Absorbent Core Turning Apparatus for High-Speed Hygiene Article Production
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Solution Overview
Problem
Conventional manufacturing processes for disposable personal hygiene absorbent articles, such as diapers, face limitations in increasing production speed beyond 1100 units per minute due to mechanical forces during the turn and repitch operation of absorbent cores, which restricts line speed and efficiency.
Innovation Solution
A method and apparatus that involve forming continuous absorbent cores in a cross-machine direction, turning them into a machine direction, and dividing the supply into multiple sub-lines for further assembly, allowing simultaneous reorientation and division to enhance production speed and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If absorbent cores are turned in machine direction on a single line, then article assembly can be completed, but line speed is limited to maximum 700 units per minute due to high mechanical forces during turn and repitch operation
Solution Approach 1:
The patent divides the single production line into multiple parallel sub-lines (first sub-line and second sub-line), each handling a portion of the absorbent core flow. This segmentation allows the total production load to be distributed across multiple independent paths, enabling higher overall productivity while reducing the mechanical burden on each individual sub-line, thus resolving the contradiction between line speed and mechanical forces.
2Productivity
If conventional discrete transformations are used, then article elements can be assembled, but production speed cannot exceed 1100 diapers per minute due to intermittent gluing and discrete patches
Solution Approach 1:
The patent implements continuous transforming members that continuously apply adhesive and attach article elements (such as elastic leg cuffs) to the absorbent cores as they move through the production line. This continuous action eliminates the intermittent stopping and starting associated with discrete transformations, allowing production speeds to exceed 1100 units per minute by maintaining uninterrupted manufacturing flow.
Data Source
AI summary
A method and device for turning a continuous supply of absorbent cores oriented in cross machine direction into a machine direction orientation and dividing the supply of absorbent cores into two or more sub-lines is provided. The device includes a plurality of turning plates which each include means for picking up, holding and releasing the absorbent cores, means for reversibly transferring the turning plates from a core pick-up point to a core release point, each turning plate being mounted rotationally on an axis, so that the absorbent cores can be re-oriented from a cross-machine direction at the pick-up point into machine direction at the release point while being held on the turning plates. Each turning plate includes means for picking up, holding and releasing two or more absorbent cores.