Production process and production line of medium-thick edge thin stoma bag bottom disc

Abstract

The present application relates to a kind of medium-thick edge thin ostomy bag bottom disc production process and its production line, stripping paper, edge thin material, medium-thick material is entered into composite roller after composite process, three materials are effectively combined, reach ultrasonic welding station, positioning is carried out by visual positioning system, and melt is welded, after melt, again by punching process, the shape punching is completed, after by machine, the finished product is taken out from production line, and the remaining waste is rolled up.The present application can effectively realize the production of medium-thick edge thin glue disc;Backing material does not need to be stripped or again composite after forming is completed, can completely guarantee the perfect combination of backing and hydrogel, there is no bubble wrinkle and other defects;Middle does not need to go material, integrity is better, the possibility of two materials separation is less;Alignment is accurate, precision is guaranteed by servo motor, much higher than manual alignment precision.

Description

Technical Field

[0001] This invention relates to ostomy bag baseplates, and more particularly to a production process and production line for an ostomy bag baseplate with accurate alignment, better integrity, and a baseplate that is thicker in the middle and thinner at the periphery, and which combines two types of adhesive to effectively bond the baseplate. Background Technology

[0002] Existing production processes for medium-thick and thin-edge materials generally involve using the same material and pressing it together with rollers to create the desired shape. This process cannot achieve the combination of two materials, and it is difficult to achieve performance differences or functional zoning with the same material. Summary of the Invention

[0003] The purpose of this invention is to address the shortcomings of existing production processes that typically use only one material, formed by pressing the shape of the roller surface, which cannot achieve composite materials, make it difficult to achieve performance differences from the same material, and fail to achieve functional zoning. This invention provides a production process and production line for a medium-thick, thin-edge ostomy bag base. The main purpose is to produce an ostomy base that is thick in the middle and thin at the periphery. This base is composed of two materials, with the materials used for the thicker middle section and the thinner periphery material having different properties. The base produced by this method has the characteristics of being thick in the middle and thin at the periphery, and the two adhesives are tightly and effectively bonded together.

[0004] Another objective of this invention is to provide a production line for a medium-thick edge thin ostomy bag base.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A manufacturing process for a medium-thickness, thin-edge ostomy bag baseplate, the manufacturing process comprising the following steps:

[0007] S1: The peeling paper is fed into the lamination process after passing through the correction, buffering and tensioning devices;

[0008] S2: Medium-thick material is fed, and after passing through the correction, buffer, and tensioning devices, it undergoes a half-cutting process. The release material on the surface of the medium-thick hydrocolloid is adsorbed away by vacuum adsorption and then enters the composite roller.

[0009] S3: Thin material is fed, and after correction, buffering, tensioning, embossing, and winding of the upper release paper, it enters the composite roller;

[0010] S4: Composite, materials S1, S2 and S3 enter the composite step at the same time, and the materials S1, S2 and S3 are heated and composited together by a composite roller;

[0011] S5: After S4 is completed, the product undergoes welding, fusion, punching, and scrap collection processes to finally obtain the finished product;

[0012] The thickness of the thin edge material is 0.3-0.5 mm, and the thickness of the medium-thick material is 0.8-1 mm.

[0013] The distance between the composite rollers is less than the sum of the thickness of the medium-thick material and the thickness of the edge-thin material.

[0014] In this invention, the thinner material consists of release material, hydrocolloid and backing film from top to bottom, with a thickness of 0.3-0.5 mm; the medium-thicker material consists of release material, thickened hydrocolloid and PET film from top to bottom, with a thickness of 0.8-1 mm.

[0015] After passing through the correction, buffering, and tensioning devices, the medium-thick material undergoes a half-cutting process. The PET film is a non-torn layer. After the half-cutting is completed, the waste material is collected by the winding device, leaving only the following: Figure 3 The portion shown is where the release material on the surface of the medium-thickness hydrocolloid is adsorbed away by vacuum adsorption and then enters the composite roller;

[0016] After passing through the correction, buffer, and tensioning devices, the release paper enters the composite roller;

[0017] After the thin material undergoes correction, buffering, tensioning, embossing, and upper release paper winding, it enters the composite roller.

[0018] After the three materials enter the composite roller, they undergo a composite process to effectively combine them. The materials then reach the ultrasonic welding station, where they are positioned by a vision positioning system and fused together. After fusion, the shape is punched through a punching process. After passing through a machine, the finished product is taken out of the production line, and the remaining waste material is rolled up.

[0019] Preferably, in step S4, the heating temperature is 40-60℃. In this technical solution, the heating device is for preheating, thereby facilitating subsequent composite processes.

[0020] Preferably, all deviation corrections are accurate to ±1mm.

[0021] Preferably, in step S5, the welding is ultrasonic welding, the welding time is ≤4s, and the ultrasonic welding is driven by a cylinder or a servo motor with a cylinder buffer, with the cylinder pressure between 4Bar and 7Bar.

[0022] A production line for a medium-thickness, thin-edge ostomy bag base plate includes a peeling paper feeding mechanism, a medium-thickness material feeding mechanism, a thin-edge material feeding mechanism, a composite mechanism, an ultrasonic welding mechanism, a punching mechanism, and a waste collection mechanism. The peeling paper feeding mechanism, the medium-thickness material feeding mechanism, and the thin-edge material feeding mechanism are connected by a conveyor belt and enter the composite mechanism. The composited material is then conveyed by the conveyor belt to the ultrasonic welding mechanism, the punching mechanism, and the waste collection mechanism, and the finished product is taken out of the production line.

[0023] In this technical solution, the release paper feeding and thickened hydrocolloid winding are actively unwound, and the motor speed is controlled by a servo motor, which is adjustable within a range of 10 meters / minute; the waste material winding and release paper winding motors are both torque-controlled to ensure constant torque, and the torque value can be adjusted according to the material characteristics; the waste material collection mechanism of the whole machine is actively winding, and the winding speed is automatically controlled in a closed loop according to the torque.

[0024] Preferably, the peeling paper feeding mechanism includes, in sequence, a peeling paper feeding roll, a first buffer device, a deviation correction device, and a second buffer device.

[0025] As a preferred embodiment, the medium-thick material feeding mechanism includes, in sequence, a medium-thick material feeding roll, a correction device, a first buffer device, a half-cutting mechanism, a medium-thick material waste collection mechanism, and a vacuum adsorption mechanism.

[0026] Preferably, the thin material feeding device includes, in sequence, a thin material feeding roll, a correction device, a first buffer device, a embossing roller and a release paper collecting device, and the rollers after passing through the embossing roller are provided with recesses at corresponding positions.

[0027] In this technical solution, the thin edge material is formed into the shape of a medium-thick material before entering the composite roller. This ensures that the PET material surface and the thin edge material are effectively bonded together without gaps after the medium-thick material is added. To achieve this effect, the embossing roller uses the protrusions distributed on the convex roller to extrude equidistantly distributed recessed areas on the surface of the thin hydrocolloid. When it is composited with the medium-thick material, the medium-thick material just fills the recessed areas.

[0028] Preferably, the composite mechanism includes a composite roller and a driven roller. The composite roller has a protrusion in the middle and a recess on the driven roller corresponding to the composite roller. The depth of the recess is less than the thickness of the medium-thickness material.

[0029] In this technical solution, since the material is thicker in the middle and thinner at the edges, in order to ensure that all surfaces are in effective and sufficient contact during the lamination process, the lamination roller is also recessed. The recess depth is 0.7-0.9mm, which is required to be slightly less than the height of the boss. The driven roller is provided with recesses of the same thickness, and the recess depth is slightly lower than the thickness of the medium-thick hydrocolloid to ensure effective lamination. At the same time, the spacing between the recesses and the bosses is consistent with the spacing of the recess and boss forming rollers, and the linear speed is also consistent to ensure that the medium-thick material and the thin-edge material can be accurately aligned and laminated.

[0030] Preferably, the convex roller of the embossing roller is provided with multiple protrusions, the height of which matches the thickness of the medium-thick material; the thickness of the non-convex part of the embossing roller is the same as the thickness of the thin edge material.

[0031] In this technical solution, in order to prevent the thin material from being stretched flat by tension and changing its shape after the embossing process, all rollers that pass through after the embossing process are provided with recesses to ensure that the shape of the recessed area remains good before entering the composite process.

[0032] Compared with the prior art, the present invention has the following beneficial effects:

[0033] 1. Effectively produces medium-thickness, thin-walled plastic discs; 2. Backing material does not need to be peeled off or re-laminated after molding, ensuring a perfect bond between the backing and the hydrocolloid without defects such as bubbles or wrinkles; 3. No material removal is required in the middle, resulting in better overall integrity and a lower possibility of material separation; 4. Accurate alignment, with precision guaranteed by a servo motor, significantly higher than manual alignment. Attached Figure Description

[0034] Figure 1 This is the production line of the present invention.

[0035] Figure 2 This is a cross-sectional view of the embossing roller.

[0036] Figure 3 This is a cross-sectional view of the composite roller.

[0037] In the diagram, 1. Release paper feeding roll; 2. First buffer device; 3. Correction device; 4. Second buffer device; 5. Medium-thick material feeding roll; 6. Half-cutting mechanism; 7. Medium-thick material waste collection mechanism; 8. Vacuum adsorption mechanism; 9. Thin material feeding roll; 10. Concave-convex forming roller; 11. Composite mechanism; 12. Composite roller; 13. Driven roller; 14. Ultrasonic welding mechanism; 15. Punching mechanism; 16. Whole machine waste collection mechanism; 17. Release paper collection device; 18. Boss; 19. Protrusion; 20. Recess; 21. Vision positioning system. Detailed Implementation

[0038] The specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It should be noted that the embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the invention. In the following description, numerous specific details are set forth to facilitate a thorough understanding of the invention. However, those skilled in the art will understand that these specific details are not essential for carrying out the invention. Furthermore, in some embodiments, well-known structures, materials, or methods are not specifically described to avoid obscuring the invention.

[0039] Throughout this specification, references to "an embodiment," "an example," or "an example" mean that a particular feature, structure, or characteristic described in connection with that embodiment or example is included in at least one embodiment of the invention. Therefore, the phrases "in an embodiment," "in an embodiment," "an example," or "an example" appearing in various places throughout the specification do not necessarily refer to the same embodiment or example. Furthermore, specific features, structures, or characteristics can be combined in one or more embodiments or examples in any suitable combination and / or sub-combination. Moreover, those skilled in the art will understand that the accompanying drawings provided herein are for illustrative purposes, with the same reference numerals indicating the same elements. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0040] See Figure 1 This invention provides a production line for a medium-thickness, thin-edge ostomy bag base, including a paper peeling feeding mechanism, a medium-thickness material feeding mechanism, a thin-edge material feeding mechanism, a composite mechanism 11, an ultrasonic welding mechanism 14, a punching mechanism 15, and a waste collection mechanism 16. The paper peeling feeding mechanism, the medium-thickness material feeding mechanism, and the thin-edge material feeding mechanism are connected by a conveyor belt and enter the composite mechanism simultaneously. The composited material is then conveyed by the conveyor belt to the ultrasonic welding mechanism 14, the punching mechanism 15, and the waste collection mechanism 16, and the finished product is taken out of the production line.

[0041] The peeling paper feeding mechanism includes, in sequence, a peeling paper feeding roll 1, a first buffer device 2, a correction device 3, and a second buffer device 4, all of which are connected by a conveyor belt.

[0042] The medium-thick material feeding mechanism includes, in sequence, a medium-thick material feeding roll 5, a deviation correction device 3, a first buffer device 2, a half-cutting mechanism 6, a medium-thick material waste collection mechanism 7, and a vacuum adsorption mechanism 8, all of which are connected by a conveyor belt.

[0043] See Figure 1 The thin material feeding device includes, in sequence, a thin material feeding roll 9, a correction device 3, a first buffer device 2, a embossing roller 10, and a release paper collecting device 17. The rollers after passing through the embossing roller 10 are provided with recesses at corresponding positions and are connected by a conveyor belt. The convex roller of the embossing roller 10 is provided with multiple protrusions 18, the height of which matches the thickness of the medium-thick material. The thickness of the non-convex part of the embossing roller 10 is the same as the thickness of the thin material.

[0044] See Figure 3 The composite mechanism 11 includes a composite roller 12 and a driven roller 13. The composite roller 12 has a protrusion 19 in the middle and a recess 20 corresponding to the composite roller 12 on the driven roller 13. The depth of the recess 20 is less than the thickness of the medium-thickness material. Example

[0045] The present invention also provides a manufacturing process for a medium-thick-edge thin ostomy bag base, the manufacturing process comprising the following steps:

[0046] S1: The peeling paper is fed into the lamination process after passing through the correction, buffering and tensioning devices;

[0047] S2: Medium-thick material is fed, and after passing through the correction, buffer, and tensioning devices, it undergoes a half-cutting process. The release material on the surface of the medium-thick hydrocolloid is adsorbed away by vacuum adsorption and then enters the composite roller.

[0048] S3: Thin material is fed, and after correction, buffering, tensioning, embossing, and winding of the upper release paper, it enters the composite roller;

[0049] S4: Composite, materials S1, S2 and S3 enter the composite step at the same time. The composite roller heats and combines the materials S1, S2 and S3 together at a temperature of 40℃.

[0050] S5: After S4 is completed, the material arrives at the ultrasonic welding mechanism, where it is positioned using a vision positioning system (a system commonly used in existing processes) and then welded. After welding, the material is punched to complete the shape, and the remaining waste is rolled up. The finished product is then removed from the production line by machinery, and finally the finished product is obtained. The welding is ultrasonic welding, with a welding time of 1 second. The ultrasonic welding is driven by a servo motor with a cylinder buffer, and the cylinder pressure is 4 Bar.

[0051] The thinnest materials, from top to bottom, consist of release material, hydrocolloid, and backing film, with a thickness of 0.3mm; the medium-thickness materials, from top to bottom, consist of release material, thickened hydrocolloid, and PET film, with a thickness of 0.8mm.

[0052] The distance between the composite rollers is less than the sum of the thickness of the medium-thick material and the thickness of the edge-thin material.

[0053] All correction offsets are accurate to ±1mm. Example

[0054] This invention also provides a manufacturing process for a medium-thickness, thin-edge ostomy bag base, the manufacturing process comprising the following steps:

[0055] S1: The peeling paper is fed into the lamination process after passing through the correction, buffering and tensioning devices;

[0056] S2: Medium-thick material is fed, and after passing through the correction, buffer, and tensioning devices, it undergoes a half-cutting process. The release material on the surface of the medium-thick hydrocolloid is adsorbed away by vacuum adsorption and then enters the composite roller.

[0057] S3: Thin material is fed, and after correction, buffering, tensioning, embossing, and winding of the upper release paper, it enters the composite roller;

[0058] S4: Composite, materials S1, S2 and S3 enter the composite step at the same time, and the materials S1, S2 and S3 are heated and composited together by a composite roller at a temperature of 50°C.

[0059] S5: After S4 is completed, the material arrives at the ultrasonic welding mechanism, where it is positioned by a vision positioning system and then welded. After welding, the material is punched through a punching process to complete the outer shape punching. The remaining waste material is then rolled up and mechanically removed from the production line to obtain the finished product. The welding is ultrasonic welding, with a welding time of 5 seconds. The ultrasonic welding is driven by a servo motor with a cylinder buffer, and the cylinder pressure is 8 Bar.

[0060] The thinnest materials, from top to bottom, consist of release material, hydrocolloid, and backing film, with a thickness of 0.7mm; the medium-thickness materials, from top to bottom, consist of release material, thickened hydrocolloid, and PET film, with a thickness of 0.9mm.

[0061] The distance between the composite rollers is less than the sum of the thickness of the medium-thick material and the thickness of the edge-thin material.

[0062] All correction offsets are accurate to ±1mm. Example

[0063] This invention also provides a manufacturing process for a medium-thickness, thin-edge ostomy bag base, the manufacturing process comprising the following steps:

[0064] S1: The peeling paper is fed into the lamination process after passing through the correction, buffering and tensioning devices;

[0065] S2: Medium-thick material is fed, and after passing through the correction, buffer, and tensioning devices, it undergoes a half-cutting process. The release material on the surface of the medium-thick hydrocolloid is adsorbed away by vacuum adsorption and then enters the composite roller.

[0066] S3: Thin material is fed, and after correction, buffering, tensioning, embossing, and winding of the upper release paper, it enters the composite roller;

[0067] S4: Composite, materials S1, S2 and S3 enter the composite step at the same time. The composite roller heats and combines the materials S1, S2 and S3 together at a temperature of 60℃.

[0068] S5: After S4 is completed, the product arrives at the ultrasonic welding mechanism, where it is positioned by a vision positioning system and then welded. After welding, the product is punched through a punching process to complete the outer shape punching. The remaining waste material is rolled up and then mechanically removed from the production line to obtain the finished product. The welding is ultrasonic welding, with a welding time of 4 seconds. The ultrasonic welding is driven by a cylinder with a cylinder pressure of 7 Bar.

[0069] The thinnest materials, from top to bottom, consist of release material, hydrocolloid, and backing film, with a thickness of 0.5mm; the medium-thickness materials, from top to bottom, consist of release material, thickened hydrocolloid, and PET film, with a thickness of 1mm.

[0070] The distance between the composite rollers is less than the sum of the thickness of the medium-thick material and the thickness of the edge-thin material.

[0071] All correction offsets are accurate to ±1mm.

[0072] See Figure 1 The lower left section of medium-thick material undergoes a half-cutting process after passing through correction, buffering, and tensioning devices. The PET film is a non-torn layer. After the half-cutting is completed, the waste material is collected by a winding device, leaving only the material shown below. Figure 3 The portion shown is where the release material on the surface of the medium-thickness hydrocolloid is adsorbed away by vacuum adsorption and then enters the composite roller;

[0073] The upper left stripping paper enters the composite roller after passing through the correction, buffer, and tensioning devices.

[0074] The thin material on the upper right side goes through correction, buffering, tensioning, embossing, and upper release paper winding before entering the composite roller;

[0075] After the three materials enter the composite roller, they undergo a composite process to effectively combine them. The materials then reach the ultrasonic welding station, where they are positioned by a vision positioning system and fused together. After fusion, the shape is punched through a punching process. After passing through a machine, the finished product is taken out of the production line, and the remaining waste material is rolled up.

[0076] Concave-convex forming of thin edge material: Before entering the composite roller, the thin edge material needs to be shaped into the shape of the medium-thick material to ensure that the PET material surface and the thin edge material are effectively combined without gaps after the medium-thick material is added. To achieve this effect, the concave-convex forming roller uses the protrusions distributed on the convex roller to squeeze the surface of the thin hydrocolloid into equally spaced concave areas. When it is composited with the medium-thick material, the medium-thick material just fills into the concave areas.

[0077] Because the material is thicker in the middle and thinner at the edges, the composite roller is also recessed to ensure effective and sufficient contact of all surfaces during lamination. Figure 3As shown, the driven roller has recesses of uniform thickness, and the depth of the recesses is slightly lower than the thickness of the medium-thickness hydrocolloid to ensure effective bonding. At the same time, the spacing between the recesses and the recesses is consistent with the spacing of the recess-forming rollers, and the linear speed is also consistent to ensure that the medium-thickness material and the thin edge material can be accurately aligned and bonded.

[0078] To prevent thin materials from being stretched flat by tension and changing shape after embossing, all rollers that pass through after embossing are provided with recesses to ensure that the shape of the recessed areas remains good before entering the composite process.

[0079] This invention can effectively realize the production of medium-thick edge thin plastic discs; the backing material does not need to be peeled off or re-laminated after molding, which can completely ensure the perfect combination of the backing and hydrocolloid, and there are no defects such as bubbles and wrinkles; no material needs to be removed in the middle, the integrity is better, and the possibility of separation of the two materials is smaller; the alignment is accurate, and the precision is guaranteed by the servo motor, which is much higher than the accuracy of manual alignment.

[0080] Although the invention has been described with reference to several exemplary embodiments, it should be understood that the terminology used is descriptive and exemplary, and not restrictive. Since the invention can be embodied in many forms without departing from the spirit or essence of the invention, it should be understood that the above embodiments are not limited to any of the foregoing details, but should be interpreted broadly within the spirit and scope defined by the appended claims. Therefore, all variations and modifications falling within the scope of the claims or their equivalents should be covered by the appended claims.

Claims

1. A manufacturing process for a medium-thick-edge thin-walled ostomy bag base plate, characterized in that, The production process is achieved through a production line for medium-thickness, thin-edge ostomy bag bases. This production line includes a paper peeling feeding mechanism, a medium-thickness material feeding mechanism, a thin-edge material feeding mechanism, a laminating mechanism, an ultrasonic welding mechanism, a punching mechanism, and a waste collection mechanism. The paper peeling feeding mechanism, the medium-thickness material feeding mechanism, and the thin-edge material feeding mechanism are connected by a conveyor belt and simultaneously enter the laminating mechanism. The laminated material is then conveyed by the conveyor belt to the ultrasonic welding mechanism, the punching mechanism, and the waste collection mechanism, where the finished product is removed from the production line. The composite mechanism includes a composite roller and a driven roller. The composite roller has a protrusion in the middle, and the driven roller has a corresponding recess. The depth of the recess is less than the thickness of the medium-thick material. The thin-edge material feeding mechanism includes, in sequence, a thin-edge material feeding roll, a correction device, a first buffer device, a embossing roller, and a release paper collecting device. The rollers after passing through the embossing roller have recesses at corresponding positions. The convex roller of the embossing roller has multiple protrusions, the height of which matches the thickness of the medium-thick material. The thickness of the non-convex / concave part of the embossing roller is the same as the thickness of the thin-edge material. The production process includes the following steps: S1: The peeling paper is fed into the lamination process after passing through the correction, buffering and tensioning devices; S2: Medium-thick material is fed, and after passing through the correction, buffer, and tensioning devices, it undergoes a half-cutting process. The release material on the surface of the medium-thick hydrocolloid is adsorbed away by vacuum adsorption and then enters the composite roller. S3: Thin material is fed, and after correction, buffering, tensioning, embossing, and winding of the upper release paper, it enters the composite roller; S4: Composite, materials S1, S2 and S3 enter the composite step at the same time, and the materials S1, S2 and S3 are heated and composited together by a composite roller; S5: After S4 is completed, the product undergoes welding, fusion, punching, and scrap collection processes to finally obtain the finished product; The thickness of the thin edge material is 0.3-0.5 mm, and the thickness of the medium-thick material is 0.8-1 mm. The distance between the composite rollers is less than the sum of the thickness of the medium-thick material and the thickness of the edge-thin material.

2. The manufacturing process of a medium-thick-edge thin-walled ostomy bag base plate according to claim 1, characterized in that, In step S4, the heating temperature is 40-60℃.

3. The manufacturing process of a medium-thick-edge thin-walled ostomy bag base plate according to claim 1, characterized in that, All correction offsets are accurate to ±1mm.

4. The manufacturing process of a medium-thick-edge thin-walled ostomy bag base plate according to claim 1, characterized in that, In S5, the welding is ultrasonic welding, the welding time is ≤4s, and the ultrasonic welding is driven by a cylinder or a servo motor with a cylinder buffer, with the cylinder pressure between 4Bar and 7Bar.

5. The manufacturing process of a medium-thick-edge thin-walled ostomy bag base plate according to claim 1, characterized in that, The peeling paper feeding mechanism includes, in sequence, a peeling paper feeding roll, a first buffer device, a correction device, and a second buffer device.

6. The manufacturing process of a medium-thick-edge thin-walled ostomy bag base plate according to claim 1, characterized in that, The medium-thickness material feeding mechanism includes, in sequence, a medium-thickness material feeding roll, a correction device, a first buffer device, a half-cutting mechanism, a medium-thickness material waste collection mechanism, and a vacuum adsorption mechanism.

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