Disposable Diaper Web Folding and Cutting Method
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Solution Overview
Problem
Existing methods for producing disposable diapers result in significant material wastage and poor crotch fit due to the necessity of trimming the cloth web to form narrow crotch portions, leading to increased production costs and environmental impact.
Innovation Solution
A method involving a combined member with protruding portions for the crotch and torso sections, which is folded and cut to form individual articles, allowing for adjustable fit and reduced material waste by minimizing the discarded web portion, using air suction for holding and cutting precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the cloth web is trimmed substantially to form narrow crotch portions, then the crotch fit is improved, but the portion of web to be discarded increases
Solution Approach 1:
The method performs preliminary folding of the combined member at the crotch portion before cutting. This preliminary action creates a pre-formed narrow crotch shape that maintains proper fit without requiring excessive trimming of the web material, thereby resolving the contradiction between crotch fit and material waste
Solution Approach 2:
The combined member is divided into multiple protruding portions, each forming a crotch portion with specific geometry. By segmenting the web into these predetermined shapes and folding them appropriately, the invention achieves proper crotch fit while minimizing waste through optimized material utilization
2Ease of manufacture
If the ratio of core portion width to torso portion length is fixed at about one half, then the production process is simplified, but the crotch fit cannot be adjusted
Solution Approach 1:
The invention enables dynamic adjustment of the crotch fit by allowing variation in the ratio of core portion width to torso portion length. Different protruding portions can have different ratios according to specific fit requirements, providing adaptability while maintaining a relatively simple production process through continuous folding and cutting operations
3Manufacturing precision
If opposite ends of the core portion are cut off to improve crotch fit, then the crotch fit is improved, but the portion of web to be discarded increases
Solution Approach 1:
Instead of cutting off ends after formation, the method performs preliminary folding at the crotch portion during the formation process itself. This preliminary action achieves the desired narrow crotch shape without requiring subsequent cutting operations that would waste material, thereby improving crotch fit while minimizing web discard
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 reduces material wastage, simplifies production, and improves the fit of the crotch area by allowing adjustment of the core portion's ratio to the torso portion, thereby enhancing the overall efficiency and cost-effectiveness of disposable diaper production.
Implementation Method 1
the distal portion may be held by air suction and a portion of the strip material that is laid on the distal portion may be held on the skin surface side of the distal portion by an air flowing through the distal portion in the folding step
Data Source
AI summary
A method for producing a disposable worn article of the present invention is directed to a method for producing a worn article including a core portion 2 covering the crotch of the wearer, and a torso portion 3 that fits to the torso of the wearer, wherein the torso portion 3 includes a back portion 3L and a front portion 3S. The method includes: a step of carrying a first web W1 including a waist portion 31 of a first back portion 3L1 and a second web W2 including a waist portion 31 of a second back portion 3L2 in the longitudinal direction Y of the webs; a step of forming a combined member by placing the core portion 2 so as to bridge between the first and second webs W1 and W2; and a step of cutting the combined member so as to divide the combined member into a first group G1 and a second group G2.