Flexible Packaging Carrier for Absorbent Articles
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Solution Overview
Problem
Existing high-speed absorbent article assembly lines and packaging apparatuses are inefficient for producing low-count and variety packages, as they require reconfiguration or manual labor, which is costly and time-consuming.
Innovation Solution
A method using a carrier connected to a track with a linear synchronous motor to divert and transport absorbent articles to a selectable packaging apparatus, allowing for flexible production of various packages without stopping or reconfiguring the assembly line, utilizing a drive mechanism for intermittent acceleration and deceleration to manage the carrier's movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If assembly lines are configured to operate at high speeds for mass production, then productivity is improved, but adaptability deteriorates
Solution Approach 1:
The system segments the packaging process by providing multiple selectable packaging apparatuses (first packaging apparatus for mass production, second packaging apparatus for low-count and variety packages) that can be independently selected based on package requirements. The divert mechanism segments the product flow to direct articles to different packaging apparatuses, allowing the assembly line to maintain high-speed operation for the majority of products while accommodating specialized packaging needs without reconfiguration.
Solution Approach 2:
The assembly line is designed with multi-functionality by incorporating a divert mechanism and multiple selectable packaging apparatuses, enabling it to serve both high-speed mass production and low-count/variety packaging operations through a single integrated system. The control system provides universal control over the divert mechanism to direct articles to appropriate packaging apparatuses based on real-time packaging requirements.
2Adaptability or versatility
If assembly lines are reconfigured to produce different package types, then adaptability is improved, but productivity deteriorates
Solution Approach 1:
The system implements dynamic routing through the divert mechanism, which can real-time direct absorbent articles to different packaging apparatuses based on package type requirements. This dynamic capability allows the system to switch between mass production mode (directing to first packaging apparatus) and low-count/variety mode (directing to second packaging apparatus) without physical reconfiguration, maintaining high productivity across different package types.
Solution Approach 2:
The divert mechanism serves as an intermediary device between the assembly line and multiple packaging apparatuses. It mediates the product flow by selectively directing articles to the appropriate packaging apparatus based on real-time requirements, enabling the system to accommodate different package types without stopping or reconfiguring the assembly line, thus maintaining continuous high-speed operation.
3Adaptability or versatility
If manual labor is used to produce specialized packages, then adaptability is improved, but productivity deteriorates
Solution Approach 1:
The system implements automated self-service packaging through the second packaging apparatus, which is specifically configured to handle low-count and variety packages automatically. This eliminates the need for manual labor while maintaining the ability to produce customized package assortments. The automated apparatus handles sorting, packaging, and sealing operations, achieving both adaptability for custom packages and high productivity through automation.
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
Enables the efficient production of low-count and variety packages of absorbent articles by maintaining high-speed assembly line operations, reducing the need for reconfiguration and manual labor, thus lowering costs and increasing efficiency.
Implementation Method 1
moving the carrier along the track with a linear synchronous motor from the receiving zone to a drop off zone
Implementation Method 2
connecting the carrier with a drive mechanism upon entering the receiving zone wherein the drive mechanism comprises a screw rotatably driven by a motor and threadedly engageable with the carrier; intermittently accelerating and decelerating the carrier on the track with the drive mechanism
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
Apparatuses and methods herein may be configured to utilize existing high speed assembly lines with dedicated packaging apparatuses to assemble various kinds of packages of absorbent articles. Absorbent articles advancing from an assembly line are diverted before reaching a dedicated packaging apparatus. The diverted absorbent articles are transported to a selectable packaging apparatus to be placed in containers containing desired quantities and/or types of absorbent articles to create select packages. Carriers are movably connected with a track, wherein a linear synchronous motor independently moves the carriers along the track. Diverted absorbent articles are transferred to a carrier in a receiving zone, and the diverted absorbent articles are moved along the track from the receiving zone to a drop off zone. The diverted absorbent articles are then transferred from the carrier in the drop off zone to a selectable packaging apparatus.