Absorbent Article Tri-Folding with 45-Degree Pathway Transition
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Solution Overview
Problem
Current methods for folding absorbent articles into three parts, such as sanitary napkins and diapers, result in inconsistent product length and increased variation at high production speeds due to required speed changes and directional transitions during the folding process, leading to defects in the tri-folded article length and packaging quality.
Innovation Solution
A method and apparatus that first folds the leading end portion of the absorbent article and then the trailing end portion, with a maximum moving direction change of 45 degrees between pathways, minimizing article transition distance and direction changes, ensuring consistent tri-folded article length and reducing length variation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the article is folded by first folding the trailing end portion and then folding the leading end portion, then the folding process can be completed, but spacing between articles must be increased before first folding and reduced after tri-folding, requiring speed changes that increase article length variation
Solution Approach 1:
The article is pre-positioned and spaced appropriately before entering the first folding station, ensuring proper alignment and reducing the need for speed adjustments during folding. The convey system is configured in advance to deliver articles at optimal positions for folding operations.
Solution Approach 2:
The convey system dynamically adjusts the movement of articles through different folding pathways, maintaining consistent speed and positioning articles precisely during transition between folding operations, thereby minimizing length variation caused by speed changes.
2Ease of manufacture
If the first folded article is turned about 180 degree between first and second folding steps, then the folding sequence can be achieved, but product transition direction change increases article length variation
Solution Approach 1:
The second pathway is configured with an asymmetric angle (not higher than about 45 degree) relative to the first and third pathways, eliminating the need for 180-degree article rotation. This asymmetric layout allows continuous folding in the same general direction, reducing length variation.
3Ease of manufacture
If a wide pad transition distance is used between first and second folding steps, then the folding process can be completed, but article length variation increases
Solution Approach 1:
The folding process transitions from a linear sequence to a multi-dimensional pathway configuration where the second pathway branches at a controlled angle. This spatial reconfiguration reduces the transition distance while maintaining folding effectiveness, thereby minimizing article length variation.
Data Source
AI summary
The present invention is related to a method for folding an article into three parts comprising first folding a leading end portion of the article to form a first folded article, and second folding a trailing end portion of the first folded article, wherein the first folded article is transported with a moving direction change no higher than about 45 degree.