Compliant Anvil Roll Bonding for High-Speed Substrate Seam Strength
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Solution Overview
Problem
In high-speed manufacturing processes for absorbent articles, such as diapers, the instantaneous compression of substrates using rigid anvil rolls and compression tools results in suboptimal seam strength and quality due to tangential compression, which is not conducive to forming strong and durable side seams.
Innovation Solution
An apparatus featuring a drum with a compliant anvil roll and a press member that rotates with a fluid nozzle to partially melt substrates, allowing for non-tangential compression and extended contact time between the substrates, enhancing seam strength and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rigid anvil rolls and compression tools are used in high-speed manufacturing, then productivity is improved, but seam strength and quality deteriorate due to instantaneous tangential compression
Solution Approach 1:
The patent changes the physical state of the anvil roll from rigid to compliant, allowing it to deform under compression. This parameter change enables extended compression time while maintaining high-speed manufacturing capability, resolving the contradiction between productivity and seam strength
Solution Approach 2:
The compliant anvil roll introduces dynamic deformation capability to the compression system. As substrates are compressed, the anvil roll dynamically adjusts its shape to maintain contact, extending the compression duration without reducing manufacturing speed, thus improving seam strength while preserving productivity
2Reliability
If rigid anvil rolls and compression tools are spaced apart to prevent interference, then device reliability is improved, but compression time decreases to nearly instantaneous
Solution Approach 1:
Changing the anvil roll from rigid to compliant modifies its mechanical properties, allowing it to be positioned closer to the compression tool without causing interference. The compliant material absorbs deformation, enabling extended compression time while maintaining process reliability through proper spacing
3Device complexity
If substrates are compressed in a tangential direction using rigid tools, then device complexity is reduced, but seam quality deteriorates
Solution Approach 1:
The compliant anvil roll changes the compression mechanics by deforming in the radial direction rather than requiring complex non-tangential compression paths. This simplifies the device while improving seam quality, as the compliant material naturally conforms to the substrate surface during compression
Solution Approach 2:
The compliant anvil roll's ability to deform radially inward creates a curved compression path that improves contact with the substrate. This curvature effect enhances compression uniformity and seam quality without increasing device complexity
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
The apparatus effectively increases compression time and improves seam quality by deforming the substrates in a non-tangential direction, resulting in stronger and more durable bonds between substrates, even in high-speed manufacturing environments.
Implementation Method 1
A fluid is heated to a temperature sufficient to at least partially melt the overlap area of the first and second substrates. The fluid nozzles direct a jet of the heated fluid through the aperture and onto an overlap area of the first and second substrates to partially melts the overlap area.
Implementation Method 2
the press member moves radially outward through the aperture. The overlap area is then compressed between the press member and anvil roll, creating a bond between the first and second substrates.
Data Source
AI summary
An apparatus includes a drum that rotates about an axis and rotating an anvil roll that rotates about an axis of rotation. The drum includes a fluid nozzle and a press member, the press member having an outer surface. The anvil roll includes a compliant outer circumferential surface. First and second substrates are advanced in a machine direction onto the drum. The fluid nozzle moves radially outward and a jet of heated fluid may be directed onto the substrates. The fluid nozzle retracts radially inward and the press member may be shifted radially outward. The substrates may be compressed between the press member and the anvil roll such that the press member deforms the compliant outer circumferential surface of the anvil roll.