Elastic Laminate Transfer Wheel Positioning

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Solution Overview

Problem

Existing methods for producing elastic laminates for absorbent sanitary articles face challenges in accurately positioning and aligning stretched elastic films with respect to non-woven webs, leading to difficulties in precise spacing and transfer from inclined surfaces to cylindrical surfaces.

Innovation Solution

The method involves applying stretched elastic films directly to the outer cylindrical surface of a transfer wheel, where they are precisely positioned and aligned with the non-woven web, allowing for accurate transfer and positioning without the interposition of a non-woven web, and then applying these films to an anvil wheel for ultrasonic welding with another non-woven web.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If elastic films are transferred from inclined surfaces of spreading devices to a non-woven web on a cylindrical anvil wheel, then the elastic films can be applied to the laminate structure, but the positioning precision of the elastic films in the transverse direction deteriorates due to the difficulty of accurate transfer from inclined to cylindrical surfaces

Engineering Contradiction:

Improveapplicability of elastic films to laminateVSAvoidpositioning precision of elastic films

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

A cylindrical transfer wheel with a surface matching the curvature radius of the anvil wheel is introduced as an intermediary component. The elastic films are first applied to this transfer wheel on a flat plane, then transferred to the cylindrical anvil wheel surface, solving the positioning problem by avoiding direct transfer from inclined surfaces to cylindrical surfaces

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The elastic films are preliminarily positioned and applied to the transfer wheel before the actual laminate assembly process. This preliminary action on a flat surface ensures accurate positioning, which is then maintained during the transfer to the cylindrical anvil wheel

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If elastic films are applied in two areas angularly offset from each other on the anvil wheel, then the laminate structure can be formed, but the spacing precision between the two elastic films deteriorates

Engineering Contradiction:

Improveformation of laminate structureVSAvoidspacing precision between elastic films

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The transfer wheel serves as a mediator that maintains the precise angular relationship between the two elastic films. By applying both films to the transfer wheel before transfer to the anvil wheel, the angular offset is precisely controlled, ensuring accurate spacing in the final laminate structure

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If elastic films are stretched in the transverse direction on spreading devices with inclined surfaces, then the elastic films can be prepared for application, but the transfer accuracy to the cylindrical anvil wheel surface deteriorates

Engineering Contradiction:

Improvecapability to stretch and apply elastic filmsVSAvoidtransfer accuracy to cylindrical surface

Core Design Contradiction:

Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

The transfer wheel with a flat surface acts as an intermediary that receives stretched elastic films from the spreading device and then transfers them to the cylindrical anvil wheel. This intermediate flat surface allows accurate positioning without the complications of direct inclined-to-cylindrical transfer

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The transfer wheel is designed with a cylindrical surface whose curvature radius matches that of the anvil wheel, allowing smooth transfer while maintaining positioning accuracy. The curved surface accommodates the cylindrical geometry of the anvil wheel while providing a controlled transfer interface

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 enhances the precision of elastic film positioning and spacing, resulting in more accurate and efficient production of elastic laminates with improved alignment and reduced errors compared to previous methods.

Implementation Method 1

the first and second non-woven web are welded together ultrasonically through the first and second elastic film

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Data Source

PatentUS11833733B2Method and apparatus for producing elastic laminates

Publication Date: 2023.12.05 FAMECCANICA DATA SPA

AI summary

A method and apparatus for producing elastic laminates wherein a first and a second elastic film are stretched in the transverse direction by respective spreader devices, and are applied on a transfer wheel which—in turn—applies the first and second elastic films on a non-woven web held on the outer cylindrical surface of an anvil wheel.