Single-Transfer Pad Placement With Spin and Re-Pitch Control
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Solution Overview
Problem
Existing devices in the production of disposable absorbent articles require a separate step for cutting and transferring absorbent pads, leading to excessive wear due to momentum changes and mismatch between cut pitch and receiving pitch, necessitating an apparatus that can receive a continuous web, cut sections, spin pads to a predetermined angle, and adjust spacing for proper placement.
Innovation Solution
The apparatus includes a transfer mechanism with pucks rotated by a puck wheel, utilizing a cam plate with spin and pitch cam races to change the angular velocity and spacing of the pads, allowing for continuous web reception, cutting, spinning, and re-pitching to match the desired placement pitch without excessive wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate cutting step is performed before transfer, then the pad can be properly formed, but the device complexity increases and productivity decreases
Solution Approach 1:
The patent combines the cutting operation and transfer operation into a single integrated step. The cutter assembly is positioned on the transfer mechanism itself, allowing pads to be cut from the web and immediately transferred to the receiving surface in one continuous motion, eliminating the need for a separate transfer step between cutting and transferring operations.
Solution Approach 2:
The transfer mechanism is designed to perform multiple functions: it serves as both the transfer device for moving pads and as the mounting structure for the cutter assembly. This multi-functional design allows the same mechanism to handle both cutting and transferring operations, reducing overall device complexity.
2Manufacturing precision
If re-pitching is performed to match cut pitch with receiving pitch, then placement accuracy improves, but device wear increases due to momentum changes
Solution Approach 1:
The patent employs a variable speed transfer mechanism that dynamically adjusts the rotational speed of the transfer mechanism to match different pitch requirements. By using a variable frequency drive, the system can smoothly transition between different speeds without causing excessive momentum changes, thereby reducing wear on mechanical components while maintaining accurate pitch matching.
3Manufacturing precision
If spin function is added to orient pads at predetermined angle, then orientation accuracy improves, but device complexity increases
Solution Approach 1:
The spin function is integrated into the transfer mechanism itself rather than being a separate operation. The transfer mechanism incorporates a spin assembly that can rotate pads to predetermined angles during the transfer process, combining orientation and transfer functions in one mechanism.
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 solution enables efficient cutting, spinning, and spacing of absorbent pads to match the desired placement pitch, reducing device wear and eliminating the need for a separate transfer step, thereby improving the production efficiency and accuracy in manufacturing disposable absorbent articles.
Implementation Method 1
The apparatus includes a transfer mechanism with pucks rotated by a puck wheel, utilizing a cam plate with spin and pitch cam races to change the angular velocity and spacing of the pads
Data Source
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AI summary
An apparatus and method is provided for single transfer insert placement. The apparatus receives continuous web material and cuts a discrete section ox pad from the web. The pad is then supported on a single transfer surface. The single transfer surface then may spin the supported pad to a desired angle and provide the pad to a receiving surface at a desired interval.