Rotating Drum Bonding Apparatus for Substrate Seam Control
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Solution Overview
Problem
Existing methods for manufacturing absorbent articles, such as diapers, lack precise control over the location and strength of bonds formed during the side seam creation process, leading to potential inconsistencies and reduced product quality.
Innovation Solution
A method and apparatus involving a drum with a fluid nozzle and press member, where substrates are partially melted and compressed to create discrete bond sites, allowing for precise control over seam formation, utilizing a rotating drum and anvil roll to direct heated fluid and apply pressure for bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional bonding methods are used to form side seams, then the manufacturing process is simple, but the location and strength of bonds cannot be precisely controlled
Solution Approach 1:
The bonding apparatus divides the bonding process into distinct functional components: a drum with fluid nozzles for controlled fluid application, separate press members for pressure application, and an anvil roll for support. This segmentation allows each component to be optimized independently for precise control of bond location and strength while maintaining manageable complexity through modular design.
Solution Approach 2:
A fluid intermediary substance is introduced between the substrates during bonding. The fluid is applied through nozzles on the drum surface, allowing precise control of its location and amount. This fluid mediator enables controlled bonding by regulating the interaction between substrates at specific locations, thereby achieving precise bond control without requiring complex direct mechanical bonding mechanisms.
2Reliability
If continuous bonding is applied to form side seams, then the manufacturing speed is high, but the bond strength consistency deteriorates
Solution Approach 1:
The bonding apparatus applies fluid and pressure in periodic cycles as substrates pass through the bonding zone. The drum rotation creates periodic contact between substrates and the fluid/pressure application points, ensuring consistent bonding intervals. This periodic action maintains bond strength consistency by repeating the same controlled bonding sequence for each bond location, while the continuous substrate feed maintains high manufacturing speed.
Solution Approach 2:
The system incorporates control mechanisms that monitor and adjust fluid application rate, pressure magnitude, and drum rotation speed based on substrate passage. This feedback control ensures that each bonding event receives the precise amount of fluid and pressure needed for consistent bond strength, while automatically maintaining optimal production velocity without sacrificing reliability.
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 enables more precise and consistent bonding of substrates, improving the quality and reliability of side seams in absorbent articles by ensuring controlled melting and compression, thus enhancing the manufacturing process.
Implementation Method 1
heating a fluid to a temperature sufficient to at least partially melt substrates; directing a jet of the heated fluid onto the first and second substrates; partially melting the first and second substrates
Implementation Method 2
shifting the press member radially outward from the drum; and compressing the first and second substrates between the press member and the anvil roll
Data Source
AI summary
An apparatus for joining substrates including a rotating drum. The drum may include an outer circumferential surface and a drum aperture in the drum outer circumferential surface. The drum may be configured to continuously advance substrates. A fluid nozzle may be moveably connected to the drum and located radially inward from the drum aperture. The fluid nozzle may be adapted to direct a fluid radially outward through the drum aperture toward the substrates. The fluid may have a temperature sufficient to at least partially melt the substrates. An anvil roll may be located adjacent the drum. The anvil roll may be adapted to rotate about an axis of rotation. A press member may be moveably connected to the drum and located radially inward from the drum aperture. The press member adapted to extend through the drum aperture to compress the substrates between the anvil roll to form a bond.