Multizone Splice Sticker for Continuous Absorbent Roll Change
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming a splice bond between rolls of material in absorbent article manufacturing require shutdown of the manufacturing line and do not effectively handle damaged outer layers of new rolls, leading to inefficiencies and potential defects.
Innovation Solution
A multizone sticker is used to facilitate the splicing process by unwinding a laminate into separate adhesive and non-stick layers, with treated and untreated adhesive zones, and applying it to the roll to ensure a continuous production line without stopping, while removing damaged outer layers automatically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional sticker is used to facilitate moving material from a roll, then the material can be moved to a splice box, but the manufacturing line must be shut down and damaged outer layers cannot be effectively handled
Solution Approach 1:
The sticker is divided into multiple adhesive zones with different properties: a first adhesive zone with strong adhesion for securing the leading edge, and a second adhesive zone with reduced adhesion for easy removal. This segmentation allows the sticker to simultaneously secure material effectively while enabling clean removal without damaging the material or requiring line shutdown.
Solution Approach 2:
Different zones of the sticker have different adhesive characteristics tailored to specific functions. The first zone (across the leading edge) has strong adhesive properties for secure attachment, while the second zone (extending in roll winding direction) has reduced adhesive properties for easy removal. This local differentiation resolves the contradiction between secure attachment and easy removal.
2Ease of manufacture
If the sticker has uniform adhesive properties across the entire surface, then application is simple, but damaged outer layers cannot be selectively removed and material waste increases
Solution Approach 1:
The sticker surface is segmented into zones with different adhesive properties. The first adhesive zone is positioned to cover damaged outer layers only, allowing selective removal of damaged material. The second adhesive zone provides secure attachment for the good material. This segmentation enables precise control over what material is secured versus what is removed, reducing waste.
Solution Approach 2:
The sticker exhibits local quality variations in adhesive strength across different zones. The first zone has reduced adhesion suitable for temporary coverage of damaged areas, while the second zone has strong adhesion for securing functional material. This localized adhesive property differentiation allows selective removal of damaged layers while preserving good material.
3Strength
If the sticker extends far beyond the leading edge in the roll winding direction, then it provides secure attachment, but it increases the risk of adhering to damaged outer layers that should be removed
Solution Approach 1:
The sticker is segmented into a first adhesive zone positioned across the leading edge for secure attachment, and a second adhesive zone extending in the roll winding direction with reduced adhesive properties. This segmentation allows the sticker to provide secure attachment where needed while having reduced adhesion in areas that might contact damaged outer layers, preventing unwanted adhesion of material that should be removed.
Solution Approach 2:
The sticker has different adhesive qualities in different zones: strong adhesion in the first zone for secure attachment of the leading edge, and reduced adhesion in the second zone extending in the roll winding direction. This local quality differentiation enables the sticker to maintain secure attachment while minimizing adhesion to damaged outer layers that need to be removed.
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 method allows for a seamless splice bond formation without line shutdown, reduces material waste, and enhances production efficiency by minimizing scrap and maintaining continuous operation.
Implementation Method 1
treating the first layer with adhesive neutralizing agent to form a first zone with untreated adhesive and a second zone with treated adhesive
Data Source
AI summary
A method is presented for making a multizone sticker for manufacturing an absorbent article. The method includes unwinding a sticker laminate. The method also includes separating the laminate into a first layer and a second layer, with the first layer including a surface with adhesive and the second layer including a non-stick backing layer. The method also includes treating the first layer with adhesive neutralizing agent to form a first zone with untreated adhesive and a second zone with treated adhesive. The method also includes recombining the first layer and the second layer, with at least a portion of the first zone configured to extend across a leading edge of a roll of material comprising a roll winding direction.