Ultrasonic Welding Position Control for Disposable Diaper Side Panels
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Solution Overview
Problem
Existing disposable diaper production methods lack accurate management of welding positions for side pieces, leading to inconsistent welds due to movable side pieces during ultrasonic welding.
Innovation Solution
A method and device that fold the main body portion to form overlapping side pieces, convey them in a controlled manner to maintain precise alignment, and weld them using an ultrasonic welding unit, ensuring both side pieces are held in place during the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If side pieces are freely movable during ultrasonic welding, then the welding process is simple, but the welding positions fluctuate and cannot be accurately managed
Solution Approach 1:
The side pieces are preliminarily held at predetermined positions by holding members before welding occurs. This preliminary positioning ensures that when ultrasonic welding takes place, the side pieces are already in the correct positions, eliminating position fluctuations while maintaining process simplicity.
Solution Approach 2:
Holding members are introduced as intermediary elements between the side pieces and the welding system. These holding members temporarily constrain the side pieces at precise locations during the welding process, acting as a mediator that enables both easy manufacturing and precise positioning.
2Manufacturing precision
If side pieces are held in fixed positions during welding, then welding position accuracy is improved, but the device complexity increases
Solution Approach 1:
Instead of fixing the entire side piece structure, holding members are applied only at the specific local positions where side pieces need to be held during welding. This localized approach provides necessary positioning accuracy without requiring a complex overall fixing mechanism.
Solution Approach 2:
The holding members are designed as simple, temporary fixtures that perform their function during the welding process and are then removed. These disposable-like holding components avoid the need for complex, permanent positioning mechanisms, reducing overall device complexity while maintaining welding precision.
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 approach allows for accurate management of welding positions, enhancing the consistency and quality of the disposable diaper's side portions, improving the manufacturing process by preventing movement of the side pieces during welding and cutting.
Implementation Method 1
a welding unit that welds the mutually-overlapping side pieces to each other along a conveying direction for each set of the two side pieces of the constituents being conveyed to form the pair of side portions
Data Source
AI summary
A welding unit welds respective side panels pieces of a partly-finished product being conveyed by a conveying unit to each other along a conveying direction. The conveying unit conveys, when the respective side panel pieces are welded to each other by the welding unit, the partly-finished product in a state in which both side portions in the width direction of the portions of the respective side panel pieces to be welded are held for each set of the respective side panel pieces.