Optical and RF Absorbent Core Profiling System
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Solution Overview
Problem
Current methods for measuring the weight and distribution of fluff pulp and super absorbent polymer (SAP) in absorbent articles are manual, subjective, and prone to errors, making them time-intensive and inefficient in high-speed production processes.
Innovation Solution
A system comprising a light emitter, image acquisition device, radio frequency (RF) transmitter and receiver, and a computer that captures images and RF signal data to measure the weight and distribution of fluff pulp and SAP in real-time, using light intensity and RF signal amplitude to determine the weight and distribution of fluff pulp and SAP in absorbent cores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement methods are used to determine the weight and distribution of fluff pulp and SAP, then measurement simplicity is maintained, but measurement precision and productivity deteriorate due to time-intensive processes and human error
Solution Approach 1:
The patent replaces manual mechanical measurement methods with an automated optical measurement system. A camera captures images of the absorbent article, and software processes these images to automatically determine the weight and distribution of fluff pulp and SAP. This substitution eliminates human error, increases measurement precision, and enables high-speed processing that maintains productivity.
Solution Approach 2:
The patent creates a digital copy (image) of the absorbent article and processes this copy to extract measurement data. Instead of physically measuring the article, the system captures an image and uses image analysis software to determine the weight and distribution of materials. This copying approach enables rapid, non-contact measurement that improves both precision and productivity.
2Productivity
If automated optical measurement systems are implemented, then productivity and measurement precision improve, but device complexity increases due to multiple components required
Solution Approach 1:
The patent employs a digital camera, which is a universal device capable of capturing images of various objects. By using a standard camera rather than a specialized measurement instrument, the system achieves automated measurement functionality without requiring complex custom-built hardware. The same camera can be used for different measurement applications, reducing overall system complexity.
Solution Approach 2:
The measurement system is designed to operate autonomously once set up. The camera automatically captures images, and the software automatically processes the images to extract measurement data without requiring operator intervention. This self-service capability reduces the need for complex control systems and manual operations, simplifying the overall device while maintaining high productivity.
3Loss of time
If traditional manual inspection methods are used, then device complexity is minimized, but loss of time increases due to subjective and time-intensive measurement processes
Solution Approach 1:
The patent replaces time-consuming manual inspection with automated optical measurement. A camera captures an image of the absorbent article, and software rapidly processes this image to determine the weight and distribution of materials. This automated process reduces measurement time from minutes to seconds, significantly reducing time loss while the relatively simple device composition keeps complexity manageable.
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
Enables real-time, accurate measurement and profiling of fluff pulp and SAP distribution, improving the consistency and quality of absorbent articles by providing precise data for optimizing production processes.
Implementation Method 1
using light intensity and RF signal amplitude to determine the weight and distribution of fluff pulp and SAP in absorbent cores
Implementation Method 2
radio frequency (RF) transmitter and receiver, and a computer that captures images and RF signal data to measure the weight and distribution
Data Source
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AI summary
Disclosed herein are apparatus, systems and methods of measuring the weight and distribution of the fluff pulp and super absorbent polymer (SAP) or absorbent gelling material (AGM) of absorbent articles. The apparatus may be located at a position after the absorbent cores are formed. Each absorbent article is passed between the light emitter and the camera as well as between the radio transmitter and the radio detector. The camera and radio detector receive the signal transmitted by the light emitter and the radio transmitter respectively through the absorbent articles. The encoder synchronizes the transmission of data by the camera and the radio receiver to the movement of the web. The computer receives the signal data from radio detector and the image data from the camera from each absorbent article and uses the data to determine at least the weight of the fluff pulp and SAP/AGM in the absorbent core.