Interchangeable Pockets for Air-Laid Fibrous Drum Changeover
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Solution Overview
Problem
Current manufacturing processes for air-laid fibrous articles require complex and costly changes to produce different sizes and shapes, as existing systems cannot easily accommodate interchangeable pockets of varying lengths on a single drum, leading to inefficiencies and stability issues.
Innovation Solution
The use of removably attached interfacing segments allows for quicker and easier swapping of pockets of different sizes on a single drum, eliminating the need to change the entire drum, thereby simplifying the process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the entire drum is changed to produce different sizes and shapes of air-laid fibrous articles, then the production versatility is improved, but the device complexity and cost increase
Solution Approach 1:
The drum is divided into multiple interchangeable pockets that can be independently replaced. Each pocket is a separate component that can be removed and substituted without affecting the entire drum structure, enabling production of different article sizes and shapes while maintaining system simplicity
Solution Approach 2:
A single drum structure serves multiple functions by accommodating different pocket configurations. The universal drum design can hold various pocket types and sizes, allowing one piece of equipment to produce multiple product variations through simple pocket interchangeability
2Adaptability or versatility
If the entire drum is changed to produce different sizes and shapes of air-laid fibrous articles, then the production versatility is improved, but the production time and efficiency worsen due to complex changeover procedures
Solution Approach 1:
By segmenting the drum into interchangeable pockets, the changeover process is reduced from replacing an entire large drum to simply swapping individual pocket components, dramatically reducing changeover time and maintaining high production efficiency
Solution Approach 2:
The system transitions from a static fixed drum configuration to a dynamic interchangeable pocket system, allowing rapid adaptation between different product specifications without disrupting the overall production flow or requiring lengthy reconfiguration
3Adaptability or versatility
If multiple drums are used to produce different sizes and shapes, then the production versatility is improved, but the weight and space requirements increase
Solution Approach 1:
One drum structure serves as a universal platform that can accommodate multiple pocket types and sizes. This eliminates the need for multiple separate drums, reducing overall system weight and space requirements while maintaining the ability to produce various article configurations
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 faster, safer, and more flexible production of various air-laid fibrous article sizes and shapes without compromising stability, reducing the need for multiple drums and associated equipment, and significantly shortening changeover times from hours to minutes.
Implementation Method 1
The discrete fibers are entrained in a stream of air and directed to a foraminous forming surface upon which the fibers are deposited to form fluff
Implementation Method 2
Generally, a vacuum is applied to one side of the foraminous surface to create a pressure differential across the foraminous forming surface to assist with drawing the discrete fibers to the foraminous forming surface
Data Source
AI summary
The present invention relates to an apparatus and a method for making air-laid fibrous articles, as well as absorbent hygiene products comprising such air-laid fibrous articles as absorbent core. It comprises a plurality of discrete pockets (1) defining the shape of the articles disposed in a circumferential relationship about the periphery of a rotatable deposition drum (50) comprising a disk-shaped backing plate (2), characterized in that the discrete pockets (1) are removably attached to interfacing segments (6) which are themselves removably attached to the backing plate (2). The present invention aims to provide an easier and quicker way of interchanging the pockets and to provide an improved handling of different pocket sizes.