Disposable Applicator Assembly Foam Insert Alignment
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Solution Overview
Problem
Existing disposable single use applicator assemblies face challenges in maintaining alignment during manufacturing and ensuring that cosmetic or hygiene chemical compositions remain in an active state, particularly when using web conversion manufacturing processes.
Innovation Solution
A disposable single use applicator assembly with a foam composition insert and a chemical composition that adheres to the insert, combined with a web conversion manufacturing system using rollers and scanners to align and seal the assembly, ensuring the chemical composition is in an active state and maintaining alignment during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If web conversion manufacturing process is used to produce disposable applicator assemblies, then productivity is improved, but maintaining alignment of components during manufacturing becomes more difficult
Solution Approach 1:
The applicator is pre-formed as a complete unit with handle and application portion before being inserted into the packet. This preliminary formation ensures proper alignment is built into the component itself, making it easier to maintain alignment during the high-speed web conversion manufacturing process without requiring complex alignment mechanisms during assembly
Solution Approach 2:
A border member is introduced as an intermediary component that receives both the applicator and sealing edges. This border member acts as a mediator that maintains proper spacing and alignment between the applicator components and the packet sealing edges, ensuring consistent positioning during the manufacturing process
2Reliability
If chemical composition is applied to the applicator, then the cosmetic function is improved, but the chemical composition may deactivate during manufacturing and storage
Solution Approach 1:
The chemical composition is applied to the applicator in advance during the manufacturing process, allowing it to be in an active state when needed. The applicator is prepared with the cosmetic composition before final packaging, ensuring the composition remains stable during storage and only becomes active when the packet is opened and applied to the user
Solution Approach 2:
The entire applicator assembly is designed as a disposable single-use item. This eliminates the need for complex preservation systems to maintain the chemical composition over long periods, as the product is intended for immediate use after manufacturing. The disposable nature ensures the chemical composition remains fresh and active without requiring extensive stabilization measures
Data Source
AI summary
The applicator assembly delivers a cosmetic, health, or hygiene chemical composition in an active state to the user for a disposable single use. The applicator assembly includes a wrapper, and an insert. The insert holds the chemical composition, and the insert is made of a foam composition compatible with the chemical composition. The system and method for manufacturing the assembly is a web conversion process for the chemical composition and foam composition of the assembly. The system and method for manufacturing the assembly includes a first roll, wrapper material, a second roll, foam material, a foam cutter, a dispenser, a flatbed hot seal packager, a sheet cutter, and an outfeed conveyor.