Diaper Pant Side Panel Tucking via Vacuum Zone Dynamics
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Solution Overview
Problem
Current side panel tucking processes in diaper manufacturing often result in side panels unintentionally moving back out of the diaper due to opposing vacuum forces and high travel speeds, leading to inconsistent tucking during the manufacturing of diaper pants.
Innovation Solution
A method involving conveyors with vacuum zones to hold the waist regions of the diaper pant apart, followed by removing the vacuum forces and pushing the side panels inward to secure them into the chassis, ensuring they remain tucked as the waist regions are pressed together.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If opposing vacuum forces are applied to hold waist regions apart during side panel tucking, then the waist regions can be held apart to allow tucking, but the side panels may unintentionally move back out due to the vacuum forces and high travel speeds
Solution Approach 1:
The vacuum forces are applied in advance to hold the waist regions apart before the tucking action occurs. This preliminary positioning ensures the waist regions are properly separated and held in place during the entire tucking process, preventing side panels from moving back out due to the forces exerted during tucking.
Solution Approach 2:
The system dynamically controls the vacuum forces throughout the tucking process. The vacuum conveyors maintain opposing vacuum forces on the waist regions during advancement and tucking, then release these forces after tucking is complete, allowing the waist regions to be pressed together while maintaining side panel positioning.
2Productivity
If high travel speeds are used in the vacuum conveyor system, then manufacturing productivity is improved, but side panels may unintentionally move back out due to the combination of vacuum forces and high speed
Solution Approach 1:
The opposing vacuum forces are applied in advance to securely hold the waist regions apart before high-speed tucking occurs. This preliminary securing ensures that even at high travel speeds, the waist regions remain stable and the side panels are properly positioned for accurate tucking.
Solution Approach 2:
The vacuum forces continuously hold the waist regions apart throughout the entire high-speed advancement and tucking process. This continuous holding action ensures consistent side panel tucking accuracy is maintained throughout the continuous manufacturing operation at high speeds.
3Ease of operation
If vacuum forces are applied during side panel tucking, then waist regions can be held apart for tucking, but the vacuum forces may cause side panels to move back out before waist regions are pressed together
Solution Approach 1:
The vacuum forces are applied in advance to hold the waist regions apart, creating the necessary separation for tucking to occur. This preliminary separation is maintained throughout the tucking process, ensuring side panels are properly positioned before the waist regions are pressed together.
Solution Approach 2:
The system dynamically manages the vacuum forces - applying them to separate and hold waist regions during advancement and tucking, then releasing them to allow waist regions to be pressed together while maintaining side panel positioning through the tucked configuration.
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
Effectively tucks side panels into the diaper pant chassis, preventing unintended movement and maintaining the tucked position, thereby improving the manufacturing efficiency and consistency of diaper pants.
Implementation Method 1
applying a first vacuum force from the first vacuum zone to the first waist region and applying a second vacuum force from the second vacuum zone to the second waist region
Data Source
AI summary
Aspects of the present disclosure relate to tucking opposing side panels into a chassis of a diaper pant. The apparatuses and methods may utilize one or more conveyors that advance the chassis along a machine direction. Each conveyor may have a vacuum zone that applies a vacuum force to hold the chassis. The chassis may be positioned between a first conveyor having a first vacuum zone and a second conveyor having a second vacuum zone. The conveyors may apply opposing vacuum forces to hold the first waist region apart from the second waist region while the chassis advances in the machine direction toward a tucking device. The vacuum forces are then removed from the waist regions as the tucking device pushes the side panels toward each other. Pushing the side panels toward each other causes the inner surfaces of the waist regions to simultaneously move toward each other.