Fiber Deposition Recirculation for Variable-Width Hygienic Articles
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Solution Overview
Problem
Existing methods for producing hygienic articles with absorbent cores face challenges in managing variable excess fiber amounts due to differing support layer widths, which can disrupt mill operations and result in inefficient production.
Innovation Solution
A method and apparatus that recirculates excess fibers back into the deposition system, utilizing a deposition station with collection nozzles and air jets to separate and redirect fibers based on support layer width, ensuring consistent fiber distribution across varying article sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the deposition device releases a predetermined amount of fibres per unit of time, then the fibre deposition rate is consistent, but the amount of excess fibres varies widely (5%-60%) depending on support layer width, causing mill operation disruptions
Solution Approach 1:
The patent implements a feedback control system where the actual width of the support layer is measured and used to adjust the fibre deposition amount in real-time. This closes the control loop, ensuring that the deposition device releases the appropriate amount of fibres matching the actual support layer width, thereby preventing both excess fibre generation and mill disruptions while maintaining consistent deposition rates.
Solution Approach 2:
The system transitions from a static predetermined fibre release mechanism to a dynamic adjustment system. The fibre deposition amount is continuously adjusted based on real-time support layer width measurements, allowing the system to adapt to varying widths and maintain optimal operation without disrupting mill processes.
2Adaptability or versatility
If the support layer strip width varies to accommodate different hygienic article sizes, then the apparatus can produce multiple article sizes, but the amount of excess fibres becomes highly variable (5%-60%), leading to production inefficiency
Solution Approach 1:
The feedback control system measures the actual support layer width and adjusts the fibre deposition accordingly. This ensures that even when producing different article sizes with varying support layer widths, the system generates minimal excess fibres (maintaining a consistent ratio between 90%-105%), thereby preserving production efficiency across all article size variations.
Solution Approach 2:
The system dynamically changes the fibre deposition parameters based on the detected support layer width. By adjusting the deposition amount as a function of width, the system maintains optimal fibre utilization across different article sizes, preventing both fibre waste and insufficient deposition.
3Ease of operation
If a predetermined amount of fibres is released from the deposition device, then the deposition process is simple to control, but fibres fall out of the sides of the support layer strip, creating excess fibres that must be managed
Solution Approach 1:
The system uses feedback control to automatically adjust the predetermined fibre release amount based on real-time support layer width measurements. This maintains operational simplicity while dynamically optimizing the deposition amount to match actual needs, thereby minimizing excess fibre generation without complicating the control process.
Solution Approach 2:
The deposition system adjusts its own operation parameters based on feedback from width measurements. The system essentially self-regulates the fibre release amount, automatically adapting to different support layer widths without requiring manual intervention, thus maintaining ease of operation while reducing waste.
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 maintains efficient production by stabilizing fiber distribution, reducing waste, and preventing mill disruptions, thereby enhancing the production of hygienic articles with absorbent cores.
Implementation Method 1
at least one jet of concentrated air is emitted towards the support layer strip so as to separate a ratio of said remaining percentage of fibres
Implementation Method 2
The deposition of the fibres takes place by falling from the deposition device. This fall is aided by an air flow which, coming from the deposition device, passes through the support layer strip.
Data Source
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AI summary
The invention concerns a method for producing a hygienic article, of the type comprising a support layer and a plurality of fibres (20) arranged on said support layer. The method comprises: - supplying a support layer strip (12) to a deposition station (120) comprising at least one deposition device (122; 222) configured to release a predetermined amount of fibres (20) per time unit; - releasing said predetermined amount of fibres (20) from said at least one deposition device (122; 222) towards the support layer strip (12) so that a first percentage of said predetermined amount of fibres (20) falls on a deposition surface (13) of the support layer strip (12) and a remaining percentage of said predetermined amount of fibres (20) falls out of the support layer strip at the opposite sides of the support layer strip (12); - collecting said remaining percentage of said predetermined amount of fibres (20); - sending said remaining percentage of said predetermined amount of fibres (20) to said at least one deposition device (122; 222). The aforesaid remaining percentage of said predetermined amount of fibres (20) varies between 5% and 60% of said predetermined amount of fibres (20), depending on the width of said support layer strip (12). The invention also concerns an apparatus (100) suitable for carrying out the aforesaid method.