Anvil Roll Hook Profile Modification in Fastening Systems
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current manufacturing processes for absorbent articles, such as diapers, often require complex and costly additional steps to achieve a secure or less secure hook profile for fastening components, leading to increased time and expense, especially when using slip-and-cut systems.
Innovation Solution
A method involving an anvil roll with a vacuum system that modifies the hook profile of fastening components by adjusting the speed difference between the incoming web and the anvil roll, allowing the hooks to slip and deform, forming a complex profile without additional manufacturing steps or equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex hook profile is provided to securely hold the absorbent article, then the fastening security is improved, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The hook profile is modified during the existing slip-and-cut manufacturing process before the hooks are applied to the diaper. The anvil roll pre-forms the hooks with complex profiles (such as J-hooks or G-hooks) as the web moves through the system, eliminating the need for separate post-forming operations and enabling secure fastening without additional manufacturing steps
Solution Approach 2:
The anvil roll serves multiple functions: it provides the vacuum suction necessary for the slip-and-cut process to hold and transfer web segments, and simultaneously acts as a forming surface that modifies the hook profile. This multi-functionality eliminates the need for separate hook-forming equipment, resolving the contradiction between fastening security and manufacturing complexity
2Reliability
If a complex hook profile is provided to securely hold the absorbent article, then the fastening security is improved, but the production time increases
Solution Approach 1:
The hook profile modification occurs continuously as the web moves through the slip-and-cut system at normal production speed. The anvil roll continuously forms hooks while the web is being cut and transferred, maintaining uninterrupted production flow and eliminating additional time requirements for separate hook-forming operations
Solution Approach 2:
Hooks are pre-formed with complex profiles during the existing manufacturing process before the diapers are assembled. This preliminary action ensures that when hooks engage with loops during diaper wear, they provide secure fastening without requiring additional production time for post-assembly modifications
3Reliability
If a complex hook profile is provided to securely hold the absorbent article, then the fastening security is improved, but the manufacturing cost increases
Solution Approach 1:
The anvil roll is utilized for its primary vacuum-holding function and simultaneously serves as a hook-forming surface. This dual usage eliminates the need for separate hook-forming equipment, tooling, and associated manufacturing costs, providing complex hook profiles at no additional expense
Solution Approach 2:
The hooks modify their own profiles by contacting the anvil roll surface during the normal slip-and-cut operation. The friction and pressure between the moving web and anvil roll automatically form the complex hook shapes without requiring external forming tools or additional processing steps, reducing manufacturing complexity and cost
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 process enhances the engagement properties of the hooks with loop materials, providing stronger or greater engagement without increasing production time or costs, and can form hooks with modified profiles that are longer and wider, engaging loops more effectively.
Implementation Method 1
a vacuum drum rotating at a speed faster than an incoming web from which the segment is to be cut. The incoming web thus slips on the drum surface until a cut-off knife cuts a correct length of the web thereby forming the segment. The cut segment is held to the surface of the drum by a vacuum drawn through holes provided in the drum.
Implementation Method 2
The incoming web thus slips on the drum surface until a cut-off knife cuts a correct length of the web
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method of modifying a male fastener of a fastening system includes feeding a web having a base substrate and a male fastening material to a modifying member having an outer surface. The male fastening material has a plurality of male fasteners with a first, unmodified profile. The profile of at least some of the plurality of male fasteners of the male fastening material are modified by engagement of the plurality of male fastener with the outer surface of the modifying member and by causing the plurality of male fasteners to slip along the outer surface of the modifying member. A modified male fastening material includes a plurality of male fasteners modified from a first profile to a second, different profile by passing the male fastening material over the outer surface of the modifying member.