Pull-on Diaper Manufacturing Adhesive Segmentation
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Solution Overview
Problem
Welding on adhesive-applied areas in diaper manufacturing can result in insufficient ultrasonic sealing strength, leading to production disruptions and poor diaper appearance due to unattached elastic members.
Innovation Solution
A method for manufacturing pull-on diapers where adhesive is applied to specific areas, allowing elastic members to be stretched and sandwiched between exterior members, then welded on separate areas to ensure strong bonding and prevent elastic drop-off, maintaining a neat appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is applied to areas to be welded, then elastic members can adhere to the exterior material, but welding strength becomes insufficient and production may stop
Solution Approach 1:
The bandlike member is divided into multiple regions: a first region where adhesive is applied for elastic member attachment, a second region where welding is performed for strong bonding, and a third region for additional adhesive application. This spatial segmentation allows each process to occur in its dedicated zone without interference.
Solution Approach 2:
Different regions of the bandlike member are given different properties: the first and third regions have adhesive applied for elasticity and attachment, while the second region is kept free of adhesive for optimal welding strength. This local differentiation resolves the contradiction by providing both adhesion and welding in appropriate locations.
2Reliability
If adhesive is not applied to areas to be welded, then welding strength is sufficient, but elastic members do not adhere and appearance deteriorates
Solution Approach 1:
The bandlike member is divided into multiple regions: a first region where adhesive is applied for elastic member attachment, a second region where welding is performed for strong bonding, and a third region for additional adhesive application. This spatial segmentation allows each process to occur in its dedicated zone without interference.
Solution Approach 2:
Different regions of the bandlike member are given different properties: the first and third regions have adhesive applied for elasticity and attachment, while the second region is kept free of adhesive for optimal welding strength. This local differentiation resolves the contradiction by providing both adhesion and welding in appropriate locations.
3Productivity
If welding is performed on adhesive-applied areas, then continuous production can proceed, but ultrasonic sealing strength becomes insufficient causing production disruptions
Solution Approach 1:
The bandlike member is divided into multiple regions: a first region where adhesive is applied for elastic member attachment, a second region where welding is performed for strong bonding, and a third region for additional adhesive application. This spatial segmentation allows each process to occur in its dedicated zone without interference.
Solution Approach 2:
Adhesive is applied to the first and third regions before the welding process occurs in the second region. This preliminary action ensures that elastic members are properly attached in zones that will not interfere with subsequent welding operations, maintaining both productivity and weld strength.
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 ensures sufficient welding strength and appearance quality by preventing adhesive interference with welding and allowing elastic members to contract, reducing side extension and enhancing the diaper's fit and appearance.
Implementation Method 1
an adhesion area is formed by putting adhesive on a first area of at least either one of the lower bandlike member and the upper bandlike member
Implementation Method 2
a welding device for welding the folded lower bandlike member and the folded upper bandlike member
Implementation Method 3
elastic force of elastic members is provided to a diaper, and this allows a user to feel good body fit
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
A method for manufacturing an absorbent article, including: while a lower bandlike member (15) is transported in a transport direction, a process in which a cutting position (CL) is determined, and an adhesion area (HMA) is formed by putting adhesive on a first area, the first area including the cutting position (CL) and having a predetermined width in the transport direction; a process in which elastic members (8B, 8F, 8L) are placed so that a part of each of the elastic members (8B, 8F, 8L) overlaps the adhesion area (HMA), the elastic members (8B, 8F, 8L) being stretched in the transport direction; a process in which the lower bandlike member (15) and the upper bandlike member (17) are stacked such that the elastic members (8B, 8F, 8L) being sandwiched between the lower and upper bandlike members (15, 17), and the upper bandlike member (17) adheres to the lower bandlike member (15) and the elastic members (8B, 8F, 8L) on the adhesion area (HMA); a process in which the lower bandlike member (15) and the upper bandlike member (17) are folded on a center portion in an intersecting direction; a process in which a welded section (s1) on which the lower bandlike member (15) and the upper bandlike member (17) are to be welded to each other is formed on a second area, the second area being located on both sides of the first area in the transport direction and having a predetermined width in the transport direction; and a process in which the lower bandlike member (15), the upper bandlike member (17) and the elastic members (8B, 8F, 8L) are cut together on the cutting position (CL) and the lower exterior member (15) and the upper exterior member (17) which are shaped in the form of underpants are cut and separated.