Disposable Article Manufacturing Consistent Heating Pattern

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Solution Overview

Problem

Existing methods for manufacturing disposable worn articles, such as diapers and pants, require a change in welding patterns when the size of the article is altered, which is inconvenient and affects the texture of the final product.

Innovation Solution

A method involving the continuous conveyance of a sheet with elastic members, where non-continuous sheets are intermittently arranged to sandwich the elastic members, allowing for welding in an overlapping area and heating in a consistent pattern in both overlapping and non-overlapping areas, maintaining the same pattern regardless of size changes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If welding is performed only in overlapping areas to attach sheets, then the sheets are properly bonded, but the welding pattern must be changed when the size of the worn article is changed

Engineering Contradiction:

Improvewelding process simplicityVSAvoidpattern adaptability to size changes

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The heating device performs multiple functions: it welds sheets in overlapping areas and creates heating marks in non-overlapping areas using the same heating pattern. This universal approach allows the pattern to remain consistent across different product sizes without requiring pattern changes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention changes the state of the heating process by applying heat to both overlapping and non-overlapping areas. By extending the heating function to non-overlapping areas, the system maintains pattern consistency while adapting to different product sizes through parameter extension rather than pattern modification.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If welding pattern is changed with size changes, then proper attachment is maintained, but the texture of the worn article is degraded and manufacturing complexity increases

Engineering Contradiction:

Improveattachment precisionVSAvoidpattern adjustment complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

A single heating pattern serves dual purposes: welding in overlapping areas and creating aesthetic heating marks in non-overlapping areas. This eliminates the need for separate welding patterns for different sizes, reducing device complexity while maintaining attachment precision.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention merges the welding function and aesthetic marking function into a single heating process with one pattern. By combining these functions, the system avoids the complexity of managing multiple patterns while ensuring precise attachment and consistent texture across different product sizes.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If heating is applied only in overlapping areas, then welding is achieved, but the texture appearance is inconsistent across different areas

Engineering Contradiction:

Improveheating process simplicityVSAvoidtexture uniformity

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The heating pattern is applied uniformly across both overlapping and non-overlapping areas, creating consistent local quality (heating marks) throughout the product. This local uniformity contributes to overall texture consistency and aesthetic appearance.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

By applying the same heating pattern to both overlapping and non-overlapping areas, the invention creates homogeneous appearance characteristics across the entire product surface. This homogeneity ensures consistent texture and aesthetic quality regardless of the product size.

Inventive Principle:

Principle #33Homogeneity

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 ensures that the welded and heating patterns remain consistent across different sizes, improving the texture and eliminating the need to adjust the welding pattern, thus enhancing manufacturing efficiency and product aesthetics.

Implementation Method 1

in a non-overlapping area β where the non-continuous sheets W2 do not overlap with the continuous sheet W1, heating the continuous sheet W1 in the same pattern as said pattern

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

in an overlapping area α where the non-continuous sheets W2 overlap with the continuous sheet W1, attaching the continuous sheet W1 and the non-continuous sheets W2 to each other by welding the sheets W1, W2 to each other

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS11672707B2Method for manufacturing disposable worn article

Publication Date: 2023.06.13 ZUIKO CORP

AI summary

The method of the present invention includes the steps of: arranging a plurality of non-continuous sheets of a predetermined length intermittently and successively in the conveyance direction on the continuous sheet so that the continuous elastic members are sandwiched between the non-continuous sheets and the continuous sheet; in an overlapping area where the non-continuous sheets overlap with the continuous sheet, attaching the continuous sheet and the non-continuous sheets to each other by welding the sheets to each other in a predetermined pattern, thus producing a continuous laminate; and in a non-overlapping area where the non-continuous sheets do not overlap with the continuous sheet, heating the continuous sheet in the same pattern as said pattern.