Apparatus and method for applying discrete parts to a moving web

1. Apparatus for conveying a plurality of discrete parts and applying each discrete part to a substrate moving along a placement axis of the apparatus, the apparatus comprising:

a plurality of transfer pucks adapted to convey the discrete parts to the substrate, the plurality of transfer pucks comprising a first transfer puck and a second transfer puck; and

a drive assembly configured to rotate the first transfer puck in a first rotational direction and to rotate the second transfer puck in a second rotational direction that is opposite the first rotational direction such that a plurality of pairs of discrete parts is applied to the substrate and perpendicular to the placement axis, wherein each applied pair of discrete parts includes a first discrete part and a second discrete part spaced a first distance along the placement axis from the first discrete part, adjacent pairs of discrete parts being spaced a second distance along the placement axis that is different from the first distance.

2. The apparatus as set forth in claim 1 , further comprising a plurality of transfer segments, each of the transfer segments comprising a support arm extending outwardly from the drive assembly, and one of the plurality of transfer pucks coupled to the support arm and configured to pivot about the support arm, each of the transfer pucks being pivotable between a first position wherein the transfer puck is oriented to receive one of the first and second discrete parts, and a second position wherein the transfer puck is oriented to apply the one of the first and second discrete parts to the substrate.

3. The apparatus as set forth in claim 2 , wherein the drive assembly being configured to pivot the first transfer puck about the support arm axis in the first rotational direction, and to pivot the second transfer puck in the second rotational direction that is opposite the first rotational direction.

4. The apparatus as set forth in claim 3 , wherein the drive assembly rotates the first and second transfer pucks such that the first discrete part is applied at a first angle with respect to a placement axis, and the second discrete part is applied at a second angle with respect to the placement axis, wherein the first angle is different than the second angle.

5. The apparatus as set forth in claim 2 , wherein the drive assembly comprises a cylinder cam, each transfer segment of the plurality of transfer segments comprises:

a cam arm extending outwardly from the support arm; and

a cam follower adapted to engage the cylinder cam to selectively pivot the transfer segment about the support arm.

6. The apparatus as set forth in claim 5 , wherein the plurality of transfer segments comprise a first transfer segment having a leading cam follower, and a second transfer segment having a trailing cam follower.

7. The apparatus as set forth in claim 2 , wherein each of the transfer pucks comprises a platform adapted to contact the first and second discrete parts to convey the discrete parts to the substrate, each of the transfer pucks being coupled to the support arm at a pivot point such that the outer surface is offset a distance from the pivot point.

8. The apparatus as set forth in claim 2 , further comprising a vacuum assembly coupled to each transfer puck, the vacuum assembly configured to selectively apply a vacuum to each transfer puck to facilitate conveying each discrete part to the substrate.

9. The apparatus as set forth in claim 1 , wherein the drive assembly selectively adjusts a rotational speed of the plurality of transfer pucks as each transfer puck of the plurality of transfer pucks rotates between a pick-up location and an application location.

10. The apparatus as set forth in claim 9 , wherein the drive assembly selectively rotates each transfer puck of the plurality of transfer pucks at a first rotational speed from the pick-up location to the application location, and rotates each transfer puck of the plurality of transfer pucks at a second rotational speed from the application location to the pick-up location that is different than the first rotational speed.

11. The apparatus as set forth in claim 1 , wherein the drive assembly selectively adjusts a distance between the first transfer puck and the second transfer puck as the drive assembly rotates the first transfer puck and the second transfer puck.

12. The apparatus as set forth in claim 1 , wherein the drive assembly orients a pair of transfer pucks of the plurality of transfer pucks relative to each other such that the pair of transfer pucks is aligned along the placement axis of the substrate.

13. A method of applying a plurality of discrete parts to a substrate moving along a placement axis comprising:

directing a web including the plurality of discrete parts toward an apparatus for conveying each discrete part from the web and applying each discrete part to the substrate, the apparatus including a plurality of transfer pucks rotatably coupled to a drive assembly;

rotating a first transfer puck of the plurality of transfer pucks in a first direction;

rotating a second transfer puck of the plurality of transfer pucks in a second direction that is different than the first direction such that each discrete part from the web is conveyed to the substrate,

applying a plurality of pairs of discrete parts including a first discrete part and a second discrete part to the substrate and perpendicular to the placement axis such that the applied second discrete part is spaced a first distance along the placement axis from the applied first discrete part, and adjacent applied pairs of discrete parts being spaced a second distance along the placement axis that is different from the first distance;

selectively adjusting a rotational speed of each transfer puck as the transfer pucks are rotated between a pick-up location located adjacent the web and an application location located adjacent the substrate; and

rotating a pair of transfer pucks including the first transfer puck and the second transfer puck such that the second transfer puck is spaced a first circumferential distance from the first transfer puck at the application location, and adjacent transfer puck pairs being spaced a second circumferential distance at the application location that is less than the first circumferential distance.