Disposable Pant-Type Article Chassis Web Assembly
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Solution Overview
Problem
The production of disposable pant-type articles faces challenges in achieving high-quality, cost-efficient manufacturing while meeting demands for fit, comfort, appearance, and leakage protection, due to the complexity of combining multiple components with different physical forms and properties.
Innovation Solution
A method involving advancing continuous elastic and non-elastic web materials, attaching crotch elastic members, forming leg cuts, and creating side seams to produce individual pant-type articles from a coherent chassis web, ensuring effective leakage protection and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple components with different physical forms and properties are combined to form pant-type articles, then functionality and performance are improved, but process complexity and manufacturing difficulty increase
Solution Approach 1:
The pant-type article is divided into distinct functional components (front panel, rear panel, crotch panel, leg panels, absorbent core) that are processed separately and then assembled. This segmentation allows each component to be optimized independently for its specific function while simplifying the overall manufacturing process through modular assembly.
Solution Approach 2:
The patent combines multiple materials with different properties (elastic nonwoven fabrics, barrier materials, absorbent cores) to create a composite structure that achieves superior leakage protection and comfort. Each material is selected for its specific properties and combined in a way that complements the others, resolving the contradiction between performance and complexity.
2Manufacturing precision
If high-quality materials and complex processes are used to meet demands for fit, comfort and appearance, then product quality is improved, but production cost increases
Solution Approach 1:
Elastic panels are pre-stretched to their final dimensions before assembly, and the chassis web is pre-formed with integrated elastic elements. This preliminary action eliminates the need for complex post-assembly stretching and shaping operations, reducing manufacturing complexity and cost while maintaining high appearance quality.
Solution Approach 2:
Multiple functions are merged into single components: the chassis web integrates front and rear panels with crotch and leg panels, elastic elements are integrated directly into the chassis structure, and the absorbent core is positioned within the pre-formed chassis. This merging reduces the number of separate manufacturing steps and lowers production costs.
3Productivity
If continuous web materials are used for production, then productivity is improved, but handling and processing difficulty increases due to tension and alignment requirements
Solution Approach 1:
The chassis web acts as an intermediary structure that pre-integrates the front panel, rear panel, and elastic elements in correct alignment. This intermediary chassis eliminates the need for complex real-time alignment operations during final assembly, making handling easier while maintaining continuous production efficiency.
Solution Approach 2:
The elastic panels are pre-stretched to their final dimensional parameters before assembly into the chassis. This parameter change (pre-applied tension) simplifies subsequent handling and assembly operations, as the panels are already in their final configured state, reducing handling difficulty while maintaining continuous web production benefits.
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 method enables the production of disposable pant-type articles with enhanced functionality, comfort, and appearance, addressing the complexity of combining diverse components and reducing production costs.
Implementation Method 1
stretching each crotch elastic member in a longitudinal direction of the crotch elastic member and aligning the longitudinal direction of the crotch elastic member with the cross machine direction
Data Source
AI summary
A method for continuously producing disposable pant-type articles from webs moving in a machine direction, the method including attaching a non-elastic crotch web between a tensioned elastic front panel web and a tensioned elastic rear panel web to form a coherent chassis web of interconnected precursor articles and attaching a pair of stretched crotch elastic members to the chassis web in each precursor article with the crotch elastic members being arranged in a cross machine direction, whereafter leg cuts are formed in the chassis web between the precursor articles, the chassis web is folded along a fold-line extending in the machine direction, first and second side seams are formed in each precursor article, along dividing lines between the precursor articles, the side seams being formed from the aligned waist edges of the precursor articles, to the leg cuts, and finally severing individual pant-type articles from the chassis web.