Apparatus and method for forming and applying segments to a moving web using a side shifting disc

Abstract

An apparatus for transferring and applying discrete parts to a substrate comprises a plurality of transfer disc assemblies, a drive assembly and a translation mechanism. The plurality of transfer disc assemblies are adapted to transfer the discrete parts to the substrate, and each transfer disc assembly comprises at least one disc segment. The drive assembly is configured to rotate each transfer disc assembly about a drive axis. The translation mechanism is configured to translate the at least one disc segment in an axial direction as the plurality of transfer disc assemblies rotate about the drive axis to move the discrete parts to a formed configuration and then apply the formed discrete parts to the substrate.

Description

Technical Field

[0001] The field of the present disclosure relates generally to apparatus and methods for applying material sections to a web, and more particularly to apparatus and methods for forming and applying material sections to a moving web using a side shift puck. Background Art

[0002] Absorbent garments (such as adult incontinence garments, infant and children's diapers, swimwear, and training pants) include leg openings and a waist opening, the leg openings having elastic portions surrounding each leg opening, and the waist opening having an elastic portion at least partially surrounding the waist opening. The elastic portions around the leg openings are intended to fit tightly around the legs of the wearer to prevent body exudates from leaking out of the absorbent garment. The leakage resistance and aesthetic appearance of some absorbent garments can be improved by having leg elastics that have curvature and / or displacement (i.e., shaped, non-linear) along their length.

[0003] However, many known techniques for applying leg elastics to a moving web during the process of manufacturing an absorbent garment are generally limited in the amount of displacement (e.g., the amount of amplitude in a curved pattern) that can be achieved. As a result, the leg elastics in most known absorbent garments produced at high line speeds are generally straight or relatively straight. Known techniques that attempt to place leg elastics on a web with any significant amount of displacement (i.e., curvature) at high line speeds have not been satisfactory.

[0004] Therefore, there is a need for an apparatus and method suitable for forming material sections into highly contoured profiles, imparting desired stretch profiles to such sections, and applying such sections to a moving web (e.g., a web moving at high line speeds). Summary of the invention

[0005] In one aspect, an apparatus for transferring and applying discrete parts to a substrate includes a plurality of transfer disc assemblies, a drive assembly, and a translation mechanism. The plurality of transfer disc assemblies are adapted to transfer the discrete parts to the substrate, and each transfer disc assembly includes at least one disc segment. The drive assembly is configured to rotate each transfer disc assembly about a drive axis. The translation mechanism is configured to translate the at least one disc segment in an axial direction as the plurality of transfer disc assemblies rotate about the drive axis to move the discrete parts to a formed configuration and then apply the formed discrete parts to the substrate.

[0006] On the other hand, an apparatus for transferring discrete parts and applying the discrete parts to a substrate includes a plurality of transfer disc assemblies, a drive assembly, and a translation mechanism. The plurality of transfer disc assemblies are suitable for transferring the plurality of discrete parts to the substrate, and each transfer disc assembly includes a first disc segment and a second disc segment. The drive assembly is configured to rotate each transfer disc assembly around a drive axis. The translation mechanism is configured to translate at least one of the first disc segment and the second disc segment in an axial direction when the plurality of transfer disc assemblies rotate around the drive axis to mold the discrete parts and then apply the molded discrete parts to the substrate.

[0007] On the other hand, a method for applying discrete parts to a substrate includes feeding a plurality of discrete parts toward a plurality of transfer disc assemblies rotatably connected to a drive assembly. Each transfer disc assembly includes at least one disc segment. The method also includes receiving a discrete part of the plurality of discrete parts onto each transfer disc assembly in the transfer disc assembly. The method also includes rotating each transfer disc assembly so that each transfer disc assembly transfers each discrete part to the substrate. The method also includes simultaneously translating the at least one disc segment in an axial direction to shape the discrete parts of the plurality of discrete parts. The method also includes applying the discrete parts of the plurality of discrete parts to the substrate so that the applied discrete parts of the plurality of discrete parts have a molded configuration. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is a front view of one suitable embodiment of an absorbent article having a front waist region and a rear waist region joined together by a fastening assembly such that the article is in a pant-like configuration.

[0009] Figure 2 yes Figure 1 Plan view of an absorbent article in a longitudinally stretched and laid flat condition showing the surface of the article facing the wearer during wear.

[0010] Figure 3 Shown for manufacturing Figure 1 and Figure 2 One suitable embodiment of a process for manufacturing an absorbent article is shown.

[0011] Figure 4 Shows Figure 3 A perspective view of the manufacturing process is shown.

[0012] Figure 5 Shows Figure 3 Side perspective view of the manufacturing process shown.

[0013] Fig. 6A yes Figures 3 to 5 A top view of the transfer disc assembly in a first position showing the manufacturing process.

[0014] Figure 6B is a top view of the transfer disc assembly shown in FIG. 6 moved to a second position.

[0015] Figure 7 yes Fig. 6A and Figure 6B A side view of the transfer disc assembly shown in FIG.

[0016] Figure 8 yes Figures 3 to 5 A perspective view of the barrel cam of the translation mechanism showing the manufacturing process.

[0017] Fig. 9 yes Figures 3 to 5 A side cross-sectional view of the drive ring assembly and cam plate assembly showing the manufacturing process.

[0018] Fig.10 yes Figures 3 to 5 A side cross-sectional view of the drive ring assembly, cam plate assembly and transfer section showing the manufacturing process.

[0019] Fig.11A yes Figure 5 A schematic diagram of a portion of a barrel cam follower and connecting rod assembly is shown.

[0020] Fig. 11B yes Fig.11A Schematic diagram of the portion of the barrel cam follower and connecting rod assembly shown in FIG. 1 moving to a second position.

[0021] Fig.12 It is arranged in the first transfer disc assembly arrangement Figures 3 to 5 Schematic diagram of the transfer disc assembly shown.

[0022] Fig.13 yes Fig.12 A schematic diagram of a transfer disc assembly is shown, including leg hoops positioned on the transfer disc assembly.

[0023] Fig.14 yes Fig.13 A schematic diagram of a transfer disc assembly is shown wherein a first disc segment is translated from a first position to a second position.

[0024] Fig.15 yes Fig.13 A schematic diagram of a transfer disc assembly is shown wherein a first disc segment and a second disc segment are translated from a first position to a second position.

[0025] Fig.16 yes Fig.13 A schematic diagram of a transfer disc assembly is shown wherein a first disc segment, a second disc segment, and a third disc segment are translated from a first position to a second position.

[0026] Fig.17 It is arranged in the second transfer disc assembly arrangement Figures 3 to 5 Schematic diagram of the transfer disc assembly shown.

[0027] Fig.18 yes Fig.17 A schematic diagram of a transfer disc assembly is shown wherein a first disc segment is translated from a first position to a second position.

[0028] Fig.19A yes Fig. 6A and Figure 6B A schematic diagram of another embodiment of a follower and connecting rod assembly is shown in a first position.

[0029] Fig.19B yes Fig.19A A schematic diagram of a follower and connecting rod assembly shown moved to a second position.

[0030] Fig. 20 It is arranged in the third transfer disc assembly arrangement Figure 3 and Figure 4 Schematic diagram of the transfer disc assembly shown.

[0031] Fig.21 yes Fig. 20 A schematic diagram of a transfer disc assembly is shown, including leg hoops positioned on the transfer disc assembly.

[0032] Fig. 22 yes Fig. 20 A schematic diagram of a transfer disc assembly is shown wherein a first disc segment is translated from a first position to a second position.

[0033] Fig.23A yes Figure 3 Schematic diagram of the linear servo mechanism and rack-and-pinion system showing the manufacturing process.

[0034] Fig. 23B yes Fig.23A Another schematic diagram of the linear servo mechanism and rack-and-pinion system showing the manufacturing process.

[0035] Fig.24A yes Figure 3 Schematic diagram of the rib cam showing the manufacturing process.

[0036] Fig. 24B yes Fig.24A Another schematic diagram of a rib cam showing the manufacturing process.

[0037] Corresponding reference numerals indicate corresponding parts throughout the drawings. DETAILED DESCRIPTION

[0038] Now referring to the drawings, in particular Figure 1 and Figure 2 One suitable embodiment of an absorbent article or substrate is shown in the form of a children's diaper and is generally indicated by the reference numeral 20. Although the present disclosure will be described in the context of a diaper 20, it should be understood that various aspects of the present disclosure are also applicable to other absorbent articles, such as training pants, adult incontinence garments, diapers, swim diapers, feminine care products, and the like.

[0039] In one suitable embodiment, the diaper 20 is a disposable absorbent article. As used herein, the term "disposable absorbent article" refers to an article that absorbs and contains body exudates and is intended to be discarded after a limited period of use. The article is not intended to be washed or otherwise restored for reuse. The article can be placed against or in close proximity to the wearer's body to absorb and contain various exudates discharged from the body. It should be understood that in other suitable embodiments, the diaper 20 (or more broadly, "absorbent article") can be reused. That is, without departing from some aspects of the present disclosure, the absorbent article can be intended for a variety of uses.

[0040] like Figure 1 and Figure 2 Shown, diaper 20 has front waist region 22, back waist region 24 and crotch area 26, and this crotch area is longitudinally arranged between front waist region and back waist region and connects front waist region and back waist region to each other.Diaper 20 also has a pair of side edges 28 opposite to each other laterally and a pair of waist edges opposite to each other longitudinally, and they are respectively designated as front waist edge 30 and back waist edge 32.In the embodiment illustrated, side edges 28 are arched, so that diaper 20 has a shape that fits the body more.Front waist region 22 is adjacent to front waist edge 30, and back waist region 24 is adjacent to back waist edge 32.

[0041] like Figure 2 As shown, the diaper 20 defines a longitudinal direction 34 and a transverse direction 36 perpendicular to the longitudinal direction. The diaper 20 includes a body-facing side 38 (i.e., the side of the diaper 20 facing the wearer's body when worn) and a garment-facing side 40 (i.e., the side of the diaper 20 facing away from the wearer's body when worn). The diaper 20 also includes a liquid-impermeable backsheet 42, a topsheet 44, and an absorbent assembly disposed between the backsheet and the topsheet, the absorbent assembly generally indicated at 46. The absorbent assembly 46 is shown to extend longitudinally from the front waist region 22 through the crotch region 26 to the rear waist region 24. As shown in FIG. Figure 2 As shown, backsheet 42, topsheet 44 and absorbent assembly 46 are arranged in a superimposed relationship by a suitable method, including but not limited to adhesive, ultrasonic bonding, pressure bonding, thermal bonding, and their combination. Absorbent assembly 46 also includes a pair of anti-leakage wings 48 for suppressing the lateral flow of body discharges.

[0042] Suitably, backsheet 42 prevents waste from wetting articles such as sheets and clothes, as well as wearers and caregivers. Backsheet can comprise a variety of suitable materials, including, for example, but not limited to, substantially liquid-impermeable materials. Backsheet 42 can be a single layer of liquid-impermeable material, or can comprise a multi-layer laminated structure, wherein at least one layer is liquid-impermeable. Backsheet 42 can also comprise liquid-permeable materials.

[0043] The backsheet 42 may also be stretchable, and more suitably elastic. Specifically, the backsheet 42 may be stretchable, and more suitably elastic, in at least the transverse or circumferential direction 36 of the diaper 20. The backsheet 42 may also be stretchable, and more suitably elastic, in both the transverse direction 34 and the longitudinal direction 36.

[0044] Top sheet 44 is suitably compliant, soft and non-irritating to the wearer's skin. Top sheet 44 can also fully penetrate liquid, so that liquid body discharges easily penetrate its thickness to reach absorbent assembly 46. Top sheet 44 can comprise various suitable materials, including for example but not limited to porous foam, reticulated foam, open-cell plastic film, weaving and nonwoven web and their combination. Top sheet 44 can also be stretchable, and more suitably, it can be elastomeric.

[0045] The absorbent assembly 46 is suitably compressible, conformable, non-irritating to the wearer's skin, and capable of absorbing and retaining liquids and certain body wastes. For example, the absorbent assembly 46 may include cellulosic fibers (e.g., wood pulp fibers), other natural fibers, synthetic fibers, woven or nonwoven sheets, scrim netting or other stabilizing structures, superabsorbent materials, binder materials, surfactants, selected hydrophobic materials, pigments, lotions, odor control agents, etc., and combinations thereof.

[0046] The absorbent assembly 46 is stretchable so as not to inhibit the stretchability of other components to which the absorbent structure may be attached, such as the backsheet 42 and the topsheet 44. After being formed or cut into the desired shape, the absorbent assembly 46 may be wrapped or packaged by a suitable wrapper (not shown) that helps maintain the integrity and shape of the absorbent structure.

[0047] The absorbent assembly 46 may also include a surge management layer (not shown) located adjacent the absorbent assembly 46 (e.g., between the absorbent assembly 46 and the topsheet 44) to reduce the rate of and diffuse surges or bursts of liquid that may be rapidly introduced into the absorbent assembly 46 of the diaper 20 by the wearer. Examples of suitable surge management layers are described in U.S. Pat. No. 5,486,166, issued Jan. 23, 1996 to Bishop et al., U.S. Pat. No. 5,490,846, issued Feb. 13, 1996 to Ellis et al., and U.S. Pat. No. 5,820,973, issued Oct. 13, 1998 to Dodge, II et al., the disclosures of which are hereby incorporated by reference.

[0048] like Figure 1 As shown, the front waist region 22 of the diaper 20 can be selectively joined to the rear waist region 24 via a pair of refastenable side seams 50 to define a fastened or wearing configuration of the diaper having a waist opening indicated at 52 and two leg openings indicated at 54. The illustrated refastening seam 50 is defined by a first fastening member 56 (e.g., a loop-type fastener) that can be selectively engaged with a second fastening member 58 (e.g., a hook-type fastener). The fastening components 56, 58 may include any suitable complementary refastenable fasteners, including, for example and without limitation, hook and loop fasteners, other types of mechanical fasteners, adhesive fasteners, cohesive fasteners, and combinations thereof. In some suitable embodiments, the fastening components 56, 58 may be pre-fastened during the manufacturing process of the diaper 20 so that the diaper 20 is provided to the user in a fastened configuration. Although Figure 1 The front region 22 and the back region 24 are shown joined together via a refastenable seam 50, but it should be understood that the front region and the back region may be joined together via a non-refastenable bonded seam (e.g., by adhesive bonding, ultrasonic bonding, pressure bonding, heat bonding).

[0049] Still reference Figure 1 and Figure 2 , the illustrated diaper 20 also includes front and rear waist elastic members 60 that are configured to form a pad around the waist opening 52. The waist elastic member 60 may be formed of any suitable elastic material, including but not limited to, for example, sheets, ropes, or strips of natural rubber, synthetic rubber, or thermoplastic elastomeric polymers. Other suitable elastic materials that may form the waist elastic member 60, as well as suitable methods of incorporating the waist elastic member into the absorbent article, are described in U.S. Patent No. 9,820,889 filed on October 31, 2013 by Sina et al. and U.S. Patent No. 9,265,669 filed on October 31, 2013 by Bennett et al., the disclosures of which are incorporated herein by reference.

[0050] like Figure 2 As best shown, the illustrated diaper 20 also includes a pair of shaped leg cuffs or discrete portions 62 disposed adjacent the side edges 28 of the diaper 20 to form a cushion and reduce or inhibit leakage of body exudates around the leg openings 54. The leg cuffs 62 may be formed from a variety of suitable elastic materials, including, for example, but not limited to, sheets, cords, or bands of natural rubber, synthetic rubber, or thermoplastic elastomeric polymers. The illustrated leg cuffs 62 include at least one elastic element (e.g., an elastic cord) attached to the top sheet 44. Suitably, the leg cuffs 62 may be cut and formed from a continuous strip of elastic material and applied to the diaper 20 as discrete portions using the apparatus and methods described in more detail herein.

[0051] Specific examples of suitable elastic materials for the leg cuffs 62 include, but are not limited to, those sold under the trade names Dry-spun coalesced multifilament spandex elastomeric thread sold and available from Invista, Wichita, Kansas, USA; vertical filament laminate (VFL) materials, examples of which are described in U.S. Pat. No. 6,916,750 to Thomas et al., which is hereby incorporated by reference; elastic nonwoven composites having an apertured elastic film laminated to one or more nonwoven web materials, described in U.S. Pat. Nos. 7,803,244, issued Sept. 28, 2010 to Siqueira et al. and 8,361,913, issued Jan. 29, 2013 to Siqueira et al. Examples of such apertured elastic films are described in U.S. Pat. Nos. 5,385,775, issued January 31, 1995 to Wright, 6,057,024, issued May 2, 2000 to Mleziva et al., and 6,969,441, issued November 29, 2005 to Welch et al., all of which are hereby incorporated by reference; and other elastic laminates, such as single or double sided spandex laminates, stretch-bonded laminates (SBLs), and continuous filament stretch-bonded laminates (CFSBLs), examples of which are described in U.S. Pat. Nos. 5,385,775, issued January 31, 1995 to Wright, 6,057,024, issued May 2, 2000 to Mleziva et al., and 6,969,441, issued November 29, 2005 to Welch et al., all of which are hereby incorporated by reference.

[0052] In the illustrated embodiment, the leg cuffs 62 are attached to the body-facing side 38 of the topsheet 44. In other suitable embodiments, the leg cuffs 62 may be attached to the garment-facing side 40 of the topsheet 44. In other suitable embodiments, it is contemplated that the leg cuffs 62 may be attached to the body-facing side 38 of the backsheet 42 in addition to or in lieu of attaching the leg cuffs 62 to the topsheet 44. That is, in one suitable embodiment, the leg cuffs 62 may be attached to both the body-facing side 38 and the garment-facing side 40 of the topsheet 44.

[0053] like Figure 2 As shown, the leg cuffs 62 of the illustrated embodiment are shaped, and more particularly curved (i.e., non-linear) to provide a more snug, comfortable liner around the leg openings 54 of the diaper 20. Specifically, the leg cuffs 62 are shaped to provide improved leakage protection and a more attractive aesthetic appearance. More specifically, at least a portion of each leg cuff 62 has a radius of curvature R of less than about 40 inches, more preferably less than about 10 inches, along at least a portion of its length.

[0054] Figure 3 Schematic diagram for making Figure 1 and Figure 2 A portion of one suitable embodiment of process 100 for an absorbent article 20 is shown. Figure 4 Is manufacturing Figure 1 and Figure 2 A perspective view of process 100 of an absorbent article 20 is shown. Figure 5 Is manufacturing Figure 1 and Figure 2 A perspective side view of process 100 of an absorbent article 20 is shown. Figure 3 As shown, at least one supply of web 102 is used to form the leg cuff 62 of the absorbent article 20 and is provided from a suitable supply source (e.g., supply roll 104). Figure 3 As shown, the process 100 includes two supplies of web 102 and two supply rolls 104 to simultaneously apply the leg cuffs 62 to the absorbent article 20. However, the process 100 may include only a single supply of web 102 and a single supply roll 104.

[0055] The process 100 includes at least one applicator 106, a perforator 108, and a web handling device 110. The applicator 106 applies a hot melt adhesive (not shown) to the web 102, and the hot melt adhesive attaches the leg cuffs 62 to the absorbent article 20. The applicator 106 may include, but is not limited to, only a spray, a slot coating, a pull bead, and / or any other suitable type of adhesive applicator.

[0056] The web 102 is fed to a web handling device 110 to assemble at least a portion of the absorbent article 20. Specifically, the handling device 110 receives the web 102 as it travels in a first direction indicated by arrow 112. In this embodiment, the web 102 includes two continuous strips of elastic material 106. In another suitable embodiment that includes only a single supply of web 102 and a single supply roll 104, the web 102 includes a continuous strip of elastic material 106 that is separated into individual discrete leg cuffs 62. In the illustrated embodiment, the perforator 108 at least partially perforates the continuous strip of elastic material 106. More specifically, in this embodiment, the perforator 108 partially perforates the continuous strip of elastic material 106, weakening the continuous strip of elastic material 106, but not separating into individual leg cuffs 62. Instead, as described in more detail below, the handling device 110 separates the continuous strip of elastic material 106 into individual leg cuffs 62. In another suitable embodiment, the web 102 includes leg cuffs 62 separated by preformed perforations or other suitable weakening lines. However, it is contemplated that pre-separated leg cuffs 62 may be fed to the processing device 110. It is also contemplated that the web 102 may be cut into individual leg cuffs 62 after being fed to the processing device 110.

[0057] In one embodiment, the processing device 110 includes a drive assembly 114 and a plurality of transfer segments 118, the drive assembly being configured to rotate about a drive axis 116, the plurality of transfer segments being coupled to the drive assembly and extending outwardly from the drive assembly. The drive assembly 114 includes one or more drive sources, including, for example, servomotors and / or cam boxes, coupled to each transfer segment 118. The drive assembly 114 is configured to rotate each transfer segment 118 about the drive axis 116 between a pick-up position, generally indicated at 120, and an application position, generally indicated at 122.

[0058] like Figure 3 As shown, the transfer section 118 is configured to receive the web 102 including the leg cuffs 62 at the pick-up position 120 and transfer the leg cuffs 62 to the application position 122. In the configuration shown, when the web 102 is transferred by the processing device 110, each leg cuff 62 is separated from the adjacent leg cuff 62 along the perforations (or other weakening lines) formed by the perforator 108. More specifically, and as described in more detail below, each leg cuff 62 is received by one of the transfer sections 118. During rotation by the drive assembly 114, each of the transfer sections 118 of the processing device 110 moves apart, thereby causing the web 102 of the leg cuff 62 to rupture (i.e., separate) around the perforations. Therefore, each of the transfer sections 118 is suitable for carrying the leg cuff 62 of one of the absorbent articles 20.

[0059] In one suitable embodiment, the web handling device 110 is an oscillating cam roller, as disclosed in US Pat. Nos. 5,716,478, 5,759,340, and 6,139,004, all of which are assigned to Kimberly-Clark Worldwide, Inc., and the entire disclosures of all of which are incorporated herein by reference.

[0060] Each of the transfer sections 118 includes a support arm 124 extending radially outward from the drive assembly 114, and a transfer disc assembly 126 coupled to the support arm 124. The transfer disc assembly 126 includes a disc support 125 and at least one disc assembly 127 attached to the disc support. In this embodiment, the transfer disc assembly 126 includes two disc assemblies 127. The support arm 124 includes a first end 128 and an opposite second end 130, the first end being coupled to the drive assembly 114 and the second end being coupled to the disc support 125 of the transfer disc assembly 126. The support arm 124 extends between the first end 128 and the second end 130 along a radial axis 132. In one suitable embodiment, the first end 128 of the support arm 124 is coupled to the drive assembly 114 so that each transfer disc assembly 126 can be independently rotated about the drive axis 116 of the processing device 110 (e.g., Figure 3 and Fig.10 134), and at least one of the plurality of disk segments 138 of each disk assembly 127 is capable of translating in the axial direction (as shown by arrow 134). Fig. 6A 136).

[0061] like Fig. 6A , Figure 6B and Figure 7 As shown, each disk assembly 127 includes a plurality of disk segments 138 that define a leading edge 140, a trailing edge 142, and a platform 144 of the transfer disk assembly 126. The platform 144 extends between the leading edge 140 and the trailing edge 142 and is sized and shaped to receive the leg cuffs 62 from the web 102 and release the leg cuffs 62 to be applied to the absorbent article 20. Specifically, as shown in FIG. Figure 7 As shown, the platform 144 has a curved shape that matches the curved outer profile 146 of the device 110 .

[0062] As described above, before the leg cuff 62 is applied to the absorbent article 20, the disc segments 138 of the disc assembly 127 can be translated in the axial direction 136 to bend the curved end 170 of the leg cuff 62. More specifically, at least one disc segment 138 of each disc assembly 127 can be translated in the axial direction 136 to bend the curved end 170 of the leg cuff 62. Fig. 6A The first position represented by 148 is usually Figure 6B 150 in the figure, moves between a first position where the disc assembly is oriented to receive the leg cuff 62 at the pick-up position 120 and a second position where the disc assembly 127 is oriented to apply the leg cuff 62 to the absorbent article 20 at the application position 122.

[0063] In one suitable embodiment, the web 102 of the leg cuff 62 travels in a first direction 112 at a first speed, and the absorbent article 20 travels in a second direction 152 at a second speed different from the first speed. The drive assembly 114 is adapted to rotate each transfer disk assembly 126 about the drive axis 116 so that when the leg cuff 62 is received by the platform 144 of the disk assembly 127 at the pickup location 120, the surface speed of each disk assembly 127 is approximately equal to the speed of the web 102. In the illustrated embodiment, the drive assembly 114 accelerates each transfer disk assembly 126 so that when the leg cuff 62 is applied to the absorbent article 20 by the disk assembly 127 at the application location 122, the speed of the disk assembly 127 is approximately equal to the speed of the absorbent article 20. In addition, the transfer disk assembly 126 is accelerated to separate the disk assembly 127 so that the web 102 is separated into the leg cuffs 62 along the perforations (or other weakening lines) before the leg cuffs 62 are applied to the absorbent article 20.

[0064] In one embodiment, at least one disk segment 138 of each disk assembly 127 translates along the axial direction 136. A cylindrical or barrel cam 174 causes at least one disk segment 138 of each disk assembly 127 to translate along the axial direction 136 between the pick-up position 120 and the application position 122. In one suitable embodiment, the barrel cam 174 is configured to selectively adjust the translation distance of at least one disk segment 138 of each disk assembly 127 as the at least one disk segment 138 of each disk assembly 127 translates between the pick-up position 120 and the application position 122. More specifically, the barrel cam 174 selectively translates at least one disk segment 138 of each disk assembly 127 from the first position 148 to the second position 150, from the pick-up position 120 to the application position 122, such that the outer edge 131 of each disk segment 138 translates from the first position 133 to the second position 135. The distance between the first position 133 of the first location 148 and the second position 135 of the second location 150 defines a translation distance 154 that the disk segment 138 travels.

[0065] In one suitable embodiment, the apparatus 110 can be used to simultaneously apply a first leg cuff 156 and a second leg cuff 158 to a continuously moving product web that includes at least a portion of an absorbent article 20. In the illustrated embodiment, the translation distance 154 of the first leg cuff 156 and the second leg cuff 158 is the same. In alternative embodiments, the translation distance 154 of the first leg cuff 156 and the second leg cuff 158 is different.

[0066] Fig. 6A is a top view of the transfer disc assembly 126 in the first position 148 of the manufacturing process 100, and Figure 6B Move to the second position 150 Fig. 6A 1. A top view of the transfer disc assembly shown. In the illustrated embodiment, the transfer disc assembly 126 includes a first disc assembly 161 and a second disc assembly 163. The first disc assembly 161 and the second disc assembly 163 each include a base disc segment 160 and a translation disc segment 162, 164. Specifically, the first disc assembly 161 includes a first translation disc segment 162, and the second disc assembly 163 includes a second translation disc segment 164. The barrel cam 174 is configured to Figure 6B The first translating disk segment 162 is translated along the axial direction 136 in a first translation direction indicated by arrow 166 in FIG. Figure 6B The second translating disk segment 164 is translated in a second translation direction, which is opposite to the first direction, indicated by arrow 168 in FIG. The translating disk segments 162, 164 may be disposed on or connected to a linear bearing or the like to ensure precise linear movement. Before attaching the first leg cuff 156 and the second leg cuff 158 to the absorbent article 20, translating the first translating disk segment 162 and the second translating disk segment 164 causes the curved end portions 170 of the first leg cuff 156 and the second leg cuff 158 to bend. Additionally, when the curved end portions 170 are translated along the axial direction 136, the straight end portions 171 of the first leg cuff 156 and the second leg cuff 158 remain in place. That is, only a portion of the first leg cuff 156 and the second leg cuff 158 translates along the axial direction 136, while another portion of the first leg cuff and the second leg cuff remains in place.

[0067] The first disc assembly 161 conveys the first leg cuff 156, and the second disc assembly 163 conveys the second leg cuff 158. The first translating disc segment 162 translates along a first translation direction 166, and the second translating disc segment 164 translates along a second translation direction 168, so that the curved end 170 of the first leg cuff 156 is spaced apart from the curved end 170 of the second leg cuff 158.

[0068] exist Fig. 6A and Figure 6BIn the illustrated embodiment, each of the first translating disk segment 162 and the second translating disk segment 164 is translated such that the curved end 170 of the first leg cuff 156 and the second leg cuff 158 is applied to the absorbent article 20 with a radius of curvature R. In another embodiment, each of the first translating disk segment 162 and the second translating disk segment 164 is translated to a different translation distance 154 such that the curved end 170 of the first leg cuff 156 and the second leg cuff 158 is applied with a different radius of curvature R. More specifically, each of the first translating disk segment 162 and the second translating disk segment 164 is translated to a different translation distance 154 such that the curved end 170 of the first leg cuff 156 is applied with a first radius of curvature R1, and the curved end 170 of the second leg cuff 158 is applied with a second radius of curvature R2 that is different from the first radius of curvature R1. In one suitable embodiment, the second leg cuff 158 is applied with a second radius of curvature R2 that is equal to and opposite to the first radius of curvature R1. By applying the first leg cuff 156 and the second leg cuff 158 in opposite curvature orientations, the apparatus 110 can produce Figure 1 and Figure 2 Absorbent article 20.

[0069] exist Figure 8 In one suitable embodiment shown, a cylindrical or barrel cam 174 is coupled to each disc assembly 127 to translate the corresponding disc segment 138 of each transfer disc assembly 126 along the axial direction 136. The barrel cam 174 includes a radial outer surface 176 and a cam track 178 defined along the radial outer surface. Fig.11A and Fig. 11B As shown, each transfer disc assembly 126 includes a cam arm 180, a cam follower 182 coupled to the cam arm 180, a first cam pivot 181 also coupled to the cam arm 180, a second cam pivot 183, and a cam belt 185 coupled to both the first cam pivot and the second cam pivot. The cam follower 182 is positioned within the cam track 178 and is rotated from the cam track 178 to the cam track 178. Fig.11A The first positioning 187 shown moves to Fig. 11B The cam follower 182 is shown in the second position 189. Specifically, the cam track 178 has a curved shape, and the cam follower 182 follows the curved shape of the cam track. The cam arm 180 is attached to the cam follower 182 and rotates as the cam follower moves between the first position 187 and the second position 189. The cam arm 180 is also attached to the first cam pivot 181 and rotates the first cam pivot. The first cam pivot 181 rotates the cam belt 185, and the cam belt rotates the second cam pivot 183.

[0070] The second cam pivot 183 is coupled to the first translating disk segment 162 and the second translating disk segment 164 and includes a pivot point 184. In one embodiment, the apparatus 110 includes a first translating disk segment 186 associated with the first translating disk segment 162 and a second translating disk segment 188 associated with the second translating disk segment 164. The second cam pivot 183 is coupled to the first translating disk segment 186 and the second translating disk segment 188 such that rotation of the second cam pivot translates the first translating disk segment 162 and the second translating disk segment 164 along the axial direction 136. The cam follower 182 is adapted to engage the cam track 178 to facilitate selective translation of the first translating disk segment 162 and the second translating disk segment 164 along the axial direction 136. More specifically, cam follower 182 rotates cam arm 180, which rotates first cam pivot 181, which rotates cam belt 185, which rotates second cam pivot 183 about pivot point 184, and second cam pivot translates first and second translating segments 186, 188 and first and second translating disc segments 162, 164 as each transfer disc assembly 126 rotates about drive axis 116. Rotation of cam arm 180, through connection with translating segments 186, 188, causes first and second translating segments 186, 188 and first and second translating disc segments 162, 164 to translate along axial direction 136.

[0071] It should be appreciated that many other options exist for converting the rotational motion of the cam arm 180 into translational motion of the disc segments 162, 164. Fig.11A , Fig. 11B The specific mechanism shown should not be considered limiting. For example, process 100 may include other mechanisms for translating disk segments 162 and 164, such as: (1) two linear servo mechanisms (not shown), one attached to each disk segment, each linear servo mechanism translating at least one of the first disk segment and the second disk segment along axial direction 136; (2) a single linear servo mechanism 260 (attached to the disk segment); Fig.23A and Fig. 23B ), the single linear servo actuates the rack-and-pinion system 262 (in Fig.23A and Fig. 23B ), the rack-and-pinion system translates the first and second disc segments along the axial direction 136; (3) two rib cams 270 (in Fig.24A and Fig. 24B ), each disc segment is attached with a rib cam, each rib cam translates the first disc segment and the second disc segment along the axial direction 136; and / or (4) any other mechanism for translating the first disc segment and the second disc segment along the axial direction 136 as described herein.

[0072] Specifically, in Fig.23A and Fig. 23B In the illustrated alternative embodiment, each transfer disc assembly 126 can include a linear servo 260 and a rack-and-pinion system 262 attached to the linear servo for translating the first disc segment and the second disc segment along the axial direction 136. The rack-and-pinion system 262 includes a pinion 264, a first rack 266 attached to the first disc segment 162 and movably attached to the pinion, and a second rack 268 attached to the second disc segment 164 and movably attached to the pinion. The first rack 266 is also slidably attached to the linear servo 260. Rotation of the transfer segment 118 actuates the linear servo 260, and the linear servo translates the first rack 266 and the first disc segment 162 along the axial direction 136, as described herein. Translation of the first rack 266 also rotates the pinion 264. Rotation of the pinion 264 translates the second rack 268 and the second disc segment 164 along the axial direction 136, as described herein.

[0073] In addition, Fig.24A and Fig. 24B In the illustrated alternative embodiment, each transfer disc assembly 126 may include two rib cams 270, one attached to each disc segment 162 and 164, each rib cam translating the first disc segment and the second disc segment along the axial direction 136. Each rib cam 270 includes a rib 272 extending from the radial outer surface 176 of the barrel cam 174, a cam follower 274 movably attached to the rib 272, and a cam arm 276 attached to the cam follower 274 and the first disc segment 162 and the second disc segment 164. The cam follower 274 is positioned on the rib 272, and the rib 272 has a curved shape similar to the cam track 178. The cam follower 274 follows the curved shape of the rib 272, and the cam arm 180 translates the first disc segment 162 and the second disc segment 164 as the cam follower and the cam arm follow the curved shape of the rib.

[0074] Fig. 9 and Fig.10 1 is a schematic diagram of a portion of one suitable embodiment of the drive assembly 114. As described above, the apparatus 110 includes a plurality of transfer disc assemblies 126, each transfer disc assembly including at least a first translating disc segment 162 and a second translating disc segment 164. The illustrated drive assembly 114 is configured to rotate each transfer disc assembly 126 about the drive axis 116 and translate the first translating disc segment 162 and the second translating disc segment 164 so that the curved ends 170 of the first leg cuff 156 and the second leg cuff 158 are bent away from each other.

[0075] like Fig. 9 and Fig.10 As shown, the drive assembly 114 includes a drive ring assembly 190 and a cam plate assembly 192. The drive ring assembly 190 and the cam plate assembly 194 are each coupled to each transmission segment 118 to rotate the transmission segment about the drive axis 116. The drive ring assembly 190 includes a drive ring 194. In another embodiment, the drive ring assembly 190 includes a plurality of drive rings (not shown). Fig. 9 As shown, the cam plate assembly 194 includes a cam plate 195 that includes the cam track 178 .

[0076] In one embodiment, a drive ring 194 and cam tracks 178 are coupled to each transfer segment 118. The drive ring 194 rotates each transfer segment 118 about the drive axis 116, and the cam tracks 178 engage the cam followers 182 to translate the disc segments 138 along the axial direction 136 as the transfer segments 118 rotate about the drive axis 116.

[0077] Reference again Figures 3 to 5 In a suitable embodiment, the apparatus 110 includes a vacuum assembly 196 connected to each disc support 125 via a vacuum hose 197 to selectively apply vacuum suction to the platform 144 via the disc support 125, thereby enabling the transfer disc assembly 126 to selectively receive, hold and release the corresponding leg cuff 62. More specifically, as Fig.12 As shown, the disk segment 138 defines a plurality of vacuum holes 198 that are fluidly connected to a vacuum assembly 196. The vacuum assembly 196 selectively applies vacuum suction through a vacuum hose 197, the disk support 125, the platform 144, and the vacuum holes 198.

[0078] The control system 200 is coupled to the drive assembly 114 and the vacuum assembly 196 in an operable control communication manner to operate the drive assembly 114 and the vacuum assembly 196 to transfer the first leg cuff 156 and the second leg cuff 158 from the fiber web 102, and to apply the first leg cuff 156 and the second leg cuff 158 to the absorbent article 20. The control system 200 includes a controller 202 coupled to the drive assembly 114, the vacuum assembly 196, and one or more sensors 204. Each sensor 204 senses various parameters related to the operation of the drive assembly 114, the transfer section 118 and / or the vacuum assembly 196. The sensor 204 may include, but is not limited to, only a positioning sensor, an angular velocity sensor, a proximity sensor, and / or any other sensor that senses various parameters related to the operation of the device 110. The sensor 204 may be any suitable sensor, such as an encoder, a reed switch, a reed sensor, an infrared type sensor, and / or a photo-eye sensor. Alternatively, any sensor capable of operating the device 110 as described herein may be used.

[0079] In one embodiment, the controller 202 includes a processor 206 and a memory device 208. The processor 206 includes any suitable programmable circuit, which may include one or more system and microcontrollers, microprocessors, reduced instruction set circuits (RISC), application specific integrated circuits (ASICs), programmable logic circuits (PLCs), field programmable gate arrays (FPGAs), and any other circuits capable of performing the functions described herein. The above examples are merely exemplary and are therefore not intended to limit the definition and / or meaning of the term "processor" in any way. The memory device 208 includes a computer-readable medium such as, but not limited to, a random access memory (RAM), a flash memory, a hard drive, a solid-state drive, a floppy disk, a flash drive, an optical disk, a digital video disk, and / or any suitable device that enables the processor 206 to store, retrieve, and / or execute instructions and / or data.

[0080] In one embodiment, the control system 200 is configured to control the positioning of a rotary valve or vacuum plug (not shown) to selectively apply vacuum suction to the platform 144 of the transfer disc assembly 126. Specifically, when the disc segment 138 is located in the pick-up position 120 adjacent to the web 102, the rotary valve allows the vacuum assembly 196 to apply vacuum suction through the vacuum holes 198 to attach the web 102 to the platform 144 of the transfer disc assembly 126. When the disc segment 138 is in the application position 122 adjacent to the absorbent article 20, the rotary valve cuts off the fluid communication between the vacuum assembly 196 and the transfer disc assembly 126 to release the corresponding first leg cuff 156 and second leg cuff 158 from the platform 144 of the transfer disc assembly 126, thereby enabling the transfer disc assembly 126 to release the first leg cuff 156 and second leg cuff 158 and thereby apply the first leg cuff 156 and second leg cuff 158 to the absorbent article 20.

[0081] Fig.12 and Fig.13 A first disc assembly 161 of the transfer disc assembly 126 arranged in a first transfer disc assembly arrangement 210 is shown. Figures 14 to 18 The first disc assembly 161 of the transfer disc assembly 126 arranged in the second transfer disc assembly arrangement 254 is shown. Figure 20 to Figure 22 The first disc assembly 161 of the transfer disc assembly 126 is shown arranged in the third transfer disc assembly arrangement 246. Figures 14 to 18As best shown, a first disc assembly 161 of a transfer disc assembly 126 arranged in a second transfer disc assembly arrangement 254 is shown, the first disc assembly 161 including a first disc segment 212, a second disc segment 214, a third disc segment 216 and a fourth disc segment or base disc segment 218, which are arranged so that the transfer disc assembly 126 has a rectangular shape. However, the transfer disc assembly 126 can include any number of disc segments that enable the transfer disc assembly 126 to operate as described herein. Specifically, each disc segment 212-218 has a length 220 and a width 222, and each disc also defines a rectangular shape. In the illustrated embodiment, the width 222 of each disc segment 212-218 is the same, and the length 220 of the first disc segment, the second disc segment and the third disc segment 212-216 is also the same. The length 220 of the fourth disc segment 218 is greater than the length 220 of the first, second, and third disc segments 212-216. More specifically, in this embodiment, the width 222 of each disc segment 212-218 is about 0.25 inches to about 4.0 inches, the length 220 of the fourth disc segment 218 is about 1.0 inches to about 6.0 inches, and the length 220 of the first, second, and third disc segments 212-216 is about 0.25 inches to about 4.0 inches. The radius of curvature R of the first leg cuff 156 and the second leg cuff 158 is at least partially determined by the length 110 of the disc segments 212-218.

[0082] In addition, each disk segment 212-218 has a first side edge 224, a second side edge 226, a disk leading edge 228, and a disk trailing edge 230. Figures 12 to 16 As shown, the disc segments 212-218 are linearly arranged so that the first disc segment 212 is slidably positioned beside the second disc segment 214, the second disc segment 214 is slidably positioned beside the third disc segment 216, and the third disc segment 216 is slidably positioned beside the fourth disc segment 218. Specifically, the disc trailing edge 230 of the first disc segment 212 is positioned beside the disc leading edge 228 of the second disc segment 214, the disc trailing edge 230 of the second disc segment 214 is positioned beside the disc leading edge 228 of the third disc segment 216, and the disc trailing edge 230 of the third disc segment 216 is positioned beside the disc leading edge 228 of the fourth disc segment 218.

[0083] The disc segments 212-218 each include a joint assembly (not shown) that allows the disc segments to slide or translate along the axial direction 136 without separating from each other. For example, the joint assembly may include a tongue and groove assembly that enables the disc segments 212-218 to slide or translate along the axial direction 136 without separating from each other. Specifically, the disc leading edge 228 of the second, third, and fourth disc segments 214-218 may each include a ridge (not shown), and the disc trailing edge 230 of the first, second, and third disc segments 212-216 may each include a groove or slit (not shown) having a shape and size corresponding to the shape and size of the ridge of the first, second, and third disc segments. The ridges of the second, third, and fourth disk segments 214-218 are positioned within the grooves of the first, second, and third disk segments 212-216 and maintain the positioning of the disk segments 212-218 relative to each other in the circumferential direction 232 as the disk segments slide or translate in the axial direction 136. In an alternative embodiment, the disk segments 212-218 may include a joint assembly that enables the transfer disk assembly 126 to operate as described herein.

[0084] exist Fig.12 and Fig.13 In the illustrated alternative embodiment, the first transfer disc assembly arrangement 210 includes only the first disc segment 212, and the second disc segment, the third disc segment, and the fourth disc segment 214-218 are combined into a fifth disc 256. In the illustrated embodiment, the length 220 of the fifth disc 256 is equal to the combined length 220 of the second disc segment, the third disc segment, and the fourth disc segment 214-218. As described below, the first disc segment 212 and the fifth disc segment 256 are connected to each other in a manner similar to that of the first disc segment 212 and the fifth disc segment 256. Figures 12 to 16 The transfer puck assembly 126 shown operates in a consistent manner.

[0085] As described above, the disc segments 212-218 each define a vacuum hole 198 that is fluidly connected to the vacuum assembly 196, and the vacuum assembly 196 selectively applies vacuum suction through the vacuum holes 198 to retain the leg cuffs 62 on the transfer disc assembly 126. The vacuum holes 198 each define a vacuum hole diameter 234, and are arranged in rows 236 and columns 238. In the second transfer disc assembly arrangement 254, each disc segment 212-218 includes five columns 238 of vacuum holes 198, the fourth disc segment 218 includes 17 rows 236 of vacuum holes 198, the second disc segment 214 and the third disc segment 216 each include seven rows 236 of vacuum holes 198, and the first disc segment 212 includes six rows 236 of vacuum holes 198. In alternative embodiments, the disk segments 212-218 may each include any number of rows 236 and columns 238 of vacuum holes 198 that enable the transfer disk assembly 126 to operate as described herein. Fig.12 In the illustrated first transfer disc assembly arrangement 210, the first disc segment 212 includes six rows 236 of vacuum holes 198, and the fifth disc 256 includes thirty-one rows 236 of vacuum holes 198. Additionally, in the second transfer disc assembly arrangement 254, the vacuum hole diameter 234 of each of the vacuum holes 198 is the same. In alternative embodiments, the vacuum hole diameter 234 of each of the vacuum holes 198 is different. In the illustrated embodiment, the vacuum hole diameter 234 of each of the vacuum holes 198 is about 0.06 inches to about 0.15 inches. In alternative embodiments, the vacuum hole diameter 234 of each of the vacuum holes 198 can be any size that enables the transfer disc assembly 126 to operate as described herein.

[0086] like Fig.14 and Fig.15 As shown, in the second transfer disc assembly arrangement 254, when the transfer disc assembly 126 is in the first position 148, oriented to receive the leg cuff 62 in the pick-up position 120, the disc segments 212-218 are arranged so that the transfer disc assembly has a rectangular shape. Specifically, in the first position 148, the disc segments 212-218 are arranged so that the first side edges 224 of the disc segments are aligned, and the second side edges 226 of the disc segments are aligned, thereby forming the rectangular shape of the transfer disc assembly 126. In addition, the columns 238 of the vacuum holes 198 of each disc segment 212-218 are aligned in a linear arrangement. Fig.12 In the first transfer disc assembly arrangement 210 shown, the first disc segment 212 is aligned with the fifth disc 256, so that the first transfer disc assembly arrangement has a similar Fig.14 The linear arrangement of transfer disc assemblies 126 is shown as being rectangular in shape.

[0087] like Fig.16, Fig.17 and Fig.18 As shown, in the second transfer disk assembly arrangement 254, when the transfer disk assembly 126 is in the second position 150, oriented to apply the leg cuff 62 to the absorbent article 20 at the application position 122, before applying the leg cuff 62 to the absorbent article 20, one or more of the first disk segment, the second disk segment, and the third disk segment 212-216 translate in the axial direction 136 to bend the leg cuff 62. Fig.14 In the illustrated embodiment, only the first disk segment 212 translates in the axial direction 136. Fig.15 and Fig.16 In the illustrated embodiment, the first and second disk segments 212 and 214 and the first, second, and third disk segments 212 - 216 , respectively, translate in the axial direction 136 .

[0088] Similarly, if Fig.12 and Fig.13 The first transfer disc assembly arrangement 210 is shown, with the transfer disc assembly 126 in the second position 150, oriented to apply the leg cuff 62 to the absorbent article 20 at the application position 122, and the first disc segment 212 translates in the axial direction 136 relative to the fifth disc 256 to bend the leg cuff 62 before applying the leg cuff 62 to the absorbent article 20.

[0089] Specifically, in Fig.14 In the illustrated embodiment, only the first disk segment 212 is translated a first translation distance 240 in the axial direction 136 to bend the leg cuff 62 prior to applying the leg cuff 62 to the absorbent article 20. In the illustrated embodiment, the first translation distance 240 is from about 0.5 inches to about 2.0 inches. In alternative embodiments, the first translation distance 240 can be any distance that enables the transfer disk assembly 126 to operate as described herein.

[0090] exist Fig.16 In the illustrated embodiment, prior to applying the leg cuff 62 to the absorbent article 20, the first disk segment 212 is translated a first translation distance 240 in the axial direction 136 and the second disk segment 214 is translated a second translation distance 242 to bend the leg cuff 62. In the illustrated embodiment, the first translation distance 240 is from about 0.5 inches to about 2.0 inches and the second translation distance 242 is from about 0.25 inches to about 1.0 inches. Specifically, the first translation distance 240 is greater than the second translation distance 242. In alternative embodiments, the first translation distance 240 and the second translation distance 242 can be any distances that enable the transfer disk assembly 126 to operate as described herein.

[0091] exist Fig.18In the illustrated embodiment, prior to applying the leg cuff 62 to the absorbent article 20, the first disk segment 212 is translated a first translation distance 240, the second disk segment 214 is translated a second translation distance 242, and the third disk segment 216 is translated a third translation distance 244 in the axial direction 136 to bend the leg cuff 62. In the illustrated embodiment, the first translation distance 240 is from about 0.75 inches to about 3.0 inches, the second translation distance 242 is from about 0.5 inches to about 2.0 inches, and the third translation distance 244 is from about 0.25 inches to about 1.0 inches. Specifically, the first translation distance 240 is greater than the second translation distance 242 and the third translation distance 244, and the second translation distance 242 is greater than the third translation distance 244. In alternative embodiments, the first translation distance, the second translation distance, and the third translation distances 240-244 can be any distances that enable the transfer disk assembly 126 to operate as described herein.

[0092] As described above, the barrel cam 174 is coupled to each transfer disc assembly 126 to translate at least one of the first disc segment, the second disc segment, and the third disc segment 212-216 of each transfer disc assembly 126 along the axial direction 136. More specifically, as Fig.19A and Fig.19B As shown, the apparatus 110 includes a plurality of first translation segments 186 associated with the first, second, and third disk segments 212-216 of the first translation disk segment 162, and a plurality of second translation segments 188 associated with the first, second, and third disk segments 212-216 of the second translation disk segment 164. When each transfer disk assembly 126 rotates about the drive axis 116, the cam follower 182 rotates the cam arm 180 about the pivot point 184. The cam arm 180 translates the first and second translation segments 186, 188, and at least one of the second, third, and fourth disk segments 214-218 along the axial direction 136.

[0093] like Figure 20 to Figure 22As best shown, one side of the transfer disc assembly 126 is shown arranged in a third transfer disc assembly arrangement 246, the transfer disc assembly 126 including a first disc segment 212, a second disc segment 214, and a fourth disc segment 218. Additionally, while the first disc segment 212 and the fourth disc segment 218 each include vacuum holes 198 arranged in rows 236 and columns 238, similar to the first disc segment 212 and the fourth disc segment 218 of the second transfer disc assembly arrangement 254, the second disc segment 214 includes vacuum holes 198 arranged in rows 236 and curved columns 248. More specifically, in third transfer disk assembly arrangement 246 , second disk segment 214 includes seven rows 236 of vacuum apertures 198 and three curved columns 248 of vacuum apertures 198 that are at least partially misaligned with columns 238 of vacuum apertures 198 of first and fourth disk segments 212 , 218 .

[0094] like Fig. 20 and Fig.21 As shown, in the third transfer disk assembly arrangement 246, when the transfer disk assembly 126 is in the first position 148, oriented to receive the leg cuff 62 in the pick-up position 120, the disk segments 212, 214, and 218 are arranged in a linear arrangement similar to the linear arrangement of the second transfer disk assembly arrangement 254. Specifically, the columns 238 of vacuum apertures 198 of the first disk segment 212 and the fourth disk segment 218 are aligned in a linear arrangement, but the curvature of the curved columns 248 causes the curved columns 248 of vacuum apertures 198 of the second disk segment 214 to be at least partially misaligned with the columns 238 of vacuum apertures 198 of the first disk segment 212 and the fourth disk segment 218.

[0095] like Fig.21As shown, in the third transfer disk assembly arrangement 246, when the transfer disk assembly 126 is in the second position 150, oriented to apply the leg cuff 62 to the absorbent article 20 at the application position 122, only the first disk segment 212 is translated in the axial direction 136 to bend the leg cuff 62 before the leg cuff 62 is applied to the absorbent article 20. Specifically, only the first disk segment 212 is translated a fourth translation distance 252, thereby causing the portion 250 of the leg cuff 62 covering the second disk segment 214 to also translate in the axial direction 136. The translation of the portion 250 of the leg cuff 62 covering the second disk segment 214 causes the leg cuff 62 to assume a curved shape corresponding to the curvature of the curved column 248 of the second disk segment 214. In the illustrated embodiment, the fourth translation distance 252 is about 0.5 inches to about 2.0 inches. In alternative embodiments, the fourth translation distance 252 can be any distance that enables the transfer disc assembly 126 to operate as described herein. The curved hole pattern of the curved row 248 of the second disc segment 214 reduces friction and enables the radius of curvature R of the first leg cuff 156 and the second leg cuff 158 to be controlled. Therefore, the curvature of the curved row 248 of the third transfer disc assembly arrangement 246 enables the transfer disc assembly 126 to control the radius of curvature R of the first leg cuff 156 and the second leg cuff 158 and reduce friction between the first leg cuff 156 and the second leg cuff 158 and the disc segments 212, 214, and 218.

[0096] When introducing elements of the present invention or the preferred embodiments thereof, the articles "a", "an", and "the" are intended to mean that there are one or more of the elements. The terms "comprising", "including", and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements.

[0097] As various changes could be made in the above construction without departing from the scope of the disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

Claims

1. An apparatus for transferring and applying discrete parts to a substrate, the apparatus comprising: a plurality of transfer puck assemblies adapted to transfer the discrete portions to the substrate, each transfer puck assembly comprising at least one puck segment; a drive assembly configured to rotate each transfer disc assembly about a drive axis; a plurality of support arms extending radially outward from the drive assembly, wherein each of the plurality of transfer disc assemblies is coupled to one of the plurality of support arms and radially opposite the drive assembly; a translation mechanism configured to translate the at least one disk segment in an axial direction as the plurality of transfer disk assemblies rotate about the drive axis to move the discrete portion to a forming configuration and then apply the discrete portion to the substrate; as well as A plurality of transfer sections, each of the transfer sections comprising: a transfer disc assembly among the plurality of transfer disc assemblies; an extended cam arm; and A cam follower is adapted to engage the translation mechanism and the cam arm to selectively translate the at least one disk segment in the axial direction.

2. The apparatus of claim 1 , wherein the at least one disc segment is capable of translating between a first position in which the transfer disc assembly is oriented to receive the discrete portion and a second position in which the transfer disc assembly is oriented to apply the discrete portion to the substrate.

3. The apparatus of claim 2, wherein the plurality of transfer disc assemblies include a first transfer disc assembly and a second transfer disc assembly, and the drive assembly is configured to rotate the first transfer disc assembly and the second transfer disc assembly around a drive axis so that the first transfer disc assembly is separated from the second transfer disc assembly, and the discrete portions conveyed on the first transfer disc assembly are separated from the discrete portions conveyed on the second transfer disc assembly, wherein the discrete portions are formed by the supply of the fiber web.

4. The apparatus of claim 3, further comprising a perforator for at least partially perforating the web.

5. The apparatus of claim 3, further comprising an applicator for applying adhesive to the web.

6. The device of claim 3, wherein each of the plurality of transfer segments further comprises a translation segment connected to the cam arm and the at least one disc segment, wherein rotation of the cam arm translates the translation segment, and translation of the translation segment translates the at least one disc segment in the axial direction.

7. The apparatus of claim 3, further comprising a vacuum assembly coupled to the transfer puck assembly, the vacuum assembly configured to selectively apply a vacuum to the transfer puck assembly to facilitate transferring each discrete portion from the web to the substrate.

8. The apparatus of claim 1, wherein each of the plurality of transfer puck assemblies is configured to apply a pair of discrete portions to the substrate.

9. The device of claim 1, wherein the discrete portion is a leg cuff comprising an elastic material.

10. An apparatus for transferring discrete parts and applying the discrete parts to a substrate, the apparatus comprising: a plurality of transfer puck assemblies adapted to transfer the plurality of discrete portions to the substrate, each transfer puck assembly comprising a first puck segment and a second puck segment; a drive assembly configured to rotate each transfer disc assembly about a drive axis; a plurality of support arms extending radially outward from the drive assembly, wherein each of the plurality of transfer disc assemblies is coupled to one of the plurality of support arms and radially opposite the drive assembly; a translation mechanism configured to translate at least one of the first disk segment and the second disk segment in an axial direction as the plurality of transfer disk assemblies rotate about the drive axis to shape the discrete portion and then apply the discrete portion to the substrate; as well as A plurality of transfer sections, each of the transfer sections comprising: a transfer disc assembly among the plurality of transfer disc assemblies; an extended cam arm; and A cam follower is adapted to engage the translation mechanism and the cam arm to selectively translate at least one disk segment in the axial direction.

11. The apparatus of claim 10, wherein the first disk segment translates a first translation distance in the axial direction.

12. The apparatus of claim 10, wherein each transfer disc assembly further comprises a third disc segment, and wherein the first disc segment translates a first translation distance in the axial direction, and the second disc segment translates a second translation distance in the axial direction, the first translation distance being greater than the second translation distance.

13. The apparatus of claim 12, wherein each transfer disc assembly further comprises a fourth disc segment, and wherein the first disc segment translates a first translation distance in the axial direction, the second disc segment translates a second translation distance in the axial direction, and the third disc segment translates a third translation distance in the axial direction, the first translation distance being greater than the second translation distance and the third translation distance, and the second translation distance being greater than the third translation distance.

14. The apparatus of claim 10, wherein each of the first and second disk segments comprises a plurality of vacuum holes, the apparatus further comprising a vacuum assembly in fluid communication with each of the vacuum holes to selectively apply a vacuum.

15. The apparatus of claim 14, wherein the vacuum holes of the first and second disk segments are arranged in a plurality of rows and columns, wherein the columns of vacuum holes of the first and second disk segments are aligned.

16. The apparatus of claim 14, wherein the vacuum holes of the first disk segment and the second disk segment are arranged in a plurality of rows, the vacuum holes of the first disk segment are arranged in a plurality of columns, and at least some of the vacuum holes of the second disk segment are arranged in a plurality of curved columns.

17. A method of applying discrete parts to a substrate using an apparatus according to any preceding claim, comprising: feeding the plurality of discrete portions toward a plurality of transfer disc assemblies rotatably coupled to a drive assembly, each transfer disc assembly including at least one disc segment; receiving a discrete portion of the plurality of discrete portions onto each of the transfer disc assemblies; rotating each transfer puck assembly so that each transfer puck assembly transfers each discrete portion to the substrate; simultaneously translating the at least one disk segment in an axial direction to shape the discrete portions of the plurality of discrete portions; as well as The discrete portion of the plurality of discrete portions is applied to the substrate such that the applied discrete portion of the plurality of discrete portions has a shaped configuration.

18. The method of claim 17, wherein translating the at least one disc segment in an axial direction to form the discrete portions of the plurality of discrete portions comprises translating the at least one disc segment from a first position to a second position, wherein the transfer disc assembly is oriented to receive the discrete portions of the plurality of discrete portions from the web, and wherein the transfer disc assembly is oriented to apply the discrete portions of the plurality of discrete portions to the substrate.

19. The method of claim 17, further comprising: Each transfer puck assembly is accelerated such that a velocity of the transfer puck assembly is approximately equal to a velocity of the substrate when the discrete portion of the plurality of discrete portions is applied to the substrate by the transfer puck assembly at an application location.

Images