Continuous Tampon Forming Drums for High-Speed Production
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Solution Overview
Problem
Current tampon production methods are limited by low process speed and high energy consumption, with most achieving only 100-140 items per minute, and require careful handling of sensitive, hygroscopic materials, leading to quality issues and increased maintenance.
Innovation Solution
A continuous tampon forming apparatus using multiple processing drums and transfer stations, such as transfer wheels, to facilitate continuous processing and transfer of band-form materials, allowing for higher production speeds while maintaining product quality and reducing wear on components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional cycled production lines with multiple workstations are used, then processing steps can be specialized, but production speed is limited to 100-140 items per minute and energy consumption is high
Solution Approach 1:
The patent implements continuous processing where the band-form material is fed continuously through multiple processing drums (winding drum, pressing drum, head forming drum) without stopping or cycled transfer between workstations. This continuous action eliminates idle time and acceleration/deceleration cycles, enabling production speeds exceeding 140 items per minute while reducing energy consumption compared to traditional intermittent systems
Solution Approach 2:
The processing system is divided into multiple independent processing drums, each performing a specific function (winding, pressing, head forming). This segmentation allows each drum to operate continuously at optimal speed for its specific task, contributing to overall high productivity while maintaining specialized processing capabilities
2Reliability
If traditional cycled transfer between workstations is used, then specialized processing can be performed, but heavy wear and high maintenance are caused by constant acceleration and deceleration
Solution Approach 1:
Multiple processing functions (winding, pressing, head forming) are merged into a single continuous processing line where materials flow through adjacent processing drums without intermediate transfer stations. This eliminates the acceleration and deceleration cycles that cause wear, significantly improving reliability and reducing maintenance requirements while maintaining specialized processing capabilities
3Manufacturing precision
If careful handling of hygroscopic material is used, then product quality is maintained, but production speed is limited
Solution Approach 1:
The continuous processing through adjacent drums maintains constant material flow without stopping or reversing, which prevents moisture loss and quality degradation in hygroscopic materials. The continuous action allows high production speeds exceeding 140 items per minute while maintaining product quality by avoiding the interruptions inherent in cycled transfer systems
Data Source
AI summary
The present invention relates to an apparatus for forming tampons, which comprises a plurality of processing drums 2, 4, 5.1, 5.2 for forming a tampon from band-form material. It also comprises at least one transfer station 7 for continuously transferring a preform from a first processing drum 2, 4, 5.1, 5.2 to a second processing drum 4, 5.1, 5.2. The invention also relates to a method for forming a tampon from band-form material, wherein transfer from a first processing drum to a second processing drum takes place by means of a continuously rotating transfer wheel.