Multi-piece transfer system assembly for use in manufacturing absorbent products

Abstract

A multi-piece transfer system assembly includes a shell having a plurality of cavities formed in an outer surface, each of the plurality of cavities having at least one vacuum hole formed in a bottom surface of the corresponding cavity, the vacuum hole configured for communication with a vacuum system; and a plurality of inserts sized and dimensioned to be received within a corresponding one of the cavities, each of the inserts including at least one tapered hole extending through the insert and configured to align with the vacuum hole in the cavity; wherein the tapered holes are larger at an end adjacent the vacuum hole and are smaller at the opposing end. The shell can be constructed of a plurality of individual shell segments.

Description

MULTI-PIECE TRANSFER SYSTEM ASSEMBLY FOR USE IN MANUFACTURINGABSORBENT PRODUCTSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Patent Application Serial No. 63 / 602,111, filed on November 22, 2023, which is incorporated herein by reference in its entirety.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

[0002] Not applicable.BACKGROUND

[0003] The present disclosure relates to a transfer system, such as a transfer drum, for use in the production of absorbent products. More specifically, the present disclosure relates to systems and methods of manufacturing and using a multi-piece transfer system to enable vacuum transfer of a discrete fluff and / or superabsorbent polymer core without plugging of the vacuum holes.

[0004] In the manufacturing process for disposable absorbent products like diapers, incontinence pads, sanitary towels, panty liners and the like, transfer systems such as drums are used for compressing, shaping, and transporting the absorbent materials. In a typical process, absorbent materials, such as fluff pulp, SAP (Superabsorbent Polymer), and other components, are initially combined to form a continuous mat or discrete absorbent sections on a rotary or screen forming system. These materials are typically in loose or fluffy form and need to be compacted and shaped to form the core of the product.

[0005] As the materials exit the forming system, they are guided towards the transfer system, which is usually a cylindrical drum component with a smooth, non-stick surface, and perforations formed in the surface. The perforations are in communication with a vacuum source, such as a blower or vacuum pump.

[0006] The vacuum pump generates a negative pressure through the perforations on the drum's surface. As the vacuum is applied, the negative pressure generated by the vacuum system effectively suctions and holds the absorbent materials to the drum's surface. This suction force prevents the materials from shifting or being displaced during subsequent processing steps.

[0007] Once the absorbent materials are on the transfer drum, they undergo compression and optional shaping. The rotation of the drum, combined with pressure exerted on the materials, compacts the materials, reducing their volume and increasing their density. This compression helps create a more uniform absorbent core with increased integrity due to fiber entanglement.

[0008] The transfer drum and corresponding vacuum system, therefore, are often important components in the production of absorbent products. While there are significant advantages to the use of transfer drums with vacuum systems in processing fluff pulp and / or SAP, however, these systems can also suffer from a number of disadvantages. For example, because fluff pulp is made from wood fibers, both the fluff pulp itself and fine dust and particles produced when processing the fluff pulp can clog perforations and apertures in the transfer drums, and in vacuum system components, such as hoses, filters, and nozzles. SAP particles likewise can create clogs. This can lead to a decrease in suction power, which is problematic for production, and also necessitates regular cleaning and maintenance, increasing downtime in the production process. If the vacuum system is not designed and operated properly, the system can also contribute to pulp and / or SAP agglomeration, affecting the quality of the absorbent core and potentially leading to uneven distribution of absorbency within the disposable absorbent product.

[0009] The present disclosure addresses these and other issues.SUMMARY

[0010] According to the present disclosure, a multi-piece transfer system assembly includes a shell with cavities formed in the outer surface, and vacuum holes or apertures formed in the cavities. Inserts including tapered holes are sized and dimensioned to be coupled in the cavities, such that the tapered holes align with the vacuum holes in the shell. The tapered holes have a larger opening adjacent the vacuum holes in the shell, and a smaller opening at the outside surface. When connected to a vacuum source, therefore, a higher flow rate of air is enabled by the larger diameter opening adjacent the vacuum holes, while the continuous diameter change leading to the smaller diameter opening adjacent the surface of the shell enables a uniform suction with an even distribution.

[0011] The present disclosure also relates to a method of manufacturing a transfer drum. In the disclosed method, a cylindrical shell is formed with cavities extending along an outer surface of the shell, and with apertures formed in a bottom surface of the cavities. Inserts sized anddimensioned to be received in the cavities are formed in a flat sheet of material, and tapered holes are formed in the bottom of each insert. The inserts can then be coupled to the cavities in the cylindrical shell, with the tapered holes in the inserts aligned with vacuum holes in the cylindrical shell, and the assembled components can be ground to assure that the inserts match the curvature of the cylindrical shell. The outward-facing surfaces of the inserts are then grinded to match the curvature of the cylindrical shell.

[0012] In one aspect, the present disclosure is addressed to a multi-piece transfer system assembly comprising: a shell having a plurality of cavities formed in an outer surface, each of the plurality of cavities having at least one vacuum hole formed in a bottom surface of the corresponding cavity, the vacuum hole configured for communication with a vacuum system; a plurality of inserts sized and dimensioned to be received within a corresponding one of the cavities, each of the inserts including at least one tapered hole extending through the insert and configured to align with the vacuum hole in the cavity; wherein the at least one tapered hole extends from an end adjacent the vacuum hole to an opposing end offset from the vacuum hole, and wherein the at least one tapered hole is larger in diameter at the end adjacent the vacuum hole and are is_smaller at the opposing end.

[0013] The multi-piece transfer system assembly can include at least one mounting hole formed in each cavity, and at least one corresponding mounting hole formed in each insert, the at least one mounting hole formed in each cavity and the at least one corresponding mounting hole formed in each insert can be aligned and configured to receive a fastener to couple the inserts to the cavities in the shell.

[0014] The shell can also include a plurality of holes coupling a vacuum source to the shell.

[0015] The plurality of cavities can include a plurality of vacuum holes formed in a bottom surface of the corresponding cavity.

[0016] Each of the inserts can include a plurality of tapered holes extending through the insert and configured to align with a respective vacuum hole in the corresponding cavity. Each of the inserts can also include a plurality of sets of tapered holes extending through the insert, each set of tapered holes configured to align with a respective vacuum hole in the corresponding cavity. Each of the plurality of inserts can include at least one mounting hole, and each of the plurality of cavities can include a corresponding mounting hole positioned to align with the mounting hole inthe insert. The shell can be cylindrical, and an outer surface of the insert and an outer surface of the shell can be ground to provide a continuous radius of curvature when assembled.

[0017] The plurality of tapered holes can be registered to an embossing pattern on an embossing roll.

[0018] The cavities can be elongate and extend across at least a portion of the shell from a position adjacent a first end face to a position adjacent a second end face.

[0019] The at least one tapered hole can have stepped or parabolic-shaped sides extending between the end adjacent the vacuum hole and the opposing end.

[0020] In another aspect, the disclosure is addressed to a method for manufacturing a multipiece shell transfer system assembly for use in manufacturing absorbent core materials, the method comprising: forming a plurality of cavities in an outer surface of a shell and providing at least one vacuum hole configured for communication with a vacuum system in a bottom surface of the cavity; forming a plurality of inserts sized and dimensioned to be received in the corresponding plurality of cavities from a sheet of material; forming at least one tapered hole through each of the plurality of inserts; and coupling the plurality of inserts to the plurality of cavities, wherein a larger end of the at least one tapered hole is positioned adjacent and aligns with the at least one vacuum hole in each cavity.

[0021] The method can include grinding the inserts to match a curvature of the outer surface of the shell.

[0022] In yet another aspect, the disclosure is addressed to a system for producing absorptive products. The system comprises a mill configured to fiberize a base material; a forming surface coupled to one or more vacuum source to secure the fiberized base material on the forming surface to form a mat; a multi-piece transfer system assembly positioned to transfer the mat off the forming surface, the multi-piece transfer system assembly comprising: a shell having a plurality of cavities formed in an outer surface, each of the plurality of cavities having at least one vacuum hole formed in a bottom surface of the corresponding cavity, the vacuum hole configured for communication with a vacuum system; a plurality of inserts sized and dimensioned to be received within a corresponding one of the cavities, each of the inserts including at least one tapered hole extending through the insert and configured to align with the vacuum hole in the cavity; and a cylindrical compression roll.

[0023] The system can include an embossing unit positioned adjacent the transfer drum, the embossing unit comprising a raised embossing pattern on the outer surface and being configured to impress the embossing pattern on the mat.

[0024] The tapered holes in the inserts can be registered with the raised embossing pattern such that the raised embossing pattern does not align with any of the tapered holes. The raised embossing pattern can be a lattice pattern, and the tapered holes can be arranged to align with the openings in the lattice pattern.

[0025] The tapered holes can be larger in diameter in a surface of each of the plurality of inserts that is configured to be positioned adjacent the vacuum holes in the corresponding plurality of cavities than at an end formed in a surface opposing the end that is configured to be positioned adjacent the vacuum holes. The tapered holes can be larger in diameter in a surface of each of the plurality of inserts that is configured to be positioned adjacent the vacuum source than at an end formed in a surface opposing the end that is configured to be positioned adjacent the vacuum source.

[0026] The inserts can be removably coupled to the cylindrical shell.

[0027] The shell can comprise a plurality of shell segments, each of the shell segments forming a portion of the shell.

[0028] A system according to any of the embodiments of the invention may be used to carry out a method according to any of the embodiments of the invention. A method according to any of the embodiments of the invention may be carried out using a system according to any of the embodiments of the invention.

[0029] These and other advantages and features will be more readily understood from the following detailed description of preferred embodiments of the invention that is provided in connection with the accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The features, aspects and advantages of the disclosure will become apparent when consideration is given to the following detailed description thereof. Such detailed description makes reference to the following drawings.

[0031] FIG. l is a schematic view of a system for manufacturing an absorbent structure.

[0032] FIG. 2 shows an isometric schematic view of a multi-piece transfer assembly.

[0033] FIG. 3 shows a schematic view of the multi-piece transfer assembly of FIG. 2.

[0034] FIG. 4 shows a partial side view of the outside of a multi-piece transfer shell similar to the multi-piece transfer assembly of FIG. 2, and illustrating a variation in the hole design.

[0035] FIG. 5 shows a partial bottom view of the multi-piece transfer shell of FIG. 4.

[0036] FIG. 6 shows a cross-sectional view of the multi-piece transfer shell of FIG. 4.

[0037] FIG. 7 is a partial view illustrating the engagement of a multi-piece transfer assembly and an embossing roll illustrating registration of hole patterns in the shell with an embossing pattern.

[0038] FIG. 8 is a partial view illustrating the engagement of an alternate embodiment of a multi-piece transfer assembly and an alternate embodiment of an embossing roll illustrating registration between hole patterns in the shell with an embossing pattern.

[0039] The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals.DETAILED DESCRIPTION

[0040] As generally described above, the present disclosure relates to a multi-piece transfer assembly and methods for manufacturing a multi-piece vacuum transfer assembly.

[0041] Referring first to FIG. 1, a system 100 for producing absorptive products using a transfer drum 101 is shown. Transfer drum 101 may be integrated within a system 100 that includes an absorbent material supply such as a mill 102 configured to fiberize one or more infeeds of a base material 104 such as wood pulp into a plurality of fibers and / or a particulate feeder 108 configured to feed a particulate material such as SAP. The absorbent material is supplied to a forming surface 110 onto which the absorbent material is arranged to form a mat 112. The forming surface 110 may be provided on a rotary forming drum 122 as shown in FIG. 1 or a flat or planar screen according to alternate embodiments. The forming drum 122 can be coupled to one or more vacuum sources 124 to secure the deposited absorbent material on the forming drum 122, and further control the shape and other parameters of the mat 112. Optionally, one or more scarfing rollers 126 may be provided to help achieve a desired thickness and / or uniformity. The transfer drum 101 is positioned to transfer the mat 112 off the forming surface 110. The mat 112 is debulked as it passes through a gap defined between the transfer drum 101 and a cylindrical compression roll 128, and a transfer drum or debulking shell, such as the transfer assembly 10described below, can be provided on the outer circumference of the transfer drum 101 for use in the debulking process. An embossing pattern may be imparted into the debulked mat 112 by way of an optional embossing roll 130 positioned adjacent the transfer drum 101. Embossing roll 130 may include an outer surface with a raised embossing pattern, and may impart any desired compression pattern within the mat 112, including, as examples, one or more continuous lines or an arrangement of dots, dashes, cross-hatches, a lattice pattern, or any other desired shapes or patterns. Although a transfer drum 101 is described here, a transfer system can also be flat or formed as arcs or in other shapes. The use of the term cylindrical in the description is therefore not intended to be limiting.

[0042] Referring now to FIGS. 2 and 3, the transfer drum 101 can advantageously comprise a multi-piece transfer system assembly 10 that includes a cylindrical shell 11 and inserts 12, which are coupled to the cylindrical shell 11. The transfer system assembly 10, in use, can be coupled to a transfer drum 101 and extend over a vacuum source 124, which provides vacuum through aligned holes in the cylindrical shell 11 and inserts 12. The vacuum source 124 may be stationary or rotating in alternative embodiments. The negative pressure from the vacuum source 124 can be used for handling fluff pulp, SAP, and other additives in manufacturing processes, while minimizing problems with clogging, as described below. Referring specifically to FIG. 2, the cylindrical shell 11 can be a unitary construction, or constructed of individual shell segments, which can be coupled together to form the cylindrical shell 11. Here, three shell segments 11 A, 1 IB, and 11C, are shown. It will be apparent that the cylindrical shell 11 can be divided into any number of segments.

[0043] Referring now to FIG. 4, the cylindrical shell 11 includes a plurality of elongate cavities 17 that are formed in a side-by-side configuration in an outer surface of the shell 11. The cavities 17 extend continuously across the surface of the cylindrical shell 11 from a position adjacent a first circular edge of the cylindrical shell 11 to a position adjacent an opposing second circular edge of the cylindrical shell 11. A lower surface of each of the cavities 17 includes vacuum perforations, apertures, or holes 13, which can be in a central region 20 of each cavity 17, as shown. In the embodiment shown, the central perforated region 20 includes an alternating number of vacuum holes 13 in each row, e.g., five and six vacuum holes 13 alternated as shown. The staggered pattern of the vacuum holes 13 beneficially provides higher strength in the cylindrical shell 11 and avoids continuous lanes of dead zone in the machine direction with no vacuum appliedto the core. The pattern of vacuum holes 13 may be registered to the embossing pattern of the embossing roll 130 in some embodiments to avoid undesired compression with these regions. At least one mounting hole or aperture 14 can be provided in each of two lateral regions 22 and 24 adjacent opposing ends of each cavity 17 for connection to inserts 12. A mounting hole 18 can also be formed in the cylindrical shell 11, or in individual segments 11A, 11B, and 11C of the cylindrical shell 11, between the outer edges of the aligned cavities 17 and the outer edge of the shell 11 and is configured to receive a threaded fastener such as a bolt or screw to secure the transfer system assembly 10 to the transfer drum 101 and / or vacuum.

[0044] Referring still to FIG. 4, a plurality of inserts 12 are sized and dimensioned to be received within corresponding cavities 17 in cylindrical shell 11, with the upper surface of each insert 12 aligning with the outer curvature of the cylindrical shell 11. Each insert 12 further includes mounting holes 15 that are located to align with the mounting holes 14 in the corresponding cavities 17. The mounting holes 15 can be counter bores or threaded holes and are sized and dimensioned to receive a fastener such as a bolt, screw, or rivet to secure the inserts 12 to the cavities 17 of the cylindrical shell 11. In the embodiment shown, there are two mounting holes 15 at opposing ends of the inserts 12, but other configurations are possible, such as having two or more mounting holes 15 at opposing ends of the cavities 17 and corresponding holes in inserts 12, as can be seen in FIGS. 2 and 3.

[0045] Referring now to FIGS. 4 and 5, the inserts 12 each comprise tapered holes or perforations 16 that extend through the insert 12 from an upper surface to a lower surface. Referring now specifically to FIG. 5, the tapered holes 16 align above the vacuum holes 13 in the cylindrical shell 11. In the embodiment shown, the inserts 12 include sets of four tapered holes 16 arranged in a diamond-shaped pattern or configuration, and each diamond-shaped set of tapered holes 16 aligns above a corresponding vacuum holes 13.

[0046] Referring now to FIG. 6, a cross-sectional view of the transfer assembly 10 with a plurality of inserts 12 secured to corresponding cavities 17 in the cylindrical shell 11, and a plurality of other cavities 17 open, is shown. The tapered holes 16 are smaller at an upper opening 26 in the upper surface of the insert 12 than at a lower opening 28 at the lower surface of the insert 12, and the diameter of each tapered hole 16 continuously increases between the upper opening 26 and lower opening 28, which is adjacent the vacuum hole. The tapered holes 16 enable any pulp fluff, SAP, or other clogged material to be removed from the tapered holes 16 by the vacuumsource 124, and also enable easier cleaning of the holes. Although some inserts 12 are omitted in the illustration to show details in the surface of the cavities 17, in operation, inserts 12 are typically provided in all of the cavities 17.

[0047] To assure proper alignment between the inserts 12 and the cylindrical shell 11 or shell segments 11A, 1 IB, 11C, the insert 12 can be coupled to the shell 11 or shell segments 11A, 1 IB, and 11C and the assembled components can then be finish ground to the final outer radius of the cylindrical shell 10, assuring that the outer circumference of the transfer assembly 10 is smooth and has a consistent radius of curvature despite the multiple piece construction. In some applications, the inserts 12 may be partially ground when fabricated and then finish ground when installed on the cylindrical shell 10. An optional coating (e.g., for wear resistance) may be applied to the finish ground outer circumference of the cylindrical shell 11 and inserts 12.

[0048] Because the tapered holes 16 are formed in an insert 12 that can be removably coupled to a cylindrical shell 11, the transfer assembly 10 can be manufactured in a cost-effective and consistent manner that may reduce waste. The construction of transfer assembly 10 also reduces maintenance downtime since individual inserts 12 can be removed for cleaning versus having to completely disassemble the cylindrical shell 11 from the underlying drum body.

[0049] Referring now to FIGS. 7 and 8, partial views illustrating engagement of the transfer assembly 10 with an embossing roll 130 during use are shown. Referring first to FIG. 7, in a first embodiment, a lattice-shaped embossing pattern 132 is provided on the embossing roll 130. As described above, the tapered holes 16 and corresponding vacuum holes 13 are registered to the embossing pattern 132, such that the sets of tapered holes 16 are aligned with the openings in the lattice-shaped embossing pattern 132. Referring now to FIG. 8, in a second embodiment, a straight line or “striped” embossing pattern 134 is shown. Here, the pattern of the tapered holes 16 is again registered to the embossing pattern 134, such that no tapered holes 16 are formed in the inserts 12 in an overlap area 136, illustrated by hatching, where the embossing pattern 134 engages against the transfer assembly 10.

[0050] Referring again to FIGS. 3 and 4, in operation, the transfer assembly 10 is assembled by inserting the inserts 12 into cavities 17 in the cylindrical shell 11 using fasteners such as bolts or screws extending through the aligned mounting holes 14 and 15, by way of example, and the transfer assembly is coupled to a transfer drum 101 (FIG. 1). Where individual shell segments11 A, 1 IB, and 1 1C are used, the cylindrical shell 11 can be assembled from the segments 11 A, 1 IB, and 11C either before or after assembly of the inserts 12,

[0051] A vacuum source 124 can be coupled to the transfer assembly 10, and secured by applying threaded fasteners through apertures or holes 18 in the cylindrical shell segments 11. Negative pressure from the vacuum source 124 can be applied through vacuum holes 13 in the cavities 17, and through tapered holes 16, to transfer fluff from pulp bodies or materials with a superabsorbent polymer core, and / or to maintain pulp bodies against the peripheral surface of the transfer assembly 10. As negative pressure is applied by the vacuum source 124, each tapered hole 16 advantageously prevents clogging by providing a path for loose fluff pulp or superabsorbent polymer materials that are not formed in the pulp body to be carried away by the internal vacuum during the compression process of manufacturing. As described above, the tapered hole 16 enables the vacuum source 124 to remove any clogged materials, which can be more easily pulled from the larger diameter lower opening 28 by the vacuum source 124. The tapered holes 16 can also be more easily cleaned because of the larger diameter lower opening 28. Further, when the inserts 12 require maintenance, the individual components can be removed and / or replaced, decreasing down time and also aiding in extending the life of the equipment.

[0052] When an embossing roll 130 is used, the tapered holes 16 are registered with an embossing pattern 132, 134 to prevent an overlap of the embossing pattern and the tapered holes 16. The embossing roll 130, therefore, does not interfere with the application of negative pressure by the vacuum source 124 while providing embossing to the mat 112.

[0053] The described multi-piece transfer drum therefore reduces clogging of the vacuum system, and thus can improve efficiency of the manufacturing process, and the quality of the final product. As described above, this type of system is useful in the manufacturing of absorbent articles, specifically fluff pulp and / or superabsorbent polymers (SAP). For example, for processing fluff having a particle size ranging from one to five millimeters, an inlet diameter of the tapered hole 16 can have a diameter of 1 - 5 mm, and the outlet diameter can be in a range of 105 - 250% of the cross-sectional area of the diameter of the inlet, or more particularly in a range of 110 - 130% of the cross-sectional area of the diameter of the inlet. The sides of the tapered holes 16 can, for example, be angled between 1.5 and 7.5 degrees per side, thereby providing a full included angle between three and fifteen degrees.

[0054] In alternative embodiments, the geometrical structure of cylindrical shell 11 and inserts 12 are formed as a unitary, continuous structure. In such cases, the unitary structure may be 3D printed in a manner that forms the vacuum holes 13 and tapered holes 16 within the unitary structure. Alternatively, the vacuum holes 13 may be bored from the inward-facing surface of the combined insert / shell structure, and the tapered holes 16 may be formed in a subsequent machining process. These tapered holes 16 can be formed all the way through to the outward-facing surface of the structure or only part of the way, with the remaining material thickness drilled with a uniform diameter from the outward-facing surface inward.

[0055] In addition to processing fluff or SAP, the multi-piece design described above can also be used in many other applications, including, for example, vacuum transfer processes used in manufacturing resin material, fiber-reinforced composite, other types of fluff and fibrous materials, and many other types of lightweight particulate materials, and other materials which can be moved through the application of vacuum sources.

[0056] Within this specification, embodiments have been described in a way which enables a clear and concise specification to be written, but it is intended and will be appreciated that embodiments may be variously combined or separated without parting from the invention. For example, it will be appreciated that the features described herein are applicable to all aspects of the embodiments described herein. Further, it is to be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the description or illustrated in the drawings. The present disclosure is capable of other configurations and of being practiced or of being carried out in various ways. For example, although an insert for providing tapered holes is described above, it will be apparent that tapered holes could also be directly added to the cylindrical shell, in a single piece construction.

[0057] Additionally, although the inserts 12 are described above as removably coupled to the cylindrical shell segments 11 with threaded fasteners, in some applications, the inserts 12 may be coupled to the cylindrical shell segments 11 using rivets, adhesives, welding, or other connecting methods which may or may not be readily removable.

[0058] Furthermore, although the aligned vacuum holes 13 and tapered holes 16 are described to have specific shapes, and to be located in a central region 20 of the cavities 17, it will be apparent that the pattern, shape, number and position of the vacuum holes 13 and corresponding tapered holes 16 can be varied as is suitable for the application. In some applications, for example, it maybe desirable for the vacuum to be applied at the outer edges of the transfer drum 10 rather than in a central region, and the tapered holes 16 that align with the vacuum holes, therefore, can be positioned to accommodate the application. Similarly, the position and number of mounting holes can be varied, depending on the application.

[0059] Although a specific shape for the cavities is described above, it will also be apparent that the shape and location of the cavities can be customized to a specific application. In some applications, therefore, cavities may be formed over only a portion of the cylindrical surface. In other applications, a plurality of cavities may be formed in a row extending from one side of the shell to another. Further, although the cavities are described above to include a lower surface with vacuum holes, in some applications, the entire lower surface of the cavity may be open, and the inserts connected at opposing ends of the cavities, by way of example. Additionally, although the cavities are illustrated as having a uniform shape, in some applications, the shape of the cavities may be varied across the surface of the cylindrical shell.

[0060] Further, although a specific shape and configuration has been shown and described for the vacuum holes, the tapered holes, and sets of tapered holes, it will be apparent that the number and shape of each type of hole can be modified based on application. A single tapered hole can align with a vacuum hole, or sets of tapered holes arranged in any type of pattern or shape including round or polygonal configurations, or straight rows can be aligned with the vacuum holes. Further, although the tapering has been described as continuous, in some applications, a stepped interior surface may be used. In other applications, the sides of the hole may be curved or parabolic in shape. The stepped interior surface may also include curved, angled, or parabolic segments. The term “tapered,” therefore is intended to encompass any hole configuration that includes an opening that is smaller in diameter at a first end than at a second end.

[0061] Additionally, although a cylindrical shell and transfer drum are described, in some applications, the transfer system may be in the form of a flat plate, a semi-circular or other curved surface, or other shape.

[0062] Thus, it will be appreciated by those skilled in the art that, while the disclosure has been described above in connection with particular non-limiting examples and examples, the disclosure is not necessarily so limited, and numerous other non-embodiments, examples, uses, modifications and departures from the non-limiting examples, examples and uses are intended to be encompassed by the claims attached hereto. The figures, similarly, depict selected configurations and are notintended to limit the scope of the present disclosure. The present disclosure is to be accorded the widest scope consistent with the principles and features disclosed herein.

[0063] Various features and advantages of the invention are set forth in the following claims.

Claims

CLAIMSWe Claim:

1. A multi-piece transfer system assembly comprising: a shell having a plurality of cavities formed in an outer surface, each of the plurality of cavities having at least one vacuum hole formed in a bottom surface of the corresponding cavity, the vacuum hole configured for communication with a vacuum system; and a plurality of inserts sized and dimensioned to be received within a corresponding one of the cavities, each of the inserts including at least one tapered hole extending through the insert and configured to align with the vacuum hole in the cavity; wherein the at least one tapered hole extends from an end adjacent the vacuum hole to an opposing end offset from the vacuum hole, and wherein the at least one tapered hole is larger in diameter at the end adjacent the vacuum hole and is smaller at the opposing end.

2. The multi-piece transfer system assembly of claim 1, further comprising at least one mounting hole formed in each cavity, and at least one corresponding mounting hole formed in each insert, the at least one mounting hole formed in each cavity and the at least one corresponding mounting hole formed in each insert being aligned and configured to receive a fastener to couple the inserts to the cavities in the shell.

3. The multi-piece transfer system assembly of claim 1, wherein the shell comprises a plurality of holes coupling a vacuum source to the shell.

4. The multi-piece transfer system assembly of claim 1, wherein each of the plurality of cavities has a plurality of vacuum holes formed in a bottom surface of the corresponding cavity.

5. The multi-piece transfer system assembly of claim 1, wherein each of the inserts includes a plurality of tapered holes extending through the insert and configured to align with a respective vacuum hole in the corresponding cavity.

6. The multi-piece transfer system assembly of claim 1 , wherein each of the inserts includes a plurality of sets of tapered holes extending through the insert, each set of tapered holes configured to align with a respective vacuum hole in the corresponding cavity.

7. The multi-piece transfer system assembly of claim 5, wherein the plurality of tapered holes are registered to an embossing pattern on an embossing roll.

8. The multi -piece transfer system assembly of claim 1, wherein each of the plurality of inserts includes at least one mounting hole, and each of the plurality of cavities includes a corresponding mounting hole positioned to align with the mounting hole in the insert.

9. The multi-piece transfer system assembly of claim 1, wherein the cavities are elongate and extend across at least a portion of the shell from a position adjacent a first end face to a position adjacent a second end face.

10. The multi-piece transfer system assembly of claim 1, wherein the shell is cylindrical, and an outer surface of the insert and an outer surface of the shell are ground to provide a continuous radius of curvature when assembled.

11. The multi-piece transfer system assembly of claim 1, wherein the at least one tapered hole has stepped or parabolic-shaped sides extending between the end adjacent the vacuum hole and the opposing end.

12. A method for manufacturing a multi-piece shell transfer system assembly for use in manufacturing absorbent core materials, the method comprising: forming a plurality of cavities in an outer surface of a shell and providing at least one vacuum hole configured for communication with a vacuum system in a bottom surface of the cavity; forming a plurality of inserts sized and dimensioned to be received in the corresponding plurality of cavities from a sheet of material; forming at least one tapered hole through each of the plurality of inserts; andcoupling the plurality of inserts to the plurality of cavities, wherein a larger end of the at least one tapered hole is positioned adjacent and aligns with the at least one vacuum hole in each cavity.

13. The method of claim 12, wherein the shell is cylindrical, and further comprising grinding the inserts to match a curvature of the outer surface of the cylindrical shell.

14. A system for producing absorptive products, the system comprising: a mill configured to fiberize a base material; a forming surface coupled to one or more vacuum source to secure the fiberized base material on the forming surface to form a mat; a multi-piece transfer system assembly positioned to transfer the mat off the forming surface, the multi-piece transfer drum comprising: a shell having a plurality of cavities formed in an outer surface, each of the plurality of cavities having at least one vacuum hole formed in a bottom surface of the corresponding cavity, the vacuum hole configured for communication with a vacuum system; a plurality of inserts sized and dimensioned to be received within a corresponding one of the cavities, each of the inserts including at least one tapered hole extending through the insert and configured to align with the vacuum hole in the cavity; and a cylindrical compression roll.

15. The system of claim 14, further comprising an embossing unit positioned adjacent the transfer system assembly, the embossing unit comprising a raised embossing pattern on the outer surface and being configured to impress the embossing pattern on the mat.

16. The system of claim 15, wherein the tapered holes in the inserts are registered with the raised embossing pattern such that the raised embossing pattern does not align with any of the tapered holes.

17. The system of claim 15, wherein the raised embossing pattern is a lattice pattern, and the tapered holes are arranged to align with the openings in the lattice pattern.

18. The system of claim 14, wherein the tapered holes are larger in diameter in a surface of each of the plurality of inserts that is configured to be positioned adjacent the vacuum holes in the corresponding plurality of cavities than at an end formed in a surface opposing the end that is configured to be positioned adjacent the vacuum holes.

19. The system of claim 14, wherein the tapered holes are larger in diameter in a surface of each of the plurality of inserts that is configured to be positioned adjacent the vacuum source than at an end formed in a surface opposing the end that is configured to be positioned adjacent the vacuum source.

20. The system of claim 14, wherein the inserts are removably coupled to the shell.

21. The system of claim 14, wherein the shell comprises a plurality of shell segments, each of the shell segments forming a portion of the shell.

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