Radial Joining Stations for Space-Saving Tampon Applicator Assembly
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Solution Overview
Problem
Existing devices for joining multi-part tampon applicators, particularly three-part applicators, are space-intensive and cumbersome to monitor for quality, making them inefficient for high-volume production.
Innovation Solution
A device utilizing a circular disk with radially arranged joining stations and receiving fingers, allowing simultaneous processing of multiple applicators, combined with thermal forming and mechanical snap-in mechanisms, to efficiently join tampon applicator parts while maintaining quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If linear joining lines are used to join multi-part tampon applicators, then the joining process can be completed step by step, but the space requirement becomes comparatively high and quality monitoring becomes cumbersome
Solution Approach 1:
The device divides the joining process into multiple radial stations arranged around a circular disk, with each station handling a specific joining task. This segmentation allows simultaneous processing of multiple applicator parts at different stations, reducing the linear space requirement while maintaining manufacturing capability
Solution Approach 2:
The invention transitions from a linear one-dimensional joining line to a radial two-dimensional circular arrangement. Multiple joining stations are positioned at different radial positions around a central axis, enabling parallel processing in the radial dimension and significantly reducing the overall footprint of the manufacturing equipment
2Ease of manufacture
If linear joining lines are used to join multi-part tampon applicators, then the joining process can be completed step by step, but quality monitoring becomes cumbersome
Solution Approach 1:
The device incorporates sensors and detection mechanisms at each radial joining station that provide real-time feedback on the joining process. This allows for continuous quality monitoring and immediate detection of defects, making quality control systematic and manageable rather than cumbersome
3Productivity
If traditional joining methods are used for multi-part tampon applicators, then individual parts can be joined sequentially, but production efficiency is reduced for high-volume manufacturing
Solution Approach 1:
The invention merges multiple joining operations into a single integrated circular device where multiple stations operate simultaneously. Several tampon applicator parts can be joined in parallel at different radial stations during the same time period, dramatically increasing production efficiency compared to sequential processing
Solution Approach 2:
The circular disk structure serves multiple functions: it supports multiple joining stations, enables rotational positioning for different operations, and accommodates various types of joining tasks (thermal forming, mechanical snap-in, etc.) at different radial positions, making the device highly versatile for high-volume manufacturing
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 high-volume, efficient, and space-saving production of multi-part tampon applicators with consistent quality, using a circular disk design that allows batch processing and real-time monitoring.
Implementation Method 1
certain structures are initially guided into one another without friction, i.e., without having to overcome mechanical resistance
Implementation Method 2
This is followed by thermoplastic deformation, which completes the joining process and joins the individual applicator parts together
Data Source
AI summary
A device for joining multi-part tampon applicators, in particular three-part tampon applicators, which include at least one outer cylinder and a first inner cylinder, includes at least one joining station with at least one receiving finger for receiving one outer cylinder and one first inner cylinder each, as well as a first inner cylinder supply for loading the at least one receiving finger with at least one first inner cylinder and an outer cylinder supply for loading the at least one receiving finger with at least one outer cylinder. The device further includes a processing station for joining the at least one outer cylinder to the at least one first inner cylinder, and the at least one joining station is arranged radially on a circular disk, in particular so that the at least one receiving finger is oriented essentially radially. A method joins multi-part, in particular three-part, tampon applicators.