Anvil Roll Projections for Wearable Laminate Jointing
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Solution Overview
Problem
Existing methods for producing stretchable laminates for wearable articles often result in the elastic members being removed from carrying grooves and ruptured during the jointing process due to sheet displacement on the anvil roll.
Innovation Solution
The use of an anvil roll with first projections that include carrying grooves for the elastic members and receiving parts to suppress sheet shrinkage and displacement, combined with a fusion device for ultrasonic fusion bonding at specific joint portions, prevents the elastic members from being dislodged and ruptured.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the anvil roll has projections for jointing with height of 100 μm or larger to house stretched elastic members, then the elastic members can be housed in carrying grooves, but the sheets wound on the anvil roll shrink in radial direction and displace in axial direction causing elastic member removal and rupture
Solution Approach 1:
The anvil roll surface is segmented into multiple functional zones: carrying grooves for housing elastic members, receiving parts for supporting sheets, and projections for ultrasonic jointing. This segmentation allows each zone to perform its specific function independently, preventing interference between sheet handling and elastic member positioning.
Solution Approach 2:
Different regions of the anvil roll are given different surface characteristics and heights. The carrying grooves have specific depth and shape to securely hold elastic members, while receiving parts provide support without causing displacement. This localized differentiation ensures that each area contributes optimally to preventing elastic member removal and rupture.
2Productivity
If projections are provided intermittently in axis direction for jointing, then joint portions are formed, but sheet displacement occurs causing elastic member removal from carrying grooves
Solution Approach 1:
The carrying grooves and receiving parts are pre-formed on the anvil roll surface before the jointing process. This preliminary preparation ensures that when sheets and elastic members are fed onto the anvil roll, they are immediately positioned correctly without displacement, preventing elastic member removal during subsequent jointing operations.
Solution Approach 2:
The receiving parts act as intermediary elements between the projections and the sheets. They provide a transitional zone that supports the sheets and prevents direct contact between projections and sheets that would cause displacement, thereby stabilizing elastic member position during the jointing process.
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 suppresses the removal of elastic members from carrying grooves and prevents rupture during jointing, ensuring a stable and secure stretchable laminate is produced for wearable articles.
Implementation Method 1
a fusion device that, in cooperation with the anvil roll, fuses the pair of first and second sheets mutually
Implementation Method 2
fuses the pair of first and second sheets mutually by making use of ultrasonic vibration
Data Source
Figure 1
Figure 2A~2B
Figure 3(a)~3(b)
AI summary
There are disposed, in a width direction of an anvil roll, a plurality of first projections for producing joint portions where a pair of sheets are jointed to each other; each of the first projections extends in a circumferential direction of the anvil roll and includes a carrying groove carrying an elastic member while the elastic member has entered in the groove; and between one first projection and another first projection adjacent to each other in the width direction, at least one receiving part for receiving the pair of sheets is arranged.