Absorbent Core Forming Station for Uniform Cellulose Layering
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Solution Overview
Problem
Existing forming stations for absorbent cores in disposable hygiene products face issues with non-uniform distribution of cellulose flakes due to electrostatic charging and clumping, leading to uneven deposits and increased energy consumption, particularly in faster production lines and for thinner cores.
Innovation Solution
A forming station with horizontal axis rotating brushes, a screen with alternating movement, and a collection unit under vacuum suction, ensuring uniform distribution of cellulose flakes by combining brush rotation with screen movement and controlled suction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a suction hood is used to distribute cellulose flakes on a ply, then the cellulose can be conveyed towards the ply, but the cellulose flakes become electrostatically charged and clump together, resulting in non-uniform distribution
Solution Approach 1:
The suction hood is divided into multiple independent suction outlets arranged across the width of the ply. Each outlet serves a specific zone, allowing localized control of cellulose distribution. This segmentation prevents the formation of large clumps by distributing the suction force across multiple smaller zones, thereby improving uniformity while maintaining productivity.
Solution Approach 2:
The system employs adjustable suction outlets that can be independently positioned and controlled. The suction force and outlet positions can be dynamically adjusted during operation to adapt to variations in cellulose flow and ply movement, ensuring consistent uniform distribution even as operating conditions change.
2Manufacturing precision
If a levelling brush is used to distribute cellulose flakes, then the cellulose layer can be leveled, but huge energy expenditure is required, increasing consumption
Solution Approach 1:
The traditional mechanical levelling brush is replaced with a pneumatic system using adjustable suction outlets. Instead of using mechanical force to level the cellulose layer, the system uses controlled air suction to gently guide and distribute the flakes. This substitution dramatically reduces energy consumption while achieving the same uniformity goal.
Solution Approach 2:
The system uses pneumatic pressure control through adjustable suction outlets to manage cellulose distribution. By regulating air flow and suction force, the system achieves precise control over cellulose placement without requiring high-energy mechanical brushing, thereby reducing overall energy consumption.
3Productivity
If production lines become faster, then productivity increases, but the cellulose flakes have less time to distribute uniformly, exacerbating clumping
Solution Approach 1:
The cellulose distribution process is initiated before the ply enters the forming zone. The suction outlets are positioned to begin capturing and distributing cellulose flakes in advance, allowing uniform distribution to start early in the process. This preliminary action ensures that even at high production speeds, the cellulose has sufficient time to distribute uniformly before the critical forming moment.
Solution Approach 2:
The suction system operates with dynamic adjustability, allowing real-time optimization of suction force and outlet positioning based on the actual speed of ply movement. At higher production speeds, the system automatically increases suction intensity or adjusts outlet positions to maintain adequate distribution time, ensuring uniformity is preserved regardless of speed variations.
4Weight of moving object
If thinner absorbent cores are formed, then the volume and weight are reduced, but the cellulose layer becomes more susceptible to non-uniform distribution and electrostatic clumping
Solution Approach 1:
For thin absorbent cores, the suction hood is segmented into multiple closely spaced outlets that create a fine-grained distribution pattern. This segmentation allows the suction force to be applied more uniformly across the entire width, preventing the formation of large clumps that are more likely to occur with thin, light cellulose layers. The fine segmentation maintains uniformity even as the overall material quantity is reduced.
Solution Approach 2:
The system adjusts suction parameters such as airflow rate, suction pressure, and outlet positioning specifically for thin absorbent core applications. By optimizing these parameters, the system can handle the reduced material quantity without compromising uniformity, as the adjusted suction force provides sufficient control over the lightweight cellulose flakes to prevent clumping while maintaining the desired thin profile.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Achieves uniform cellulose layering without lumps or gaps, enabling thinner and lighter absorbent cores with consistent absorbency, reducing energy consumption and facilitating efficient production.
Implementation Method 1
a suction hood, located below said belt, adapted to suck said cellulose causing it to lie flat on said ply
Implementation Method 2
said brushes are functionally in contact with said screen and said cellulose flakes are adapted to pass through said holes of said screen facilitated by said suction hood and by the combined movements of said brushes and said screen
Implementation Method 3
"come and go" alternating movement means for said screen parallel to the feed direction of said ply
Data Source
AI summary
The invention concerns the sector of production and packaging lines for disposable hygiene products, for example nappies and/or absorbent underpads for babies, adults and animals. In further detail, the invention concerns a forming station (1) for forming an absorbent core for disposable hygiene products of the type comprising at least one ply (2) scattered with cellulose. Said forming station (1) comprises:—a frame (3);—means for feeding cellulose flakes adapted to convey a flow of cellulose flakes towards said ply, and means for feeding a ply (2) in a feed direction (x);—a perforated belt (5) adapted to support said ply as it is fed forward;—a suction hood (6), positioned below said belt (5), adapted to suck said cellulose, causing it to lie flat on said ply (2);—a plurality of horizontal axis rotating brushes (7), arranged transversally to the feed direction (x) of said ply (2);—a screen (8) comprising a plurality of holes (8′) arranged between said brushes (7) and said ply (2);—“come and go” alternating movement means for said screen (8) parallel to the feed direction (x) of said ply (2); wherein said brushes (7) are functionally in contact with said screen (8) and said cellulose flakes are adapted to pass through said holes (8′) of said screen (8) facilitated by said suction hood (6) and by the combined movements of said brushes (7) and said screen (8).