Absorbent Article Transfer Apparatus with Apertures
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Solution Overview
Problem
Manufacturing processes for diapers face challenges in controlling and advancing larger absorbent articles, such as adult incontinence pants, due to size disparities, leading to assembly and packaging errors and manufacturing downtime.
Innovation Solution
A method involving a transfer apparatus with a frame and transfer members that rotate and reorient absorbent articles, using positive air pressure and apertures to guide and hold the articles, ensuring accurate transfer from a first carrier apparatus to a second, while managing centrifugal and gravitational forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the same or similar processes and equipment are used to produce articles of various sizes, then manufacturing cost is reduced, but control of larger absorbent articles becomes difficult leading to assembly errors and manufacturing downtime
Solution Approach 1:
The system dynamically adjusts the speed of different sections of the conveyor apparatus to match the dimensions of the absorbent article being processed. The controller modifies the rotational speed of rollers and conveyor sections based on article size, enabling the same equipment to reliably handle both small baby diapers and large adult incontinence products without assembly errors or manufacturing downtime
Solution Approach 2:
The system changes operational parameters such as conveyor speed, roller rotation rate, and positioning coordinates based on the detected size of the absorbent article. By adjusting these parameters dynamically, the equipment maintains optimal control for each article type, resolving the contradiction between using uniform equipment and achieving reliable control across size variations
2Productivity
If high speed manufacturing is used, then productivity increases, but control of large belts becomes difficult leading to incorrect assembly and packaging
Solution Approach 1:
The system maintains high manufacturing speed while dynamically adjusting the control parameters for each article. The controller modulates the speed of conveyor sections and positioning mechanisms in real-time based on article dimensions, ensuring that even large adult incontinence products are assembled and packaged accurately at high production rates
Solution Approach 2:
The system uses sensors to detect the size and position of each absorbent article, providing feedback to the controller which then adjusts the conveyor speed and positioning mechanisms. This closed-loop control ensures that manufacturing precision is maintained at high speeds by continuously adapting to variations in article dimensions
3Device complexity
If the belt is not adequately controlled, then manufacturing process is simpler, but assembly errors and manufacturing downtime increase
Solution Approach 1:
The system uses a relatively simple conveyor structure with dynamic speed control implemented through a controller that adjusts roller rotation rates and conveyor section speeds based on article size. This dynamic adjustment capability provides adequate control for both small and large articles without requiring complex mechanical control mechanisms, maintaining assembly correctness while avoiding excessive device complexity
Solution Approach 2:
The system replaces complex mechanical control mechanisms with an electronic control system that uses sensors and a controller to regulate conveyor speed and positioning. This substitution of electronic control for mechanical complexity achieves reliable assembly correctness while keeping the physical device structure relatively simple
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
This method effectively controls and advances larger absorbent articles, preventing assembly errors and downtime by maintaining the desired orientation and flat configuration for downstream processing, enhancing manufacturing efficiency across various sizes.
Implementation Method 1
the plurality of apertures is separated into a first group of apertures and a second group of apertures... activating at least a portion of the first group of apertures such that the second end region and the central region is held to the receiving surface
Implementation Method 2
applying a positive air pressure from the fluid supply member such that the positive air pressure engages the first end region, wherein the first end region is guided to the receiving surface
Implementation Method 3
rotating the frame about a first axis of rotation; rotating the transfer member about a second axis of rotation as the transfer apparatus rotates about the first axis of rotation
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A converting apparatus operates to control and transfer a folded absorbent article from a first carrier apparatus to a second carrier apparatus. The converting apparatus includes a transfer apparatus and a fluid supply member located adjacent to the transfer apparatus. The transfer apparatus includes a frame that is rotatable about a first axis of rotation and a transfer member that is rotatable about a second axis of rotation. The transfer member defines a receiving surface. The receiving surface includes a plurality of apertures that may operate in cooperation with the fluid supply member to remove any waist region folds in the absorbent article such that a substantially flat absorbent article may be transferred from the transfer apparatus to the second carrier apparatus.