Systems and methods of applying compositions to webs
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Solution Overview
Problem
In the manufacturing of disposable absorbent articles, there is a need for a process that can effectively deposit compositions on webs based on specific features, such as apertures, while maintaining registration and functionality, as existing methods often result in offset printing due to machine direction and cross-machine direction offsets.
Innovation Solution
A system and method for non-contact printing compositions on a web, utilizing an inspection/print station that detects features and applies composition sites according to pre-rendered patterns, allowing for precise alignment and registration with intermediate features and discontinuities, which can be transformed from features to apertures through subsequent manipulation of the web.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional printing methods are used at normal operating speed, then productivity is maintained, but manufacturing precision deteriorates due to offset printing in machine direction and cross machine direction
Solution Approach 1:
The system captures images of features on the web and determines their positions before printing occurs. Pre-rendered print patterns are created based on these detected feature positions, allowing the printing system to compensate for offsets and achieve precise registration without slowing down the manufacturing process
Solution Approach 2:
The vision system continuously monitors and detects actual feature positions on the web, providing feedback to the printing system. This feedback loop enables real-time adjustment of print patterns to match the actual feature locations, maintaining manufacturing precision at normal operating speeds
2Manufacturing precision
If printing is based on particular features of the article, then manufacturing precision is improved, but device complexity increases due to need for feature detection and pattern correlation
Solution Approach 1:
The inspection/print station is designed to perform multiple functions: detecting features on the web, capturing images, determining feature positions, selecting appropriate pre-rendered patterns, and controlling printing operations. This multi-functional approach consolidates what would otherwise require separate systems into a single integrated unit, managing complexity while achieving precise feature-based printing
Solution Approach 2:
The system creates digital copies (images) of the physical features on the web and works with these copies to determine positions and generate print patterns. This allows the system to process feature information without physical contact or complex mechanical alignment mechanisms, reducing device complexity while maintaining precision
Data Source
AI summary
A method of printing composition(s) on a web is disclosed. The method includes the steps of advancing the web and printing a plurality of composition sites on the web. The method further includes the step of forming one or more discontinuities in the web. The discontinuities correspond to the printed composition sites.