Inline Manufacturing of Variable Absorbency Products
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Solution Overview
Problem
Current high-speed inline manufacturing processes for disposable absorbent articles are limited in producing products with varying absorbency levels and images, requiring separate manufacturing runs and repacking, which is inconvenient and costly for consumers and retailers, and also inefficient due to separate operations for printing and manufacturing.
Innovation Solution
The method involves printing different images and inserting extra layers of absorbency at intervals during the manufacturing process, allowing for the production of absorbent articles with varying images and absorbency levels on the same production line, using a substrate moving at a controlled velocity with tension and multiple printheads for high-speed printing and curing, enabling the creation of multi-packs without additional repacking operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate manufacturing runs are made for each absorbency level with separate packaging, then manufacturing precision and product differentiation are improved, but productivity and consumer convenience deteriorate due to multiple operations and repacking requirements
Solution Approach 1:
The patent merges multiple manufacturing operations (printing different images, inserting different absorbency cores, and packaging) into a single integrated inline process. The printing system applies different images to substrates while the substrate moves through the manufacturing line, and different absorbency cores are inserted at different positions, all followed by automatic packaging in one continuous operation, eliminating separate manufacturing runs and repacking steps
Solution Approach 2:
The manufacturing system is designed to perform multiple functions simultaneously: it can print different images on substrates, insert different types of absorbent cores (varying in absorbency levels), and package mixed products all in one process. This multi-functional capability allows the same production line to produce differentiated products without requiring separate dedicated lines for each product type
2Adaptability or versatility
If separate printing operations are performed for different images, then image quality and product variety are improved, but manufacturing complexity and costs increase due to multiple separate operations
Solution Approach 1:
The patent combines multiple printing operations into a single integrated printing system that can apply different images to different portions of the substrate while it moves through the line. The printing system is synchronized with the substrate movement and can switch between different images without stopping the production line, eliminating the need for separate printing operations for each image type
3Ease of manufacture
If preprinted substrates are used with separate printing operations, then ease of manufacture is improved, but loss of substance and waste increase due to blank spaces between images
Solution Approach 1:
The patent implements continuous printing on the moving substrate without interruption or blank spaces between different images. The printing system operates continuously as the substrate moves through the line, ensuring that every portion of the substrate is productively used. This eliminates the waste associated with blank spaces that occur in discontinuous printing methods where the line must stop or leave gaps between different image sections
Data Source
AI summary
The present invention methods for manufacturing absorbent articles that involve the placement of absorbent cores having variable absorbency levels on consecutively aligned absorbent articles within the same manufacturing line. Additionally, the present invention also includes the provision of single packages of disposable absorbent articles that contain a first absorbent article having a first absorbency level and a second absorbent article having a second absorbency level, wherein the second absorbency level is higher than the first absorbency level.