Pin Calendering Fibrous Articles Without Carrier Layer
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Solution Overview
Problem
Pin calendering processes for forming fibrous articles require a carrier layer, increasing manufacturing complexity and product cost, and potentially affecting fluid handling characteristics.
Innovation Solution
A method and apparatus for pin-calendering fibrous articles without a carrier layer, using a vacuum roll and pin calender roll to convey and compress the fibrous article through a nip, allowing for direct transfer and compression without external support layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pin calendering is performed using conventional methods with a carrier layer, then the fibrous article can be supported and processed, but the manufacturing complexity increases and product cost increases
Solution Approach 1:
The invention extracts and eliminates the carrier layer from the pin calendering process. By removing this intermediate component, the system achieves direct support of the fibrous article through the pin calendering rolls themselves, thereby reducing manufacturing complexity while maintaining processing reliability
Solution Approach 2:
The pin calendering rolls are designed to directly support and process the fibrous article without requiring an external carrier layer. The rolls themselves provide the necessary support function, making the system self-sufficient and eliminating the need for additional components
2Reliability
If pin calendering is performed using conventional methods with a carrier layer, then the fibrous article can be supported and processed, but the product cost increases
Solution Approach 1:
The invention extracts and eliminates the carrier layer from the pin calendering process. By removing this intermediate component, the system achieves direct support of the fibrous article through the pin calendering rolls themselves, thereby reducing manufacturing complexity while maintaining processing reliability
Solution Approach 2:
The pin calendering rolls are designed to directly support and process the fibrous article without requiring an external carrier layer. The rolls themselves provide the necessary support function, making the system self-sufficient and eliminating the need for additional components
3Reliability
If pin calendering is performed using conventional methods with a carrier layer, then the fibrous article can be supported and processed, but the fluid handling characteristics are adversely affected
Solution Approach 1:
The invention extracts and eliminates the carrier layer from the pin calendering process. By removing this intermediate component, the system achieves direct support of the fibrous article through the pin calendering rolls themselves, thereby reducing manufacturing complexity while maintaining processing reliability
Solution Approach 2:
The pin calendering rolls are designed to directly support and process the fibrous article without requiring an external carrier layer. The rolls themselves provide the necessary support function, making the system self-sufficient and eliminating the need for additional components
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 simplifies the manufacturing process, reduces product costs, and enhances fluid handling properties by eliminating the need for a carrier layer, resulting in improved absorbent core structures for sanitary articles.
Implementation Method 1
a vacuum roll and an opposed calender roll, wherein the vacuum roll includes a rotatable cylinder having a plurality of holes extending through a surface of the rotatable cylinder and further comprising a vacuum chamber arranged within the rotatable cylinder of the calendering station, the vacuum chamber adapted to draw air through the plurality of holes in the rotatable cylinder
Implementation Method 2
pin-calendering the fibrous article in the pin calendering station between a first roll and a second roll, wherein the fibrous article is conveyed through a nip defined between the first roll and the second roll
Implementation Method 3
the vacuum roll of the pin calendering station includes a vacuum chamber arranged within a rotatable cylinder of the vacuum roll
Data Source
Figure 1
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AI summary
The present invention generally relates to a method and apparatus for a making a formed fibrous article and more specifically to method and apparatus for making a formed fibrous article useful as an absorbent core structure in a disposable sanitary article such as a sanitary napkin, panty liner, diaper or the like. The present invention also relates to a disposable sanitary article including a formed fibrous article according to the present invention as a core structure thereof.