 140) such that the robot can automatically move along the movement axis 158 into the splice box 102. This embodiment of the cantilevered splice box 102 advantageously allows a robotic thread up arm to penetrate the splice box 102 from one side to enable web thread up. In one embodiment, the robot 169 automatically picks up the leading edge of the new web 140 and automatically moves along the movement axis 158 through the opening 154 of the cantilevered splice box 102. In some embodiments, once inside the splice box 102 the robot 169 automatically attaches the leading edge of the new web 140 to the mandrel 107 with the motor 109 such that the controller 110 can then transmit a signal to the motor 109 to collect the outer layers 162 of the new web 140 on the mandrel 107. The outer layer blade 128 then cuts the unwanted outer layers 162 from the new web 140. In other embodiments, the robot 169 includes the mandrel 107 and the motor 109 and moves the mandrel 107 (with the attached leading edge of the new roll 140) and the motor 109 into the splice box 102 after which the robot 169 activates the motor 109 to collect the unwanted layers 162 of the new roll 140 on the mandrel 107. The outer layer blade 128 of the splice box 102 is then activated by the controller 110 to cut the unwanted outer layers 162 from the new roll 140. The robot 169 then moves out of the splice box 102 through one of the openings 154 along the movement axis 158. The cantilevered splice box 102 of FIG. 5I is distinct from a non-cantilevered splice box 102 (FIG. 5J) where the side 156 of the splice box 102 does not feature an opening aligned with the robot movement axis 158 and thus automated motion of the robot 169 into the non-cantilevered splice box 102 is not possible due to a lack of access of the robot 169 along the movement axis 158 into the splice box 102. Yet further, in another example embodiment, such robots can be used for an automated mechanism for picking up the leading edge 141 of the new web 140. These embodiments of a robotic component used to automatically convey the leading edge 141 of the new web 140 into the splice box 102 will now be discussed.

[0101] Some embodiments of a device are designed to enable automated pick up the start of the roll (e.g. leading edge of the new web 140). This is a challenging task without tape as the system needs to distinguish between materials of the same color and texture. Two design options are illustrated one with the use of vacuum (FIGS. 5A and 5B), and a second with the use of air blade and mechanical finger gripper (FIGS. 5C and 5D).

[0102] FIGS. 5A and 5B are side views that illustrate an example of the mandrel 103 of the new web 140 and a vacuum device to automatically pick up the leading edge 171 of the new second web 140. In some embodiments, the leading edge 171 of FIG. 5B is different from the leading edge 141 of FIG. 2C, since the leading edge 171 of the new web 140 includes the outer layers 162 which are to be removed from the new roll 140. However, in other embodiments, the leading edge 171 is the same as the leading edge 141 of FIG. 1B, since in these embodiments the outer layers 162 were already manually removed from the new roll 140 prior to the automated pickup of the leading edge 171. In an example embodiment, the vacuum device is a pecking vacuum device. In this embodiment, the vacuum device includes a carriage 180 with a pair of spaced apart sensors 182, 184. The sensors 182, 184 detect a presence of the leading edge 171 of the new web 140 based on the first sensor 182 detecting the second web 140 at a certain radial position but the second sensor 184 not detecting the new web 104 at the same radial position. Based on the detection of the leading edge 171 via the sensors 182, 184, the vacuum device is configured to automatically pick up the leading edge 171 and convey the leading edge 171 to the gripper 190 which is then used to feed the leading edge 171 to the splice box 102.

[0103] FIGS. 5C and 5D are side views that illustrate an example of the mandrel 103 of the new web 140 and an air blade 186 and mechanical finger 189 to automatically pick up the leading edge 171 of the new web 140. In an example embodiment, this involves mechanical friction and an air-foil effect for tail pickup. This embodiment also features the sensors 182, 184 that automatically detect the presence of the leading edge 171 of the new web 140. Based on detection of the leading edge 171, the knife blade 186 and finger gripper 189 operate to mechanically grip the leading edge 171 which is then automatically fed to the splice box 102.

[0104] In addition to the previously discussed embodiments, another option for automated pickup of the leading edge 171 of the new web 140 from the roll involves leveraging a modified outer layer sticker (e.g., featuring a non-sticky zone) to identify and pick up the leading edge 171 of the new web 140. FIG. 5E depicts a conventional sticker 172 that is used to attach the leading edge 171 to the new web 140. As shown in FIG. 5E, the conventional sticker 172 adheres to the new web 140 on both sides of the leading edge 171 so to secure the leading edge 171 to the remaining layers 175 of the new web 140. However, the inventors of the present invention recognized that this conventional sticker 172 introduces a drawback in terms of automated pick up of the leading edge 171 with a robot. As shown in FIG. 5E, the conventional sticker 172 is fully adhered to both an outer layer 174 and a first inner layer 175 of the new web 140 across the leading edge 171. Thus, the inventors noticed that the leading edge 171 is difficult to pick up with an automated robot device (e.g. vacuum device) since the vacuum force of the automated device would need to overcome the relatively large force that the sticker 172 adheres the leading edge 171 to the new web 140.

[0105] To overcome the above noted drawback with conventional stickers 172, the inventors developed the multi-zone sticker 192 depicted in FIGS. 5F through 5H. Unlike the conventional sticker 172 that is fully adhered to both the outer layer 174 and the first inner layer 175 across the leading edge 171 of the new web 140, the multi-zone sticker 192 features multiple zones which adhere to the new web 140 with different levels of force. For purposes of this description, the level of force that a sticker adheres to a surface means an amount of force that would be required to separate the sticker from the surface. As shown in FIG. 5F, in one embodiment the multi-zone sticker 192 includes a first zone 193 that adheres to the outer layer 174 with a first level of force, a second zone 194 which adheres across the leading edge 171 (to both the outer layer 174 and the first inner layer 175 across the leading edge 171) with a second level of force that is less than the first level of force and a third zone 195 that is not adhered to the second web 140. In an example embodiment, the first zone 193 is a strong adhesive zone (e.g., adhered to the new web 140 with the first level of force, as defined herein), the second zone 194 is a mild adhesive zone (e.g. adhered to the new web 140 with the second level of force that is less than the first level of force) and the third zone 195 is a no glue and pickup zone (e.g. not adhered to the new web 140). The first zone 193 may be a permanently sticky zone, and the first zone 193 may connect the tail end at the leading edge 171 of the new web of material 140, also referred to as roll of material, to the sticker permanently. In some examples, pulling the first zone 193 hard enough to be pulled off of the web 140 may damage the web 140, such as by tearing out nonwoven fibers of the web 140. The second zone 194 may be a peelable sticky zone, and the second zone 194 may be removed from (e.g., peeled off of) the new web 140 material without damaging the substrate of the new web 140. The third zone 195 may be a non-sticky zone. The third zone 195 may be adhesive-free, an adhesive zone that has been folded, an adhesive zone that has been covered with additional coating and/or substrate and/or otherwise treated to eliminate adhesive properties.

[0106] The gripper shown in FIG. 5I may grip the web in FIG. 5F in the third zone 195 (e.g., no adhesive and pick up zone) of the multizone sticker 192 and across the web in the cross-direction. The gripper will then begin to rotate to wind the web, but may do so in a way in which the exposed adhesive in the second zone 194 only contacts the web being wound onto itself and not contract portions of the gripper as the adhesive would stick to the gripper. As such, the adhesive in the second zone 194 of the sticker 192 will be on the side of the web most distal from the gripper while the side of the web opposite the side of the web that the sticker is on will be most proximal to the gripper during winding.

[0107] The multi-zone sticker 192 facilitates automated pick up of the leading edge 171 of the new web 140 with a robot device (e.g. vacuum device). In some embodiments, the robot 169 (e.g. vacuum device) adheres to the third zone 195 of the multi-zone sticker 192 and moves in the roll winding direction 2020 (e.g. corresponding to the robot movement axis 158 into the splice box 102). Since the force of movement of the robot 169 in the roll winding direction 2020 is greater than the second level of force that the second zone 194 adheres across the leading edge 171, movement of the robot 169 (and attached third zone 195) causes the second zone 194 of the sticker 192 to detach from across the leading edge 171. FIG. 5L shows the third zone 195 pulled away from the new web 140 as well as the portion of the second zone 194 between the leading edge 171 and the third zone 195 peeled away from the new web 140 while the first zone 193 is still adhered to the new web 140. Further movement of the robot 169 (and attached third zone 195) in the roll winding direction 2020 continues. The force of movement of the robot 169 in the roll winding direction 2020 does not exceed the first level of force that the first zone 193 is attached to the outer layer 174 of the new web 140. Thus, the first zone 193 of the sticker 192 does not detach from the outer layer 174 and thus the continued movement of the robot 169 in the roll winding direction 2020 causes the first zone 193 (and attached leading edge 171 to the first zone 193) to move with the robot in the roll winding direction 2020. In some embodiments, after the robot 169 moves the multi-zone sticker 192 and attached leading edge 171 through the opening 154 of the splice box 102, the robot 169 attaches the leading edge 171 to the mandrel 107 so that the controller 110 may activate the motor 109 and collect the unwanted outer layers 162 of the new web 140 on the mandrel 107. The outer layer blade 128 is then used to cut the unwanted outer layers 162 from the new web 140.

[0108] FIG. 5H depicts that in one embodiment, indicia may be provided in one or more zones of the multi-zone sticker 192. In one example embodiment, a robot indicia 197 is provided in one the zones (e.g. first zone 193). In this example embodiment, the robot 169 includes a scanning device that may scan the robot indicia 197 after which the robot 169 may use the scanned indicia 197 to verify that the robot 169 is assigned to pick up the leading edge 171 of the new web 140 with the scanned indicia 197. In a similar example embodiment, a roll indicia 196 is provided in one or more zones (e.g. second zone 194). The roll indicia 196 may, for example, include a printed code, such as a barcode or a QR code. In this example embodiment, the robot 169 includes the scanning device that may scan the roll indicia 196 after which the robot 169 may use the scanned indicia 196 to verify that the new web 140 having the scanned indicia 196 is in a database of new web rolls assigned to that particular robot 169 for automated pick up of the leading edge 171.

[0109] Although FIGS. 5F through 5H depict the multi-zone sticker 192 with three different zones, in other embodiments less or more than three zones are provided in the multi-zone sticker 192. For example, two zones may be provided in the multi-zone sticker 192 (e.g. a first zone that sticks to the new web 140 and a second zone that is not attached to the new web 140).

[0110] The multi-zone sticker 192 as described above may improve the process of picking up and moving the tail end (e.g., a leading edge 171) of a new web 140 (e.g. roll of material). For example, the multizone sticker 192 may allow for a suction grip by a vacuum. For example, a nonadhesive zone, for example the third zone 195, of the sticker may be non-porous, or substantially non-porous, and may be picked up by a vacuum. Further, including the indicia 196 for example, by printing or embedding the indicia 196 in and/or on the sticker 192, may allow for sensor detection regarding the multizone sticker 192. The sensor detection may include sticker detection and/or confirmation (e.g., determining if a multizone sticker 192 is present) for placing on a roll of material. The sensor detection, may include, for example, identifying a multizone sticker by identifying a contrast of dark print on a white background of a surface of the multizone sticker 192.

[0111] Further, as it may be possible to print on one or more surfaces of the multizone sticker 192, printing information and/or patterns (e.g., indicia 196 indicia 197) on the surface of the multizone sticker may help facilitate tracking one or more new webs (e.g., one or more rolls of material) via the multizone sticker 192.

[0112] Further the adhesive strength of the multizone sticker 192 may not tear the first layer the new web 140 (e.g., roll of material) and may not seep adhesive through subsequent layers of material of the new web 140, therefore may help prevent or at least reduce loss of otherwise usable material.

[0113] Further, the multizone sticker system may be compatible with or relatively easily adapted to be compatible with automatic application systems, for example systems for automatically applying one or more multizone stickers 192 to one or more new webs 140 (e.g., applying one or more multizone stickers with a robot, utilizing a sensor system).

[0114] Further still, the multizone sticker system 192 may be of relatively lower cost.

[0115] As shown in FIG. 5K, the first zone 193 of the multizone sticker 192 may have a length 1104, the second zone 194 of the multizone sticker 192 may have a length 1106, and the third zone of the multizone sticker may have a length 1108. The multizone sticker may have a width 1102 and a length 1107. The length 1107 of the multizone sticker 192 may include (e.g., equal) the sum of the lengths of the adhesive zones (e.g., the length of the first adhesive zone, 1104 and the length of the second adhesive zone, 1106) and the length of one or more nonadhesive zones (e.g., length of the third nonadhesive zone 1108).

[0116] In some configurations, the width 1102 may be between about 20 mm to about 100 mm, about 30 mm to about 80 mm, about 40 mm to about 70 mm, about 50 mm to about 70 mm, or about 65 mm. Further, the width 1102 may not be wider than a width of a new web 140 (e.g., if the roll of material is a continuous width). In some configurations, the width 1102 may be at least about 1 to about 100 mm, or about 5 mm to about 50 mm, or about 5 to about 10 mm narrower than the width of the new web 140, which may help facilitate appropriate placement window (e.g., area where the sticker may be placed without overlapping over the side of the roll of material). If the multizone sticker 192 overlapped over the side of the new web 140 (e.g., side of the roll of material), the adhesive from the sticker may contaminate otherwise usable material from the roll, and/or moving the sticker and/or removing the sticker may damage otherwise usable material from the roll (e.g., tearing fibers of nonwoven substrate).

[0117] In some configurations the lengths 1104 and 1106 may each be between about 20 mm to about 100 mm, about 30 mm to about 80 mm, about 40 mm to about 70 mm, about 50 mm to about 60 mm, or about 50 mm. The length 1108 may be 20 mm to about 100 mm, about 25 mm to about 80 mm, about 30 mm to about 60 mm, about 35 mm to about 50 mm, or about 50 mm. In a configuration where a vacuum applicator and/or suction cup is used to pick up the multizone sticker in a nonadhesive zone (e.g., third zone 195), better suction may be achieved when the length 1108 is longer than the diameter or longest dimension of vacuum applicator and/or suction cup. For example, if a 32 mm diameter vacuum applicator or suction cup is used to pick up the third zone 195, the third zone 195 may have a length 1108 of at least 35 mm.

[0118] FIG. 5K illustrates a distance 1700 between the tail end of the new web 140 (e.g., the leading edge of the roll 171) and the border of the nonadhesive zone (e.g., third zone 195) with the nonadhesive zone overlapping the leading edge of the material (e.g., the second adhesive zone 194). The distance 1700 may about the length of one adhesive zone or about the total length of all adhesive zones. The distance 1700 may be about 10 mm to about 100 mm, about 30 mm to about 80 mm, about 40 mm to about 70 mm, about 50 mm to about 60 mm, or about 50 mm.

[0119] FIGS. 20A and 20B are schematics illustrating a system for forming a multizone sticker, and FIG. 11 is a flowchart that illustrates an example of a method 1000 for forming a multizone sticker 192. Although the flowchart of FIG. 11 is depicted as integral steps in a particular order for purposes of illustration, in other configurations one or more steps, or portions thereof, are performed in a different order, or overlapping in time, in series or in parallel, or are deleted, or one or more other steps are added, or the method is changed in some combination of ways. In Step 1010, a sticker laminate 5100 may be unwound. Then, in Step 1020, a first layer 5114 and a second layer 5124 of the laminate may be separated from each other at a separation location 5200. The first layer 5114 may comprise an adhesive layer 5110 with at least one surface with adhesive properties. The second layer 5124 may comprise a backing layer 5120 (e.g., non-stick backing layer). In step 1030, one or more portions 5195 of the adhesive layer 5110 may be treated with adhesive neutralizing agent at a treatment location 5300. For example, a first zone 5193 of the adhesive layer may not be treated with adhesive neutralizing agent, and a second zone 5195 of the adhesive layer may be treated with adhesive neutralizing agent by an adhesive neutralizing agent applicator 5302.

[0120] In step 1040, the first layer 5114 comprising the treated adhesive layer 5112 may then be recombined with the second layer 5124 comprising the backing layer 5120 at a recombination location 5400, and because part of the adhesive layer was treated with adhesive neutralizing agent (e.g., in a second zone 5195), the resulting sticker laminate 5130 may have a surface with an adhesive first zone and a non-adhesive second zone.

[0121] In step 1050, a label may be printed onto the sticker laminate.

[0122] In step 1060, the laminate may be die cut, then excess material may be trimmed and removed from the laminate, resulting in a backing layer covered with discrete multizone stickers 192. In some configurations, the die cut operation may be configured so as to only cut the sticker material positioned on the backing material without cutting the backing layer, sometimes referred to herein as kiss cutting.

[0123] In step 1070 the backing layer with discrete labels may be wound into a roll.

[0124] The die cutting (e.g., be kiss cutting) may form perimeters 2040 of individual multizone stickers 192. The laminate may then be cut into individual stickers 192, resulting in multizone stickers with a first, adhesive zone and a second, non-adhesive zone. FIG. 12 shows a configuration of such a multizone sticker 192. A second zone 195 may be adjacent to a first zone 193, and the second zone 195 may extend away from the first zone 193 in a roll winding direction 2020.

[0125] FIG. 13 shows a configuration of a multizone sticker where the die cutting step may include kiss cutting to define an additional non-adhesive zone 2010. The additional non-adhesive zone 2010 may be adjacent to the first zone 193 and extend away from the first zone 193 opposite a roll winding direction 2020, which may help reduce and/or eliminate a risk of glue contamination in the trim removal process. In a configuration, one or more non-adhesive zones may completely surround one or more adhesive zones or the entire multizone sticker.

[0126] FIGS. 21A-21B are schematics illustrating a system for forming a multizone sticker 192 with two or more adhesive zones, and FIG. 14 describes a process for manufacturing, a multizone sticker 192 with two or more adhesive zones. Although the flowchart of FIG. 14 is depicted as integral steps in a particular order for purposes of illustration, in other configurations one or more steps, or portions thereof, are performed in a different order, or overlapping in time, in series or in parallel, or are deleted, or one or more other steps are added, or the method is changed in some combination of ways. In step 1110, a sticker laminate 5100 may be unwound. In step 1120, a first layer 5114 and a second layer 5124 of the laminate may be separated from each other at a laminate separation location 5200. The first layer 5114 may comprise an adhesive layer 5110 with at least one surface with adhesive properties. The second layer 5124 may comprise a backing layer 5120 (e.g., non-stick backing layer). In step 1130, two or more portions of the adhesive layer 5110 may be treated with adhesive neutralizing agent at an adhesive neutralizing location 5300. For example, a first zone 5193 of the adhesive layer may not be treated with adhesive a neutralizing agent, a second zone of the adhesive layer may be treated with adhesive neutralizing agent by a neutralizing agent applicator 5304 to make the second zone an adhesive zone 5194 that is less sticky than the first zone 5193, and a third zone 5195 of the adhesive layer may be treated with an adhesive neutralizing agent by a neutralizing agent applicator 5302 (e.g., a higher concentration of the same adhesive-neutralizing agent, different neutralizing agent) to make the third zone 5195 non-adhesive. Less sticky may mean it may take less force to remove from a surface. In step 1140, the first layer 5114 comprising the treated adhesive layer 6112 may then be recombined with the second layer 5120 at a recombining location 5400, and because part of the adhesive layer was treated with adhesive neutralizing agent (e.g., in the second zone 5194) and different neutralizing agent (e.g., in the third zone 5195), the resulting sticker laminate 6130 may have a surface with an adhesive first zone, and adhesive second zone that is less sticky than the first zone, and a non-adhesive third zone.

[0127] In step 1150, a label may be printed onto the sticker laminate.

[0128] In step 1160, the laminate may be die cut (e.g., kiss cut), then excess material may be trimmed and removed from the laminate, resulting in a backing layer covered with discrete multizone stickers 192.

[0129] In step 1170 the backing layer with discrete labels may be wound into a roll.

[0130] FIG. 15 shows a configuration of the multizone tape where the die cutting step may include kiss cutting to define perimeters 2040 of individual multizone stickers. The laminate may then be cut into individual stickers, resulting in multizone stickers with a first adhesive zone 193 and a second adhesive zone 194 that is less adhesive than the first adhesive zone 193, and a third non-adhesive zone 195. The second zone 194 may be adjacent to the first zone 193, and the second 194 zone may extend away from the first zone 193 in a roll winding direction 2020. The second zone 194 may also be adjacent to the third zone 195, and the second zone 194 may extend away from the third 195 zone opposite a roll winding direction 2020.

[0131] In a configuration, the kiss cutting may include kiss cutting to define an additional non-adhesive zone 2010. The additional non-adhesive zone 2010 may be adjacent to the first zone 193 and extend away from the first zone 193 in opposite a roll winding direction 2020, which may help reduce and/or eliminate a risk of glue contamination in the trim removal process. In an embodiment, one or more additional non-adhesive zones may completely surround one adhesive zone, multiple adhesive zones, or all adhesive zones.

[0132] In a configuration, adhesive may be added to sticker laminate and/or the multizone sticker to create and/or modify the adhesive properties of zones on the sticker laminate and/or multizone sticker. For example, a sticker laminate with an adhesive layer may have additional adhesive added to one or more portions to create zones with a stronger or weaker adhesive and/or adhesive strength. Additionally or alternatively, adhesive may be applied to neutralizing agent-treated zones (e.g., adhesive zones that were treated with adhesive neutralizing agent to become nonadhesive zones, adhesive zones treated with adhesive neutralizing agent to become less adhesive) and/or the non-treated zones, which may allow for further customization of adhesive strength of the sticker laminate and resulting multi-layer sticker.

[0133] In some configurations, additional coatings and/or layers of substrate with one or more adhesive surfaces may be added to sticker laminate and/or the multizone sticker to create and/or modify the adhesive properties of zones on the sticker laminate and/or multizone sticker. For example, a sticker laminate with an adhesive layer may have additional coatings and/or substrate with one or more adhesive surfaces added to one or more portions to create zones with a stronger or weaker adhesive and/or adhesive strength. In some configurations, additional coatings and/or substrates with one or more adhesive surfaces may be applied to neutralizing agent-treated zones and/or the non-treated zones, which may allow for further customization of adhesive strength of the sticker laminate and resulting multi-layer sticker.

[0134] In some configurations, additional coatings and/or layers of substrate may be added to sticker laminate and/or the multizone sticker to create or expand nonadhesive zones on the sticker laminate and/or multizone sticker. For example, additional coatings and/or substrate may be placed over a portion of an adhesive zone of a sticker laminate or multizone sticker to create a new nonadhesive zone or add to a previously created nonadhesive zone (e.g., a zone that never was adhesive, zone previously treated with adhesive-neutralizing agent, another zone that was previously covered with additional coatings and/or substrate to create and/or grow a nonadhesive zone). The additional substrate may have adhesive on the side configured to be attached to the laminate or multizone sticker, and the additional substrate may be attached to the sticker laminate and/or multizone sticker with that adhesive. Additionally or alternatively, the additional substrate may be attached to the sticker laminate and/or multizone sticker using externally-applied adhesive. Additionally or alternatively, the additional coating and/or substrate may be adhesively connected with the sticker laminate and/or multizone sticker using adhesive that was already on the surface of the sticker laminate and/or multizone sticker (e.g., adhesive on an adhesive zone of the sticker laminate and/or multizone sticker).

[0135] FIG. 22 describes a method 1300 for placing a multizone sticker on a new web 140 (e.g., roll of material). Although the flowchart of FIG. 22 is depicted as integral steps in a particular order for purposes of illustration, in other configurations one or more steps, or portions thereof, are performed in a different order, or overlapping in time, in series or in parallel, or are deleted, or one or more other steps are added, or the method is changed in some combination of ways. After the multizone sticker has been manufactured, the multizone sticker may be placed on a new web 140 (e.g., roll of material). FIG. 19 illustrates a configuration of the multizone sticker 192 placed on the new web 140. In step 1310 of the method 1300, the multizone sticker 192 may be moved across one or more rolls of material in a label making direction 2030. The label making direction 2030 may be orthogonal to the roll winding direction 2020. In step 1320, before or after moving the multizone sticker, a portion of the carrier web may be removed from the multizone sticker to expose any adhesive zones of the multizone sticker. In step 1330, after the sticker may be moved across to be in front of a correct or assigned roll 140, the sticker may be placed on a single roll 140 of the one or more rolls of material. The sticker may be adhered to the roll with adhesive from an adhesive zone of the tape. Additionally or alternatively, the sticker may be adhered to the roll via externally-applied adhesive (e.g., adhesive applied to the roll before placing the sticker on top of the adhesive applied to the roll). An adhesive first zone (e.g., 193, 194) of the tape may be placed across a leading edge 171 of the roll of material. A nonadhesive second zone 195 of the sticker may extend from the first zone in the roll winding direction. If the multizone sticker includes more than one adhesive zone, at least one adhesive zone may be placed on either side of the leading edge. At least one adhesive zone may be placed on both sides of the leading edge, and this may allow the sticker to be adhered to the roll on both sides of the leading edge. In a configuration, there may be a first adhesive zone 193 and a second adhesive zone 194 of the multizone sticker. The first zone 193 may comprise a first adhesive or adhesive strength, and the second zone 194 may comprise a second adhesive or adhesive strength. The first adhesive may be stronger than the second adhesive and/or the first adhesive strength may be greater than the second adhesive strength. The first zone 193 may be placed on the side opposite of the winding direction 2020 of the leading edge 171, and a portion of the second zone 194 may be placed on the roll winding direction side of the leading edge 171. Either the first zone 193 or the second zone 194 may be placed across the leading edge 171. In some configurations, the second zone 194 may be placed across the leading edge 171 because the relatively weaker adhesive or adhesive strength of the second zone 194 may help facilitate removing the second zone 194 from the roll of material 140 with a first force that does not overcome the force of the adhesive of the first zone holding the sticker 192 to the roll of material.

[0136] In a configuration, the method may include step 1340, which may include aligning the multizone sticker between a first side 2500 and a second side 2502 of the roll 140. Additionally or alternatively, a first edge 2506 and/or second edge 2504 of the multizone sticker 192 may be parallel or about parallel, for example, +/10 degrees, with the first side 2500 (e.g., front side) and/or second side 2502 (e.g., back side) of the roll. In some configurations, the multizone sticker may be centered or about centered between the first side 2500 and the second side 2502 of the roll.

[0137] In a configuration, the method may include step 1350, which includes inspecting the placement of the multizone sticker on the roll of material. After the multizone sticker is placed on a roll of material, the placement may be inspected to ensure that the sticker was positioned and/or adhered correctly. For example, a robot may move the sticker across one or more rolls of material and place the sticker on the roll (e.g., using an end effector). A sensor system may be used to inspect the placement of the sticker. The robot may include the sensor system onboard the robot or the sensor system may be external to the robot. The robot may be communicatively coupled with the sensor system. The sensor system may include one or more sensors and a controller. The controller may include a memory and a processor. The one or more sensors may include, for example, a camera, or other image sensor. The one or more sensors may be used to gather data (e.g., image data (e.g., photo, video)) indicative of the placement of the sticker on the roll of material. The sensor may provide that data to the controller which may determine if the placement is correct or acceptable. The controller may use predetermined thresholds in order to determine if placement is correct or acceptable, for example, to determine if portions or all of one or more edges of the sticker to be within a certain range of distances from the sides of the roll or at proper angles relative to one or more sides of the roll. The controller may analyze image data to determine if the edges of the sticker fall with the predetermined acceptable range of distances. Similarly, the controller may analyze the image data to determine if specific zones or portions of zones fall within predetermined acceptable locations relative to the roll. Similarly, the controller may analyze the data to check the orientation of the sticker falls within predetermined acceptable configurations, such as an angle of one or more sides of the sticker relative to the sides, for example front side and/or back side, of the roll.

[0138] If the sensor system determines the placement of the sticker does not meet some or all of the requirements, it may output an alert that the sticker is not placed properly. Additionally or alternatively, the sensor system may output instructions to take an action, such as for example, to adjust the placement of the sticker, remove the sticker, place a new sticker, and/or remove the roll from the row of rolls. The instructions may be sent to the robot that placed the sticker or another robot to fulfill or output the instructions to a monitor to inform a user.

[0139] While placement of the sticker on one or more rolls of material is described above as moving a sticker and placing a sticker onto a roll of a row of rolls, other methods are possible. For example, moving a roll of backing layer with discrete multizone stickers may be unwound and aligned with a row of rolls of material such that multiple multizone stickers are aligned to respective rolls simultaneously or substantially at once. After the multiple multizone stickers are placed onto the rolls, the stickers may be separated from each other by cutting the stickers and/or backing layer between the rolls. In some configurations, moving a roll to the sticker is possible. For example, individual rolls or a row of rolls may be moved individually or together towards a sticker or an array of stickers. Either the sticker or the rolls may be moved while the other is stationary during alignment and/or placement. In some configurations, the rolls and the sticker may both be moved for portions of alignment and/or placement.

[0140] FIG. 16A and FIG. 16B show a configuration of a multizone sticker 3000 that may include a splice tape section 3100. The splice tape section 3100 may include a splice tape portion 3020 and a cover section 3030. The splice tape portion 3020 may be sticky splice tape, and may, for example, be sticky on both sides. The cover section 3030 may include release tape that is configured to cover the exposed adhesive surface of the splice tape. The cover section may include an extended portion 3040 that may be a lift tab (e.g., a lift tab for the release tape). The lift tab 3040 may be a different material or the same material as the rest of the cover section 3030 (e.g., a single piece of release tape).

[0141] The multizone sticker 3000 may include a top layer 3200 that may include at least one adhesive zone 193 and at least one nonadhesive zone 195. The adhesive zone 193 may include a first adhesive portion 193A and a second adhesive portion 193B. The splice tape section 3100 may be radially inward from the top layer 3200 when the multizone sticker is placed on a roll of material 140. The cover section 3030 of the splice tape section 3100 may be at least partially (e.g., partially or fully) sandwiched between the splice tape portion 3020 and the top layer 3200. In a configuration where the top layer 3200 has an adhesive first zone 193 and a nonadhesive second zone 195, the cover section 3030 (e.g., which may be referred to as a fourth zone of the multizone tape) may be at least partially inward (e.g., partially or fully inward) from the first zone 193 and/or the second zone 195. The fourth zone 3030 may be at least partially (e.g., partially or fully) sandwiched between the first zone 193 or the second zone 195 and the splice tape portion 3020 (e.g., which may be referred to as a third zone of the multizone tape). The first zone 193 may be adhered to an outer layer of a web of material 140 (e.g., a roll of material), the second zone 195 may not be adhered to the web of material 140, the third zone 3020 may be configured to adhere to the web of material 140, and the fourth zone 3030 may not be adhered to the web of material 140. The third zone 3020 may be configured to adhere to the fourth zone 3030. The fourth zone 3030 may be configured to adhere to the first zone 193, and/or the fourth zone 3030 may configured to not adhere to the second zone 195. The fourth zone 3030 may not comprise any adhesive. In some configurations, the fourth zone 3030 may not comprise adhesive on one side (e.g., the side configured to touch the first and/or second zone). The fourth zone 3030 may comprise adhesive on one side (e.g., the side configured to adhesively attach with the third zone).

[0142] In a configuration, where the third zone 3020 and the first zone 193 are adhered to the web of material 140, the third zone 3020 may be configured to remain adhered to the web of material if the first zone 193 and/or the second zone 195 move radially away from the fourth zone 3030. Additionally, the fourth zone 3030 may be configured to remain adhered to the third zone 3020 if the first zone 193 and/or the second zone 195 move radially away from the fourth zone 3030. In a configuration, the third zone 3020 may be configured to remain adhered to the web of material 140 if the first zone is 193 removed from the fourth zone 3030. Additionally, the fourth zone 3030 may be configured to remain adhered to the third zone 3020 if the first zone 193 is removed from the fourth zone 3030. In a configuration, the fourth zone 3030 may be configured to be removed from the third zone 3020, and the third zone 3020 may be configured to remain adhered to the web of material 140 if the fourth zone 3030 is moved radially away from the third zone 3020 and/or if the fourth zone 3030 is removed from the third zone 3020.

[0143] FIGS. 17A-17G and FIG. 18 show a system and method 1400 for positioning material 4100 from a new roll of material 140 into a splice box 121. Although the flowchart of FIG. 18 is depicted as integral steps in a particular order for purposes of illustration, in other configurations one or more steps, or portions thereof, are performed in a different order, or overlapping in time, in series or in parallel, or are deleted, or one or more other steps are added, or the method is changed in some combination of ways. The third zone 3020 may be configured to be positioned into a splice box 121. Step 1410 of the method 1400 may include loading a new roll of material 140 onto an unwind spindle 4010. Step 1420 may include rotating the roll of material 140 on the spindle 4010 until the multizone sticker 3000 is located and/or oriented in a correct orientation relative to the spindle 4010. A sensor may be used to input data indicative of the presence, recognition, position, and/or orientation of the multizone tape 3000. A controller may analyze the data, and may determine the presence of and/or recognize the multizone tape 3000 (e.g., through an indicia) and/or determine that the multizone tape 3000 is in a correct orientation and/or position relative to the spindle, after which it may stop the rotation of the new roll of material. Step 1430 may include lifting the end of the roll of material 140 by lifting at least a portion of the multizone sticker 3000. The multizone sticker 3000 may be configured to be moved by a robot 169. For example, the robot 169 may be configured to pick up the multizone sticker 3000, for example, by using a gripper 4070. The gripper 4070 may include a vacuum device 4020 and/or a rotating joint. The robot 169 may lift a zone of the multizone sticker 3000 using the gripper 4070. For example, the robot may lift the second zone 195 using a vacuum 4020. After lifting the second zone 195, the first zone 193 may still be attached to the material 4100 of the roll of material 140 (e.g., due to the adhesive of the first zone). The third zone 3020 may still be attached to the roll of material 140, and the fourth zone 3030 may still be attached to the third zone 3020 (e.g., because the adhesive strength of the third zone was greater than any adhesive strength of the first and/or second zones). Step 1440 may include gripping the multizone sticker 3000 (e.g., the top layer 3200) with the gripper 4070 and/or winding the multizone sticker 3000 around the gripper 4070 (e.g., about two revolutions, the glue of the top layer 3020 may be facing away from the gripper). For example, the robot 169 may use the gripper 4070 to pull the material 4100 of the roll of the material 140 to the point where the third and fourth zones of the multizone tape are accessible, for example, by winding the material 4100 around the gripper 4070 by spinning at least a portion of the gripper 4070 about an axis of the rotating joint. The robot 169 may be further configured to place the third zone 3020 into the splice box 121 and wind the material. The robot 169 may be configured to grip the fourth zone 3030 of the multizone sticker and move the third and/or fourth zone via the gripper 4070 (e.g., via the vacuum and/or other portions of the gripper). In a configuration, the robot 169 may further remove the fourth zone 3030 using the gripper 4070.

[0144] For example, step 1450 may include moving the gripper 4070 (e.g., and the corresponding material 4100 of the new roll 140) along the thread up path 4300 while the spindle is unwinding the material of the roll of material until the splice tape section 3100 reaches a release tape peel station 4200. Step 1460 includes removing the fourth zone 3030 from the third zone 3020 to expose a surface of the third zone 3020. In some configurations, the fourth zone 3030 may be removed by a peel-off device proximate to the splice box 121 at the release tape peel station 4200. Step 1470 includes rotating the gripper 4070 to rewind the material 4100 around the gripper 4070 until the third zone 3020 reaches a position (e.g., final position) in the splice box 121. Step 1480 includes separating the outer layers of the roll of material wound around the gripper 4070 from the rest of the web of material 4100 (e.g., with a blade cut). The cutting location may be adjacent to the final location of the third zone 3020. The robot 169 (e.g., using the gripper 4070) may dispose of all separated material including the top layer 3200 of the multizone tape 3000. In some configurations, the fourth zone 3030 may be removed from the third zone by the gripper 4070 after the third zone reaches a position in the splice box 121.

[0145] The top layer 3200 of the multizone tape 3000 may have three or more zones. For example, the first adhesive zone 193 may have a first portion 193A and the second portion 193B. The first portion 193A may have an adhesive or adhesive properties and the second portion 193B may have an adhesive properties wherein the adhesive strength of the second zone 193B is less than that of the first zone 193A (e.g., it would take less force to detach the second portion 193B from the roll of material than it would to detach the first portion 193A). The top layer 3200 may be manufactured, for example, in the ways described above. In effect, the top layer 3200 may have three zones: The first zone 193A could, for example be the first portion 193A with the stronger adhesive and/or adhesive properties, the second zone 193B may be the second adhesive portion 193B, and the third zone 195 may be the nonadhesive zone.

[0146] In a configuration a nonadhesive zone of the multizone sticker may be created by folding a portion of an adhesive zone over itself. In a configuration, a nonadhesive zone may be created by adding a substrate onto an adhesive zone. For example, a substrate with nonadhesive sides may be placed over a portion of an adhesive zone to create a nonadhesive zone. In some configurations, for example, a substrate with one adhesive side may be placed over a portion of an adhesive zone (e.g., with the adhesive side of the substrate facing the adhesive of the adhesive zone and the nonadhesive side of the substrate facing away from the adhesive zone).

[0147] In a configuration, one or more adhesive zones may be manufactured by depositing adhesive onto a substrate. For example, after a label web is unwound, adhesive may be applied to a first zone of the label web to create a first, adhesive zone, and a second of the label web may remain without adhesive and is not adhesive. In some configurations, after a label web is unwound, adhesive may be applied to a first zone of a label web, and adhesive may be applied to a second zone of a label web. The adhesive strength of the first zone may be stronger than the adhesive strength of the second zone. The adhesive strength of the first zone may be, for example, due to the adhesive of the first zone being stronger than the adhesive of the second zone and/or adhesive pattern of the first zone configured for a stronger adhesive bond than the adhesive pattern of the second zone. The adhesive pattern may be configured to influence strength of an adhesive bond through geometry (e.g., specific shapes) and/or area of coverage (e.g., overall density of area covered adhesive).

[0148] In a configuration, an adhesive zone may be created from a laminate. The laminate may comprise a backing layer, an adhesive layer, and a carrier web layer. A portion of the backing layer may be removed to create a first zone and a second zone, wherein the first zone comprises a backing layer that is not externally adhesive and the second zone does not comprise a backing layer and is an adhesive zone.

[0149] In an embodiment, the system 100, 100 involves an ultrasonic splice box 102 design, that is aiming to connect the expiring web 130 with the new web 140 via an ultrasonic overlap splice (plunge splice). This advantageously eliminates the need to have an adhesive tape. Additionally, the disclosed embodiments herein enable an automated thread up solution for existing robots and/or other automated thread up systems (e.g. the automated outer layer removal from the new web 140, as shown in FIGS. 2A though 2C).

[0150] The system 100, 100 disclosed herein has different operating modes. In a first operating mode, the system is operated with a vacuum bar and material length (e.g. rotation controlled). In a second operating mode, the system is operated with a vacuum bar and sensor. In a third operating mode, the system is operated with a vacuum bar and a vacuum sonotrode/anvil. In a fourth operating mode, the system is operated with a vacuum bar, a vacuum sonotrode/anvil and an embedded sensor.

Method for Forming a Tapeless Splice Bond

[0151] FIG. 6 is a flowchart that illustrates an example of a method 200 for forming a tapeless splice bond 160 between material of the expiring web 130 and material of the new web 140, according to various embodiments. Although the flow diagram of FIG. 6 is depicted as integral steps in a particular order for purposes of illustration, in other embodiments one or more steps, or portions thereof, are performed in a different order, or overlapping in time, in series or in parallel, or are deleted, or one or more other steps are added, or the method is changed in some combination of ways.

[0152] In step 201, the expiring web 130 is conveyed through the splice box 102 and into the absorbent manufacturing line 149. As previously discussed, in step 201 the controller 110 transmits signals to the motor 104 of the first mandrel 101 such that the expiring web 130 is continuously fed through the splice box 102 and to the manufacturing line 149.

[0153] In step 202, the leading edge 141 of the new web 140 is conveyed through the splice box 102. In one embodiment, as shown in FIG. 1A, the leading edge 141 is conveyed past the splice location after which the controller 110 signals the vacuum bar 126b to adhere the new web 140 to the second component (e.g. anvil 124) of the thermal bonding apparatus. The controller 110 may then output a signal to the motor 106 of the mandrel 103 to move the new web 140 (now adhered to the anvil 124) in the upstream direction (opposite to the MD direction 132) until the leading edge 141 is within a threshold distance of the second component (e.g. anvil 124) of the thermal bonding apparatus and/or the second portion 143 of the new web 140 is adjacent to the second component of the thermal bonding apparatus. The controller 110 then signals the motor 106 of the mandrel 103 to stop and/or slow down rotation of the mandrel 103 and thus fix the second portion 143 of the new web 140 adjacent to the second component (e.g. anvil 124) of the thermal bonding apparatus.

[0154] In step 204, upon sensing the upcoming expiration of the first web 130, the speed of the expiring web 130 is adjusted. In an embodiment, in step 204 the controller 110 receives a signal from the sensor (not shown) that detects the upcoming expiration of the web 130. In one example embodiment, the sensor is on the mandrel 101 of the expiring web 130 and detects when a number of remaining layers (e.g. radial thickness) of the expiring web 130 falls below a threshold value. In another example embodiment, the sensor is an imaging device (e.g. camera) that detects that the number of remaining layers of the expiring web 130 on the mandrel 101 has fallen below the threshold value. As previously discussed, in step 204 upon detecting the upcoming expiration of the web 130, the controller 110 transmits signals to the motor 104 to slow down the rotation speed of the mandrel 101 and the expiring web 130 thereon. When the first portion 133 of the expiring web 130 is positioned adjacent to the first component (e.g. sonotrode 122) of the thermal welding apparatus, the controller 110 transmits a signal to stop and/or slow down the motor 104 and thus to fix the first portion 133 at the first component (e.g. sonotrode 122) of the thermal welding apparatus. In some embodiments, in step 204 the motor 108 of the mandrel 105 does not stop and thus the manufacturing line 149 is continuously fed from the splicer buffer system 144 of the expiring web 130. In still other embodiments, in step 204 upon detecting the upcoming expiration of the web 130, the controller 110 transmits signals to the motor 104 to speed up the rotation speed of the mandrel 101 and the expiring web 130 thereon, to increase the accumulation of the splicer buffer system 144 downstream of the splice box 102.

[0155] In step 206, the thermal weld or splice bond 160 is formed between the expiring web 130 and the new web 140. In one embodiment, in step 206 the splice bond 160 is formed between the first portion 133 of the expiring web 130 and the second portion 143 of the new web 140. In this embodiment, in step 206 the controller 110 signals a motor (not shown) of the thermal bonding apparatus to move the first and second components (e.g. sonotrode 122 and anvil 124), as well as the vacuum bars 126a, 126b, together in a direction orthogonal to the MD direction 132. The controller 110 also signals the thermal bonding apparatus to activate the sonotrode 122 and anvil 124 to form the splice bond 160. As previously discussed, the first portion 133 of the expiring web 130 and the second portion 143 of the new web 140 have an overlapping configuration (in the MD direction 132) when step 206 is performed. In an embodiment, in step 206 the sonotrode 122 vibrates against the anvil 124 to form the splice bond 160. As previously discussed, in step 202 the vacuum bar 126b was activated to adhere the second portion 143 of the new web 140 to the anvil 124, prior step 206 of the controller 110 transmitting the signals to move the sonotrode 122 and anvil 124 together to form the splice bond 160.

[0156] In step 208, either prior to or after step 206, the expiring web 130 is cut with the splice blade 120 upstream of the splice location to form the cut leading edge 150 upstream of the splice location or splice bond 160. Additionally, in step 208 the new web 140 is cut with the outer layer blade 128 downstream of the splice location to cut the tail 152 off the new web 140 downstream of the splice location or splice bond 160. Step 208 advantageously removes excess web material (e.g., the cut leading edge 150 and cut tail 152) from the splice bond 160.

[0157] In step 210, after the splice bond 160 is formed the controller 110 signals the motor 106 of the mandrel 103 to convey the new web 140 (now attached to the expiring web 130 via. the splice bond 160) through the splice box 102 and to the absorbent article manufacturing line 149. Motor 108 of the mandrel 105 is not activated in step 210 as it remains activated during the method 200 steps.

[0158] In an embodiment, the steps of the method 200 are performed without stoppage of the absorbent article manufacturing line 149 and thus either the expiring web 130 or new web 140 is continuously fed to the absorbent article manufacturing line 149 during the method 200. In an example embodiment, this is achieved in part due to the splicer buffer system 144 of the expiring web 130 that is provided prior to performing the method 200. Specifically, the steps of the method 200 that involve slowing down the expiring web 130, fixing the first and second portions 133, 143 at the thermal bonding apparatus, forming the splice bond 160 and then accelerating the new web 140 through the splice box 102. These steps are collectively performed over a time period that is less than the time period that the splicer buffer system 144 of the expiring web 130 can continuously feed the absorbent article manufacturing line 149.

Hardware

[0159] FIG. 7 is a block diagram that illustrates a computer system 300 upon which an embodiment of the invention may be implemented. Computer system 300 includes a communication mechanism such as a bus 310 for passing information between other internal and external components of the computer system 300. Information is represented as physical signals of a measurable phenomenon, typically electric voltages, but including, in other embodiments, such phenomena as magnetic, electromagnetic, pressure, chemical, molecular atomic and quantum interactions. For example, north and south magnetic fields, or a zero and non-zero electric voltage, represent two states (0, 1) of a binary digit (bit). Other phenomena can represent digits of a higher base. A superposition of multiple simultaneous quantum states before measurement represents a quantum bit (qubit). A sequence of one or more digits constitutes digital data that is used to represent a number or code for a character. In some embodiments, information called analog data is represented by a near continuum of measurable values within a particular range. Computer system 300, or a portion thereof, constitutes a means for performing one or more steps of one or more methods described herein.

[0160] A sequence of binary digits constitutes digital data that is used to represent a number or code for a character. A bus 310 includes many parallel conductors of information so that information is transferred quickly among devices coupled to the bus 310. One or more processors 302 for processing information are coupled with the bus 310. A processor 302 performs a set of operations on information. The set of operations include bringing information in from the bus 310 and placing information on the bus 310. The set of operations also typically include comparing two or more units of information, shifting positions of units of information, and combining two or more units of information, such as by addition or multiplication. A sequence of operations to be executed by the processor 302 constitutes computer instructions.

[0161] Computer system 300 also includes a memory 304 coupled to bus 310. The memory 304, such as a random access memory (RAM) or other dynamic storage device, stores information including computer instructions. Dynamic memory allows information stored therein to be changed by the computer system 300. RAM allows a unit of information stored at a location called a memory address to be stored and retrieved independently of information at neighboring addresses. The memory 304 is also used by the processor 302 to store temporary values during execution of computer instructions. The computer system 300 also includes a read only memory (ROM) 306 or other static storage device coupled to the bus 310 for storing static information, including instructions, that is not changed by the computer system 300. Also coupled to bus 310 is a non-volatile (persistent) storage device 308, such as a magnetic disk or optical disk, for storing information, including instructions, that persists even when the computer system 300 is turned off or otherwise loses power.

[0162] Information, including instructions, is provided to the bus 310 for use by the processor from an external input device 312, such as a keyboard containing alphanumeric keys operated by a human user, or a sensor. A sensor detects conditions in its vicinity and transforms those detections into signals compatible with the signals used to represent information in computer system 300. Other external devices coupled to bus 310, used primarily for interacting with humans, include a display device 314, such as a cathode ray tube (CRT) or a liquid crystal display (LCD), for presenting images, and a pointing device 316, such as a mouse or a trackball or cursor direction keys, for controlling a position of a small cursor image presented on the display 314 and issuing commands associated with graphical elements presented on the display 314.

[0163] In the illustrated embodiment, special purpose hardware, such as an application specific integrated circuit (IC) 320, is coupled to bus 310. The special purpose hardware is configured to perform operations not performed by processor 302 quickly enough for special purposes. Examples of application specific ICs include graphics accelerator cards for generating images for display 314, cryptographic boards for encrypting and decrypting messages sent over a network, speech recognition, and interfaces to special external devices, such as robotic arms and medical scanning equipment that repeatedly perform some complex sequence of operations that are more efficiently implemented in hardware.

[0164] Computer system 300 also includes one or more instances of a communications interface 370 coupled to bus 310. Communication interface 370 provides a two-way communication coupling to a variety of external devices that operate with their own processors, such as printers, scanners and external disks. In general, the coupling is with a network link 378 that is connected to a local network 380 to which a variety of external devices with their own processors are connected. For example, communication interface 370 may be a parallel port or a serial port or a universal serial bus (USB) port on a personal computer. In some embodiments, communications interface 370 is an integrated services digital network (ISDN) card or a digital subscriber line (DSL) card or a telephone modem that provides an information communication connection to a corresponding type of telephone line. In some embodiments, a communication interface 370 is a cable modem that converts signals on bus 310 into signals for a communication connection over a coaxial cable or into optical signals for a communication connection over a fiber optic cable. As another example, communications interface 370 may be a local area network (LAN) card to provide a data communication connection to a compatible LAN, such as Ethernet. Wireless links may also be implemented. Carrier waves, such as acoustic waves and electromagnetic waves, including radio, optical and infrared waves travel through space without wires or cables. Signals include man-made variations in amplitude, frequency, phase, polarization or other physical properties of carrier waves. For wireless links, the communications interface 370 sends and receives electrical, acoustic or electromagnetic signals, including infrared and optical signals, that carry information streams, such as digital data.

[0165] The term computer-readable medium is used herein to refer to any medium that participates in providing information to processor 302, including instructions for execution. Such a medium may take many forms, including, but not limited to, non-volatile media, volatile media and transmission media. Non-volatile media include, for example, optical or magnetic disks, such as storage device 308. Volatile media include, for example, dynamic memory 304. Transmission media include, for example, coaxial cables, copper wire, fiber optic cables, and waves that travel through space without wires or cables, such as acoustic waves and electromagnetic waves, including radio, optical and infrared waves. The term computer-readable storage medium is used herein to refer to any medium that participates in providing information to processor 302, except for transmission media.

[0166] Common forms of computer-readable media include, for example, a floppy disk, a flexible disk, a hard disk, a magnetic tape, or any other magnetic medium, a compact disk ROM (CD-ROM), a digital video disk (DVD) or any other optical medium, punch cards, paper tape, or any other physical medium with patterns of holes, a RAM, a programmable ROM (PROM), an erasable PROM (EPROM), a FLASH-EPROM, or any other memory chip or cartridge, a carrier wave, or any other medium from which a computer can read. The term non-transitory computer-readable storage medium is used herein to refer to any medium that participates in providing information to processor 302, except for carrier waves and other signals.

[0167] Logic encoded in one or more tangible media includes one or both of processor instructions on a computer-readable storage media and special purpose hardware, such as ASIC *320.

[0168] Network link 378 typically provides information communication through one or more networks to other devices that use or process the information. For example, network link 378 may provide a connection through local network 380 to a host computer 382 or to equipment 384 operated by an Internet Service Provider (ISP). ISP equipment 384 in turn provides data communication services through the public, world-wide packet-switching communication network of networks now commonly referred to as the Internet 390. A computer called a server 392 connected to the Internet provides a service in response to information received over the Internet. For example, server 392 provides information representing video data for presentation at display 314.

[0169] The invention is related to the use of computer system 300 for implementing the techniques described herein. According to one embodiment of the invention, those techniques are performed by computer system 300 in response to processor 302 executing one or more sequences of one or more instructions contained in memory 304. Such instructions, also called software and program code, may be read into memory 304 from another computer-readable medium such as storage device 308. Execution of the sequences of instructions contained in memory 304 causes processor 302 to perform the method steps described herein. In alternative embodiments, hardware, such as application specific integrated circuit 320, may be used in place of or in combination with software to implement the invention. Thus, embodiments of the invention are not limited to any specific combination of hardware and software.

[0170] The signals transmitted over network link 378 and other networks through communications interface 370, carry information to and from computer system 300. Computer system 300 can send and receive information, including program code, through the networks 380, 390 among others, through network link 378 and communications interface 370. In an example using the Internet 390, a server 392 transmits program code for a particular application, requested by a message sent from computer 300, through Internet 390, ISP equipment 384, local network 380 and communications interface 370. The received code may be executed by processor 302 as it is received, or may be stored in storage device 308 or other non-volatile storage for later execution, or both. In this manner, computer system 300 may obtain application program code in the form of a signal on a carrier wave.

[0171] Various forms of computer readable media may be involved in carrying one or more sequence of instructions or data or both to processor 302 for execution. For example, instructions and data may initially be carried on a magnetic disk of a remote computer such as host 382. The remote computer loads the instructions and data into its dynamic memory and sends the instructions and data over a telephone line using a modem. A modem local to the computer system 300 receives the instructions and data on a telephone line and uses an infra-red transmitter to convert the instructions and data to a signal on an infra-red a carrier wave serving as the network link 378. An infrared detector serving as communications interface 370 receives the instructions and data carried in the infrared signal and places information representing the instructions and data onto bus 310. Bus 310 carries the information to memory 304 from which processor 302 retrieves and executes the instructions using some of the data sent with the instructions. The instructions and data received in memory 304 may optionally be stored on storage device 308, either before or after execution by the processor 302.

[0172] FIG. 8 illustrates a chip set 400 upon which an embodiment of the invention may be implemented. Chip set 400 is programmed to perform one or more steps of a method described herein and includes, for instance, the processor and memory components described with respect to FIG. *3 incorporated in one or more physical packages (e.g., chips). By way of example, a physical package includes an arrangement of one or more materials, components, and/or wires on a structural assembly (e.g., a baseboard) to provide one or more characteristics such as physical strength, conservation of size, and/or limitation of electrical interaction. It is contemplated that in certain embodiments the chip set can be implemented in a single chip. Chip set 400, or a portion thereof, constitutes a means for performing one or more steps of a method described herein.

[0173] In one embodiment, the chip set 400 includes a communication mechanism such as a bus 401 for passing information among the components of the chip set 400. A processor 403 has connectivity to the bus 401 to execute instructions and process information stored in, for example, a memory 405. The processor 403 may include one or more processing cores with each core configured to perform independently. A multi-core processor enables multiprocessing within a single physical package. Examples of a multi-core processor include two, four, eight, or greater numbers of processing cores. Alternatively or in addition, the processor 403 may include one or more microprocessors configured in tandem via the bus 401 to enable independent execution of instructions, pipelining, and multithreading. The processor 403 may also be accompanied with one or more specialized components to perform certain processing functions and tasks such as one or more digital signal processors (DSP) 407, or one or more application-specific integrated circuits (ASIC) 409. A DSP 407 typically is configured to process real-world signals (e.g., sound) in real time independently of the processor 403. Similarly, an ASIC 409 can be configured to performed specialized functions not easily performed by a general purposed processor. Other specialized components to aid in performing the inventive functions described herein include one or more field programmable gate arrays (FPGA) (not shown), one or more controllers (not shown), or one or more other special-purpose computer chips.

[0174] The processor 403 and accompanying components have connectivity to the memory 405 via the bus 401. The memory 405 includes both dynamic memory (e.g., RAM, magnetic disk, writable optical disk, etc.) and static memory (e.g., ROM, CD-ROM, etc.) for storing executable instructions that when executed perform one or more steps of a method described herein. The memory 405 also stores the data associated with or generated by the execution of one or more steps of the methods described herein.

[0175] FIG. 9 is a diagram of exemplary components of a mobile terminal 500 (e.g., cell phone handset) for communications, which is capable of operating in the system of FIG. 2C, according to one embodiment. In some embodiments, mobile terminal 501, or a portion thereof, constitutes a means for performing one or more steps described herein. Generally, a radio receiver is often defined in terms of front-end and back-end characteristics. The front-end of the receiver encompasses all of the Radio Frequency (RF) circuitry whereas the back-end encompasses all of the base-band processing circuitry. As used in this application, the term circuitry refers to both: (1) hardware-only implementations (such as implementations in only analog and/or digital circuitry), and (2) to combinations of circuitry and software (and/or firmware) (such as, if applicable to the particular context, to a combination of processor(s), including digital signal processor(s), software, and memory(ies) that work together to cause an apparatus, such as a mobile phone or server, to perform various functions). This definition of circuitry applies to all uses of this term in this application, including in any claims. As a further example, as used in this application and if applicable to the particular context, the term circuitry would also cover an implementation of merely a processor (or multiple processors) and its (or their) accompanying software/or firmware. The term circuitry would also cover if applicable to the particular context, for example, a baseband integrated circuit or applications processor integrated circuit in a mobile phone or a similar integrated circuit in a cellular network device or other network devices.

[0176] Pertinent internal components of the telephone include a Main Control Unit (MCU) 503, a Digital Signal Processor (DSP) 505, and a receiver/transmitter unit including a microphone gain control unit and a speaker gain control unit. A main display unit 507 provides a display to the user in support of various applications and mobile terminal functions that perform or support the steps as described herein. The display 507 includes display circuitry configured to display at least a portion of a user interface of the mobile terminal (e.g., mobile telephone). Additionally, the display 507 and display circuitry are configured to facilitate user control of at least some functions of the mobile terminal. An audio function circuitry 509 includes a microphone 511 and microphone amplifier that amplifies the speech signal output from the microphone 511. The amplified speech signal output from the microphone 511 is fed to a coder/decoder (CODEC) 513.

[0177] A radio section 515 amplifies power and converts frequency in order to communicate with a base station, which is included in a mobile communication system, via antenna 517. The power amplifier (PA) 519 and the transmitter/modulation circuitry are operationally responsive to the MCU 503, with an output from the PA 519 coupled to the duplexer 521 or circulator or antenna switch, as known in the art. The PA 519 also couples to a battery interface and power control unit 520.

[0178] In use, a user of mobile terminal 501 speaks into the microphone 511 and his or her voice along with any detected background noise is converted into an analog voltage. The analog voltage is then converted into a digital signal through the Analog to Digital Converter (ADC) 523. The control unit 503 routes the digital signal into the DSP 505 for processing therein, such as speech encoding, channel encoding, encrypting, and interleaving. In one embodiment, the processed voice signals are encoded, by units not separately shown, using a cellular transmission protocol such as enhanced data rates for global evolution (EDGE), general packet radio service (GPRS), global system for mobile communications (GSM), Internet protocol multimedia subsystem (IMS), universal mobile telecommunications system (UMTS), etc., as well as any other suitable wireless medium, e.g., microwave access (WiMAX), Long Term Evolution (LTE) networks, code division multiple access (CDMA), wideband code division multiple access (WCDMA), wireless fidelity (WiFi), satellite, and the like, or any combination thereof.

[0179] The encoded signals are then routed to an equalizer 525 for compensation of any frequency-dependent impairments that occur during transmission though the air such as phase and amplitude distortion. After equalizing the bit stream, the modulator 527 combines the signal with a RF signal generated in the RF interface 529. The modulator 527 generates a sine wave by way of frequency or phase modulation. In order to prepare the signal for transmission, an up-converter 531 combines the sine wave output from the modulator 527 with another sine wave generated by a synthesizer 533 to achieve the desired frequency of transmission. The signal is then sent through a PA 519 to increase the signal to an appropriate power level. In practical systems, the PA 519 acts as a variable gain amplifier whose gain is controlled by the DSP 505 from information received from a network base station. The signal is then filtered within the duplexer 521 and optionally sent to an antenna coupler 535 to match impedances to provide maximum power transfer. Finally, the signal is transmitted via antenna 517 to a local base station. An automatic gain control (AGC) can be supplied to control the gain of the final stages of the receiver. The signals may be forwarded from there to a remote telephone which may be another cellular telephone, any other mobile phone or a land-line connected to a Public Switched Telephone Network (PSTN), or other telephony networks.

[0180] Voice signals transmitted to the mobile terminal 501 are received via antenna 517 and immediately amplified by a low noise amplifier (LNA) 537. A down-converter 539 lowers the carrier frequency while the demodulator 541 strips away the RF leaving only a digital bit stream. The signal then goes through the equalizer 525 and is processed by the DSP 505. A Digital to Analog Converter (DAC) 543 converts the signal and the resulting output is transmitted to the user through the speaker 545, all under control of a Main Control Unit (MCU) 503 which can be implemented as a Central Processing Unit (CPU) (not shown).

[0181] The MCU 503 receives various signals including input signals from the keyboard 547. The keyboard 547 and/or the MCU 503 in combination with other user input components (e.g., the microphone 511) comprise a user interface circuitry for managing user input. The MCU 503 runs a user interface software to facilitate user control of at least some functions of the mobile terminal 501 as described herein. The MCU 503 also delivers a display command and a switch command to the display 507 and to the speech output switching controller, respectively. Further, the MCU 503 exchanges information with the DSP 505 and can access an optionally incorporated SIM card 549 and a memory 551. In addition, the MCU 503 executes various control functions required of the terminal. The DSP 505 may, depending upon the implementation, perform any of a variety of conventional digital processing functions on the voice signals. Additionally, DSP 505 determines the background noise level of the local environment from the signals detected by microphone 511 and sets the gain of microphone 511 to a level selected to compensate for the natural tendency of the user of the mobile terminal 501.

[0182] The CODEC 513 includes the ADC 523 and DAC 543. The memory 551 stores various data including call incoming tone data and is capable of storing other data including music data received via, e.g., the global Internet. The software module could reside in RAM memory, flash memory, registers, or any other form of writable storage medium known in the art. The memory device 551 may be, but not limited to, a single memory, CD, DVD, ROM, RAM, EEPROM, optical storage, magnetic disk storage, flash memory storage, or any other non-volatile storage medium capable of storing digital data.

[0183] An optionally incorporated SIM card 549 carries, for instance, important information, such as the cellular phone number, the carrier supplying service, subscription details, and security information. The SIM card 549 serves primarily to identify the mobile terminal 501 on a radio network. The card 549 also contains a memory for storing a personal telephone number registry, text messages, and user specific mobile terminal settings.

[0184] In some embodiments, the mobile terminal 501 includes a digital camera comprising an array of optical detectors, such as charge coupled device (CCD) array 565. The output of the array is image data that is transferred to the MCU for further processing or storage in the memory 551 or both. In the illustrated embodiment, the light impinges on the optical array through a lens 563, such as a pin-hole lens or a material lens made of an optical grade glass or plastic material. In the illustrated embodiment, the mobile terminal 501 includes a light source 561, such as a LED to illuminate a subject for capture by the optical array, e.g., CCD 565. The light source is powered by the battery interface and power control module 520 and controlled by the MCU 503 based on instructions stored or loaded into the MCU 503.

[0185] As an example, an absorbent article may comprise a material (e.g., a nonwoven material) comprising a thermal weld with a tail extending from the thermal weld a distance of no greater than about 20 mm, no greater than about 10 mm or no greater than about 5 mm.

[0186] Referring to FIG. 10, Typically, rolls of webs are shipped from the roll goods manufacturer to absorbent article manufactures in a cylindrical bundle of 2-20 rolls, for example. The bundles may be about 1 meter to 2 meters in diameter, for example. The rolls are tightly wrapped with a plastic film, such as a polyethylene film, to protect the rolls from dirt and damage. Cardboard typically covers the bundle of the rolls on the flat ends of the cylindrical bundle to protect the ends. This plastic film needs to be removed prior to using the rolls in absorbent article manufacturing process. Typically, the film is manually cut off using a rotary sheer or cutter, however when cutting across the film over the curved outer surface of the rolls the manual rotary cutting may damage and cut into the outer revolutions of the web on the rolls, thereby ruining the outer revolutions of the web. The present inventors have discovered that by adding a sacrificial material 700 in a strip about the curved outer surface of the bundle 702 from the first end 704 to the second end 706 and under the film 708, automated cutting can occur to remove the film without damaging the outer revolutions of the rolls. In such a way, a robot may use a rotary sheer or cutter to cut into but not through the sacrificial material 700 while also cutting the film 708. Examples of the sacrificial material are heavy paper, cardboard, corrugated cardboard, polymer foam, and/or other low cost materials that provide sufficient caliper for protection of the underlying web. The sacrificial material may comprise a single layer or may be a laminate of multiple materials. The strip of sacrificial material may be from about 0.5 inches wide to about 15 inches wide, for example. This automated process significantly reduces scrap caused by the manual cutting and damage to the outer revolutions of the material.

EXAMPLES/COMBINATIONS

[0187] D1. A method for making a sticker for manufacturing an absorbent article, the method comprising: [0188] unwinding a sticker laminate, the sticker laminate comprising a first side and a second side across from the first side, wherein the first side is adhesive, and the second side is not adhesive; [0189] folding a portion of the first side over itself to form a first, non-adhesive zone of the sticker; [0190] E1. A method for making a sticker for manufacturing an absorbent article, the method comprising: [0191] unwinding a sticker laminate, the sticker laminate comprising a backing layer, an adhesive layer, and a carrier web layer; [0192] removing a portion of the backing layer to create a first zone and a second zone, wherein the first zone comprises a backing layer and is not externally adhesive, and the second zone does not comprise a backing layer and is an adhesive zone. [0193] F1. A method for making a sticker for manufacturing an absorbent article, the method comprising: [0194] unwinding a sticker laminate, the sticker laminate comprising a first side and a second side across from the first side, wherein the first side is adhesive, and the second side is not adhesive; [0195] adding a substrate over top a portion of the first side to create a first zone and a second zone, wherein the first zone is a non-adhesive zone, and the second zone is an adhesive zone. [0196] G1. A method for making sticky tapes used for manufacturing an absorbent article, the method comprising: [0197] unwinding a label web; and [0198] applying adhesive in a first zone of the label web; [0199] wherein a second zone of the label web remains without adhesive and is not adhesive. [0200] H1. A method for making a sticker for manufacturing an absorbent article, the method comprising: [0201] unwinding a sticker laminate; [0202] separating the sticker laminate into a first layer and a second layer, wherein the first layer comprises a surface with adhesive and the second layer comprises a non-stick backing layer; [0203] treating the first layer with adhesive neutralizing agent to form a first zone comprising untreated adhesive and a second zone comprising treated adhesive; and [0204] recombining the first layer and the second layer; [0205] wherein at least a portion of the first zone is configured to extend across a leading edge of a roll of material comprising a roll winding direction. [0206] H2. The method of paragraph H1, further comprising die cutting a perimeter defining individual multizone stickers. [0207] H3. The method of paragraph H2, wherein the first layer further comprises a third zone without adhesive, and wherein the perimeter surrounds a portion of the third zone, and wherein the third zone is adjacent to the first zone and is configured to extend away from the first zone opposite the roll winding direction. [0208] H4. The method of paragraph H1, H2, or H3, wherein the second zone is adjacent to the first zone and is configured to extend away from the first zone in the roll winding direction. [0209] H5. The method of paragraph H1, H2, H3, or H4, further comprising treating the first zone with an adhesive neutralizing agent to form a first portion and a second portion of the first zone, wherein the first portion is configured to adhere to the roll of material with a first level of force and the second portion is configured to adhere to the roll of material with a second level of force, wherein the second level of force is less than the first level of force. [0210] H6. The method of paragraph H5, further comprising die cutting a perimeter defining individual multizone stickers. [0211] H7. The method of paragraph H6, wherein the first layer further comprises a third zone without adhesive, and wherein the perimeter surrounds a portion of the third zone, wherein the third zone is adjacent to the first zone and is configured to extend away from the first zone opposite the roll winding direction. [0212] H8. The method of paragraph H5, H6, or H7, wherein the second portion of the first zone is adjacent to the second zone and is configured to extend away from the second zone opposite the roll winding direction. [0213] H9. The method of paragraph H1, further comprising applying additional adhesive to the first zone to form a first portion and a second portion of the first zone, wherein the first portion is configured to adhere to the roll of material with a first level of force and the second portion is configured to adhere to the roll of material with a second level of force, wherein the second level of force is less than the first level of force. [0214] H10. The method of paragraph H9, further comprising die cutting a perimeter defining individual multizone stickers. [0215] H11. The method of paragraph H10, wherein the first layer further comprises a third zone without adhesive, and wherein the perimeter surrounds a portion of the third zone, and wherein the third zone is adjacent to the first zone and is configured to extend away from the first zone opposite the roll winding direction. [0216] H12. The method of paragraph H9, H10, or H11, wherein the second portion of the first zone is adjacent to the second zone and is configured to extend away from the second zone opposite the roll winding direction. [0217] H13. The method of paragraph 1, further comprising applying a substrate to the first zone to form a third zone, wherein an exposed side of the substrate is an adhesive that is weaker than the adhesive of the first zone. [0218] H14. The method of paragraph H13, further comprising die cutting a perimeter defining individual multizone stickers. [0219] H15. The method of paragraph H14, wherein the first layer further comprises a third zone without adhesive, and wherein the perimeter surrounds a portion of the third zone, and wherein the third zone is adjacent to the first zone and is configured to extend away from the first zone opposite the roll winding direction. [0220] J1. A method of preparing material for automated pick up used for manufacturing an absorbent article, the method comprising: [0221] providing a roll of material comprising a leading edge, a first side, and a second side axially separated from the first side, the roll of material further comprising a roll winding direction; [0222] advancing the multizone sticker in a label making direction across the roll of material, the multizone sticker comprising a first zone and a second zone; and [0223] placing the multizone sticker on the roll of material; wherein the first zone of the multizone sticker is placed across the leading edge of the roll of material, and wherein the second zone of the multizone sticker extends from the first zone in the roll winding direction. [0224] J2. The method of paragraph J1, further comprising aligning the multizone sticker to be about centered between the first side and the second side of the roll of material. [0225] J3. The method of paragraph J1 or J2, further comprising attaching the first zone to the roll of material with an adhesive. [0226] J4. The method of paragraph J1, J2, or J3, further comprising separating at least a portion of a carrier web from the rest of the multizone sticker. [0227] J5. The method of paragraph J1, J2, J3, or J4, wherein the multizone sticker further comprises first edge and a second edge separated from the first edge in the label making direction, the method further comprising aligning the first edge of the multizone sticker to be about parallel with the first side or the second side of the roll of material. [0228] J6. The method of paragraph J1, J2, J3, J4, or J5, further comprising inspecting the multizone sticker on the roll of material to confirm that the multizone sticker is correctly applied. [0229] J7. The method of paragraph J1, J2, J3, J4, J5, or J6, further comprising placing the multizone sticker on the roll of material with a robot. [0230] J8. The method of paragraph J1, J2, J3, J4, J5, J6, or J7, further comprising moving the roll of material to align the roll of material with the multizone sticker. [0231] K1. A multizone sticker for manufacturing an absorbent article, the multizone sticker comprising: [0232] a first layer comprising a first zone and a second zone, wherein the first zone is configured to adhere to an outer layer of a roll of material, and wherein the second zone is configured to not adhere to the outer layer of the roll of material; [0233] a second layer comprising a third zone configured to adhere to the roll of material; and [0234] a fourth zone that is not adhered to the roll of material; [0235] wherein the third zone is at least partially radially inward from the first zone or the second zone when the multizone sticker positioned on the roll of material. [0236] K2. The multizone sticker of paragraph K1, wherein the fourth zone is sandwiched between the first zone and the third zone. [0237] K3. The multizone sticker of paragraph K1 or K2, wherein the first zone comprises a first adhesive coating and wherein the third zone comprises a second adhesive coating. [0238] K4. The multizone sticker of paragraph K1, K2, or K3, wherein the third zone is configured to stay adhered to the roll of material if the second zone is moved radially away from the fourth zone. [0239] K5. The multizone sticker of paragraph K1, K2, K3, or K4, wherein the third zone is configured to be positioned into a splice box. [0240] K6. The multizone sticker of paragraph K1, K2, K3, K4, or K5, wherein the fourth zone is configured to be removed from the third zone. [0241] K7. The multizone sticker of paragraph K1, K2, K3, K4, K5, or K6, wherein the fourth zone is radially inward from the second zone, and wherein there is no adhesive directly between the fourth zone and the second zone. [0242] K8. The multizone sticker of paragraph K1, K2, K3, K4, K5, K6 or K7, wherein the second zone is configured to be moved by a robot device. [0243] K9. The multizone sticker of paragraph K8, wherein the robot comprises a vacuum device. [0244] K10. The multizone sticker of paragraph K9, wherein the robot comprises a gripper, and the robot is configured to wind the third zone about the gripper. [0245] K11. The multizone sticker of paragraph K1, K2, K3, K4, K5, K6, K7, K8, K9, or K10 wherein the fourth zone is configured to be moved by a gripper of a robot. [0246] K12. The multizone sticker of paragraph K11, wherein the robot is configured to pull material of the roll of material in order to align the third zone of the sticker within the splice box. [0247] K13. The multizone sticker of paragraph K1, K2, K3, K4, K5, K6, K7, K8, K9, K10, K11, or K12, wherein a first portion of the first zone is configured to adhere to the roll of material with a first level of force and a second portion of the first zone is configured to adhere to the roll of material with a second level of force, wherein the second level of force is less than the first level of force.

[0248] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as 40 mm is intended to mean about 40 mm.

[0249] Every document cited herein, including any cross referenced or related patent or application and any patent application or patent to which this application claims priority or benefit thereof, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

[0250] While particular embodiments of the present disclosure have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.