Disposable product assembly systems and methods

Abstract

A machine for producing disposable products anticipates when a current run of a product size is coming to an end, and therefore begins loading of material rolls intended for the next product size or code that will be run. An integrated production facility layout automatically orders and stocks raw material based on production plans, and commands a production machine to produce specific products of differing configurations, and automatically loads appropriately sized raw materials into the process.

Description

RELATED APPLICATIONS[0001]This application claims the benefit of co-pending U.S. Provisional Patent Application Ser. No. 62 / 240,622, filed 13 Oct. 2015.BACKGROUND OF THE INVENTION[0002]The invention disclosed herein relates to an apparatus and methods for forming disposable products such as diapers at very high speeds, while automatically scheduling certain aspects of production, including material loading, splicing, reloading. While the description provided relates to diaper manufacturing, the apparatus and method are easily adaptable to other applications.[0003]In particular, the present invention relates to material unwind systems. Turret unwind systems, which automatically splice an expiring roll of material with a waiting roll of material are disclosed, the turret unwind systems provided with a recovery system for recovering end portions of the material carried by the expiring roll, and automatically separating an expiring roll core from the expiring material. Two waste streams...

AI Technical Summary

Benefits of technology

The present patent provides methods and apparatus for improving the efficiency and quality of web processing operations in a high speed, small footprint environment. Specifically, the patent discusses a technique for minimizing waste and improving quality and production in web processing operations by automatically splicing in new material rolls and pulling them through a running machine process. This saves considerable time compared to manually rethreading each material process and results in significantly reduced change-over times. The technique also allows for the pulling in of material widths different than what the current product code being run is setup for, which can result in unacceptable products. However, the temporary disabling or ignoring of machine capabilities is quickly restored prior to starting the next good product run. The patent also discusses the use of turret unwind systems and recovery systems for recovering end portions of material and separating an expiring roll core from the expiring material, creating two waste streams. This simplifies the recycling and downstream handling of the waste.

Problems solved by technology

This saves considerable time compared to loading each unwind manually and then manually rethreading each material process throughout the machine.

When employing the technique described herein, splicing in different width materials and pulling them through a running machine process will not result in the immediate making of acceptable products.

The present method results in intentionally pulling in material widths different than what the current product code being run is setup for, so certain details will result in unacceptable product; for instance, glue applicator patterns may exceed the new material width and therefore glue applicators are turned off for the duration of this material pull through technique.

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