Discrete Cord Delivery via Fluid Flow and Cutting
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Solution Overview
Problem
The existing process of sewing continuous cords onto tampon pledgets is inefficient, leading to excess sewing, irregular pledgets, and increased production costs due to the need for precise spacing and cutting, which often results in partially cut pledgets being discarded.
Innovation Solution
An apparatus utilizing fluid flow to deliver discrete cords to a transfer member, which includes a cutting mechanism to sever the cord supply, allowing for precise attachment to pledgets with reduced sewing requirements and improved production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If continuous cord is sewn onto multiple pledgets connected by conveyor, then cord delivery is simplified, but excess sewing thread and cord are wasted
Solution Approach 1:
The continuous cord is segmented into discrete cord portions, with each portion dedicated to a single pledget. This segmentation is achieved through the cord delivery apparatus that feeds individual cord portions to the sewing head, eliminating the waste associated with continuous cord sewing across multiple pledgets.
Solution Approach 2:
The unnecessary portions of the cord are extracted and eliminated from the process. By using discrete cord portions instead of continuous cord, the system removes the excess material that would otherwise be wasted during the sewing process.
2Manufacturing precision
If cord is cut between pledgets in separate process, then discrete cord length is achieved, but production efficiency decreases
Solution Approach 1:
The cord delivery and cutting functions are merged into a single integrated apparatus. The cord delivery mechanism includes built-in cutting capability that severes the cord to the precise length needed as it is being fed to the pledget, combining two previously separate operations into one streamlined process.
Solution Approach 2:
The cord is pre-cut to the exact required length before reaching the sewing position. The cutting mechanism in the cord delivery apparatus severs the cord at the precise moment and location needed, eliminating the need for subsequent cutting operations and ensuring accurate cord length without compromising production speed.
3Manufacturing precision
If conveyor spaces pledgets to account for desired cord length, then cord between pledgets is controlled, but system complexity increases
Solution Approach 1:
The cord delivery apparatus itself provides the spacing control function. Instead of relying on the conveyor system to space pledgets according to cord length requirements, the cord delivery mechanism independently controls the length and placement of each cord portion, making the system self-sufficient and reducing overall complexity.
4Strength
If cord is sewn onto entire longitudinal length of pledget, then attachment strength is maximized, but sewing time increases
Solution Approach 1:
The cord is attached only at the specific location where it is needed on the pledget, rather than along the entire longitudinal length. The discrete cord portion is positioned and sewn at the precise attachment point, providing sufficient strength while minimizing sewing time and material usage.
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 enables efficient delivery and attachment of discrete cords to pledgets, reducing waste and increasing production rate by minimizing excess sewing and ensuring consistent pledget quality.
Implementation Method 1
The supply path contains a fluid flow capable of carrying a deployed cord supply. The fluid flow is directed to deliver the deployed cord supply to the transfer member abutting the cutting apparatus.
Data Source
AI summary
An apparatus for delivering a discrete cord having a supply path comprising a fluid flow, a deployed cord supply, a transfer member having a first surface comprising one or more orifices capable of receiving the deployed cord supply, and a cutting apparatus comprising a cutting implement enabled to sever the deployed cord supply to form a discrete cord. The fluid flow directs the deployed cord supply towards the transfer member first surface. The transfer member first surface abuts the cutting apparatus.