Multi-functional Disposable Absorbent Article Manufacturing Machine
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Solution Overview
Problem
Current manufacturing machines are limited to producing a specific size and type of disposable absorbent articles, requiring multiple machines and increasing capital costs and operational inefficiencies, as they cannot easily switch between producing different types of absorbent products such as infant diapers and adult incontinent undergarments.
Innovation Solution
A multi-functional apparatus and method that allows the production of various disposable absorbent articles on a single machine, featuring multiple sections for forming, assembling, and packaging, including applicators for absorbent layers, bodyside liners, outer covers, elastic application, and fasteners, enabling the production of different sizes and types of absorbent articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate machines are used to produce different types and sizes of disposable absorbent articles, then each machine can be optimized for its specific function, but capital costs increase and operational efficiency decreases
Solution Approach 1:
The patent implements a single manufacturing machine capable of producing multiple types and sizes of disposable absorbent articles through programmable control systems. The machine can be configured via software to manufacture different products (diapers, training pants, adult incontinence products) in various sizes, eliminating the need for multiple dedicated machines while maintaining production flexibility and optimization for each product type
2Adaptability or versatility
If machines are retrofitted or modified to produce different sizes of absorbent articles, then production flexibility improves, but the complexity and cost of modification increase
Solution Approach 1:
The patent employs programmable control systems and adjustable parameters that allow the machine to be reconfigured for different product sizes and types through software programming rather than physical retrofitting. Key parameters such as dimensions, absorbency levels, and structural configurations can be changed by modifying control program parameters, making the machine adaptable without complex mechanical modifications
3Productivity
If multiple dedicated machines are maintained for different product lines, then each machine can operate at optimal efficiency for its specific product, but capital costs and spare parts inventory requirements increase
Solution Approach 1:
The patent implements a dynamic, reconfigurable manufacturing system where the machine can be programmatically adjusted to optimize production for different product types. The control system allows dynamic reconfiguration of manufacturing parameters, tooling, and process settings to maintain optimal efficiency when switching between product lines, combining the benefits of specialization with the flexibility of a universal machine
Data Source
Figure 1
AI summary
An apparatus and a method are disclosed for manufacturing several distinct disposable absorbent articles on a single machine. The apparatus includes three sections. The first section is capable of forming an absorbent assembly and cutting the absorbent assembly into individual absorbent assemblies. The second section is capable of moving a bodyside liner into alignment with the individual absorbent assemblies and applying an outer cover to the individual absorbent assemblies to form a continuous web having a primary stretch in a cross direction. The second section is further capable of adding at least three components to the web. The third section is capable of severing the continuous web into individual absorbent articles which can then be folded, stacked and packaged.