Articles with zoned apertured materials and registration methods

1 . A method of registering first and second simultaneously advancing webs, the method comprising:

moving a continuous first web in a machine direction;

moving a continuous second web in the machine direction in proximity to the first web, the second web comprising one or more first portions having a light transmittance value below a transmittance threshold value and one or more second portions having a light transmittance value greater than or equal to the transmittance threshold value;

capturing, with a registration system comprising an image capture device coupled to a registration processing device, a first image comprising a portion of the second web;

filtering, with the registration processing device, the captured first image to determine one or more regions of the captured first image having a light transmittance value greater than the transmittance threshold value;

modifying, with the registration processing device, the captured first image by applying a dilation morphological operation to the filtered captured first image;

determining, with the registration processing device and based at least in part on the modified captured first image, a feature of interest related to the determined one or more regions;

determining, with the registration processing device, a first difference value comprising a difference in location between the feature of interest and a reference feature of the captured first image or the modified captured first image;

adjusting, based at least in part on the determined first difference value, a speed of the second web in the machine direction; and

coupling the first web and the second web together,

wherein the registration processing device applies the dilation morphological operation multiple times to the filtered captured first image, and

wherein the registration processing device applies the dilation morphological operation such that a total number of discrete determined regions having a light transmittance value greater than the transmittance threshold value is reduced by at least 25%.

2 . The method of claim 1 , wherein the feature of interest related to the determined one or more regions comprises a leading edge, in the machine direction, of the determined one or more regions.

3 . The method of claim 1 , wherein if the determined first difference value is above a first difference value threshold, the speed of the second web is increased in the machine direction.

4 . The method of claim 1 , wherein if the determined first difference value is below a first difference value threshold, the speed of the second web is decreased in the machine direction.

5 . The method of claim 3 , wherein the first difference value threshold is a maximum value of a first difference value threshold range.

6 . The method of claim 1 , wherein the registration processing device applies the dilation morphological operation to result in a single, unified region having a light transmittance value greater than the transmittance threshold value.

7 . The method of claim 1 , further comprising filtering, with the registration processing device, the captured first image to determine one or more regions of the captured first image that have both a light transmittance value greater than the transmittance threshold value and have an area larger than a threshold area.

8 . A method of registering a first web and an apertured region of a second web, the method comprising:

moving a continuous first web in a machine direction;

moving a continuous second web in the machine direction in proximity to the first web, the second web comprising a plurality of apertures forming a plurality of discrete apertured regions spaced apart from each other in the machine direction;

capturing, with a registration system comprising an image capture device coupled to a registration processing device, a first image comprising a portion of the second web;

filtering, with the registration processing device, the captured first image to determine one or more apertured regions of the captured first image;

modifying, with the registration processing device, the filtered captured first image by applying a dilation morphological operation to the filtered captured first image;

determining, with the registration processing device and based at least in part on the modified filtered captured first image, a feature of interest related to the determined one or more apertured regions;

determining, with the registration processing device, a first difference value comprising a difference in location between the feature of interest and a reference feature of the captured first image or the modified filtered captured first image;

adjusting, based at least in part on the determined first difference value, a relative position of a discrete apertured region of first web with respect to the second web; and

combining the first web and the second web,

wherein the image capture device comprises an optical system including an image sensor.

9 . The method of claim 8 , wherein filtering, with the registration processing device, the captured first image to determine one or more apertured regions of the captured first image comprises filtering the captured first image to determine one or more regions of the captured first image having a light transmittance value greater than the transmittance threshold value.

10 . The method of claim 8 , wherein adjusting, based at least in part on the determined first difference value, a relative position of a discrete apertured region of first web with respect to the second web comprises speeding up or slowing down one of the first web and the second web.

11 . The method of claim 8 , wherein combining the first web and the second web comprises cutting the first web into discrete first web portions and applying the discrete first web portions to the second web in a spaced apart fashion.

12 . The method of claim 8 wherein adjusting, based at least in part on the determined first difference value, a relative position of a discrete apertured region of first web with respect to the second web comprises advancing the relative position of a discrete apertured region of first web in the machine direction with respect to the second web if the determined first difference value is greater than a first threshold difference value and retreating the relative position of a discrete apertured region of first web in the machine with respect to the second web if the determined first difference value is less than a second threshold difference value.

13 . A method of registering a first web and an apertured region of a second web, the method comprising:

moving a continuous first web in a machine direction;

moving a continuous second web in the machine direction in proximity to the first web, the second web comprising a plurality of apertures forming a plurality of discrete apertured regions spaced apart from each other in the machine direction;

capturing, with a registration system comprising a first image capture device coupled to a registration processing device, a first image comprising a portion of the second web;

determining, with the registration processing device, a first difference value comprising a difference in location between a first feature of interest and a first reference feature of the captured first image;

adjusting, based at least in part on registration parameters including the determined first difference value and a first difference value threshold, a relative position of a discrete apertured region of the second web with respect to the first web;

combining the first web and the second web;

capturing, with the registration system by a second image capture device coupled to the registration processing device, a second image comprising a portion of the combined first web and second web;

determining, with the registration processing device, a second difference value comprising a difference in location between a second feature of interest and a second reference feature of the captured second image; and

adjusting, with the registration processing device and based at least on the determined second difference value, at least one of the registration parameters,

wherein each of the first image capture device and the second image capture device comprises an optical system including an image sensor.

14 . The method of claim 13 , wherein the registration parameters include the determined first difference value and a first difference value threshold range instead of a first difference value threshold.

15 . The method of claim 13 , further comprising:

filtering, with the registration processing device, the captured first image to determine one or more apertured regions of the captured first image;

modifying, with the registration processing device, the filtered captured first image by applying a dilation morphological operation to the filtered captured first image; and

determining, with the registration processing device and based at least in part on the modified filtered captured first image, the first feature of interest related to the determined one or more apertured regions of the modified filtered captured first image.

16 . The method of claim 15 , wherein the first feature of interest of the determined one or more regions comprises a leading edge in the machine direction of the determined one or more regions.

17 . The method of claim 13 , further comprising:

filtering, with the registration processing device, the captured second image to determine one or more apertured regions of the captured second image;

modifying, with the registration processing device, the filtered captured second image by applying a dilation morphological operation to the filtered captured second image; and

determining, with the registration processing device and based at least in part on the modified filtered captured second image, a second feature of interest related to the determined one or more apertured regions of the modified filtered captured second image.

18 . The method of claim 13 , wherein adjusting, with the registration processing device and based at least on the determined second difference value, at least one of the registration parameters comprises adding an offset value to the first difference value.

19 . The method of claim 13 , wherein adjusting, with the registration processing device and based at least on the determined second difference value, at least one of the registration parameters comprises adjusting the first difference value threshold.