Laser Separation Transfer Heads for Discrete Articles
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Solution Overview
Problem
Existing methods for separating and positioning discrete articles from a continuous length, such as diapers, require heavy-duty transfer assemblies with anvil bars and knife rolls, leading to high manufacturing costs, operational difficulties, and limited pitch range capabilities, resulting in excessive downtime due to the need for frequent assembly changes.
Innovation Solution
Anvil-less methods using laser systems, hot air, hot wire, high-pressure water jets, or log saws for separation, combined with adjustable transfer assembly heads that can move between configurations to accommodate various article sizes and pitches, eliminating the need for anvil bars and knife rolls and allowing for a wide range of discrete article sizes to be processed with a single assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical cutting with knife roll and anvil bars is used, then discrete articles can be separated from continuous length, but the transfer assembly becomes heavy and expensive to manufacture
Solution Approach 1:
The patent removes the anvil bars from the transfer assembly, extracting the heavy mechanical cutting components. The separation is achieved through the knife roll alone contacting the continuous length of articles, eliminating the need for heavy anvil bars and reducing the overall weight and manufacturing cost of the transfer assembly.
Solution Approach 2:
The patent replaces the mechanical anvil bar system with a different approach where the knife roll operates without corresponding anvil bars. This substitution reduces the mechanical complexity and weight while maintaining the cutting function through alternative means.
2Strength
If heavy-duty transfer assembly with anvil bars is used, then high cutting forces can be withstood, but the assembly becomes difficult to rotate
Solution Approach 1:
By removing the heavy anvil bars from the transfer assembly, the patent reduces the overall mass that must be rotated. The cutting force capacity is maintained through the knife roll design and its interaction with the continuous length of articles, while the rotation ease is improved due to the reduced weight.
3Manufacturing precision
If fixed non-adjustable heads are used, then precise cutting position can be maintained, but the pitch range is limited and frequent assembly changes are required
Solution Approach 1:
The patent introduces adjustable heads that can be positioned at different locations along the transfer assembly. This dynamic adjustment capability allows the heads to accommodate various pitch ranges while maintaining precise cutting positions, eliminating the need for frequent assembly changes and improving versatility.
Solution Approach 2:
The adjustable heads provide multi-functionality by being capable of positioning at multiple locations to handle different article sizes and pitch ranges. A single transfer assembly with adjustable heads can process various discrete articles, replacing the need for multiple fixed assemblies.
4Manufacturing precision
If mechanical cutting with precise knife-anvil contact is used, then acceptably pitched discrete articles can be achieved, but the system requires precision within a few microns
Solution Approach 1:
By removing the anvil bars, the patent eliminates the need for precise knife-anvil contact alignment. The cutting precision is achieved through the knife roll design and control systems alone, reducing the mechanical precision requirements while maintaining acceptable discrete article pitch.
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
The anvil-less approach reduces manufacturing costs, simplifies operation, and significantly reduces downtime by enabling the processing of a broad range of discrete article sizes without the need for assembly changes, while maintaining precise control over the discrete articles.
Implementation Method 1
ablating a portion of the continuous length of articles intermediate the first head and the second head with the laser beam to separate the first portion of the continuous length of articles from the second portion
Implementation Method 2
applying a fluid pressure to the first plurality of fluid ports and applying a fluid pressure to the second plurality of fluid ports
Data Source
AI summary
Methods of separating and positioning discrete articles formed from a continuous length of articles are provided. The methods may comprise the steps of receiving a first portion of the continuous length on a first head in a receiving position of an orbit about a first rotational axis and receiving a second portion of the continuous length on a second head in the receiving position of the orbit about the first rotational axis. The methods may comprise providing a laser system configured to produce and direct a laser beam, and ablating a portion of the continuous length of articles intermediate the first head and the second head with the laser beam to separate the first portion of the continuous length of articles from the second portion of the continuous length of articles, thereby forming a discrete article on the first head.