Nested Zero Waste Ear Application for Diaper Chassis Webs
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Solution Overview
Problem
Current methods for manufacturing disposable hygiene products, such as diapers, result in significant waste due to the inefficiencies in processing and applying web materials, where recyclable materials are often commingled and require extra steps for separation, leading to material loss and inefficiencies in production.
Innovation Solution
The implementation of a process that uses a rotary knife or die with synchronized cutting edges to create trapezoidal ear webs, which are then rotated and applied to a chassis web with zero or minimized waste, utilizing a nested pattern and ear turner assemblies to ensure correct orientation and minimize material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional slip-and-cut applicators are used to apply web segments to diapers, then the application process can be completed, but significant material waste is generated due to inefficiencies in processing and the need to discard commingled recyclable materials
Solution Approach 1:
The incoming web is divided into multiple lanes (first lane and second lane) that are processed separately. Each lane is cut and applied independently to different sides of the diaper chassis, allowing for precise material utilization and eliminating the need to discard commingled materials. This segmentation enables zero-waste processing by ensuring that recyclable materials from each lane can be separately harvested and reused.
Solution Approach 2:
The patent implements a nested pattern where ear pieces from the first lane are positioned to nest with ear pieces from the second lane. This nesting arrangement maximizes material utilization by ensuring that no material is left unused between lanes, achieving zero-waste application while maintaining operational efficiency.
2Ease of manufacture
If recyclable materials are harvested from defective products at the end of the process, then waste can be recycled, but the harvesting process becomes intensive and requires extra steps for separating commingled waste components
Solution Approach 1:
By processing materials in separate lanes from the beginning, the patent eliminates the need for complex separation processes at the end. Each lane's materials remain separate and can be easily harvested and recycled without intensive sorting operations, significantly reducing device complexity while improving ease of manufacture.
Solution Approach 2:
The patent performs preliminary separation by dividing the incoming web into distinct lanes before processing. This preliminary action prevents materials from becoming commingled in the first place, making subsequent harvesting and recycling operations simple and efficient without requiring complex separation equipment.
3Productivity
If traditional web processing methods are used, then production can proceed, but inefficiencies of scale occur due to the rate at which web processing machines run and minimal waste accumulation
Solution Approach 1:
The nested lane pattern ensures continuous utilization of material across both lanes without interruption or waste accumulation. As the machine runs at high speed, the nested arrangement maintains continuous useful action by ensuring that every portion of the web is productively applied to the diaper, eliminating idle time and material waste that would otherwise occur at processing rates.
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 allows for the application of ear pieces with zero material waste, improving operational efficiency and reducing waste generation in the production of disposable hygiene products by ensuring precise orientation and alignment of ear pieces during the manufacturing process.
Implementation Method 1
a rotary knife or die with synchronized cutting edges to create trapezoidal ear webs
Implementation Method 2
a synchronized vacuum anvil
Implementation Method 3
ear turner assemblies to ensure correct orientation
Implementation Method 4
application of nested zero waste ear to traveling web
Data Source
Figure 1~3
Figure 4~5A
Figure 6~7B
AI summary
The present invention provides a method of providing a disposable product with zero waste ear formation and attaching the ears to a running chassis web.