Rotating Bonder Apparatus for Variable-Size Diaper Seam Formation
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Solution Overview
Problem
The manufacturing process for disposable absorbent articles, such as diapers, is inefficient as it requires switching equipment or making significant modifications to produce different sizes, leading to increased costs and time consumption.
Innovation Solution
A method and apparatus for transferring and bonding substrates, involving a bonder apparatus that rotates and adjusts velocity to partially melt and compress substrates, forming side seams in various diaper configurations without the need for equipment changes, allowing for the production of different sizes on the same equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If equipment is switched or modified to produce different sizes of absorbent articles, then manufacturing capability for different sizes is achieved, but production time and costs increase
Solution Approach 1:
The bonder apparatus is designed with a universal bonding mechanism that can accommodate multiple product sizes through adjustable parameters rather than physical reconfiguration. The system uses variable frequency drives to adjust the rotation speed of rollers and maintains consistent process tension across different sizes, allowing one piece of equipment to produce multiple diaper sizes without switching or modification.
Solution Approach 2:
The system dynamically adjusts operational parameters such as roller rotation velocity, process tension, and product pitch to accommodate different absorbent article sizes. The variable frequency drives enable real-time speed adjustments while maintaining synchronized operation of multiple rollers, allowing the equipment to adapt to different product specifications without physical changes.
2Adaptability or versatility
If equipment is switched or modified to produce different sizes of absorbent articles, then manufacturing capability for different sizes is achieved, but manufacturing costs increase
Solution Approach 1:
The bonder apparatus consolidates multiple size-production capabilities into a single universal machine. By using adjustable process parameters rather than dedicated equipment for each size, the system eliminates the need for expensive equipment switches or modifications, reducing manufacturing costs while maintaining the ability to produce various absorbent article sizes.
Solution Approach 2:
The system changes operational parameters such as roller speed, process tension, and product pitch to produce different sizes. This parameter-based adjustment approach avoids the need for physical equipment modifications or replacements, significantly reducing manufacturing costs while maintaining versatility across product sizes.
3Productivity
If process tension and product pitch are maintained consistently, then production efficiency is improved, but flexibility to adjust for different sizes is reduced
Solution Approach 1:
The system dynamically adjusts roller rotation speeds using variable frequency drives while maintaining consistent process tension through controlled differential speeds. This allows the equipment to adapt to different product sizes and pitches without compromising production efficiency, as the tension control system automatically compensates for parameter changes.
Solution Approach 2:
The system changes operational parameters such as roller velocity and product pitch in a coordinated manner. By adjusting the rotation speed of individual rollers while maintaining overall process tension consistency, the system can produce different sizes and pitches without sacrificing production efficiency, resolving the apparent contradiction between parameter consistency and adaptability.
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 the efficient production of absorbent articles of varying sizes using the same equipment, reducing production costs and time by maintaining consistent process tension and product pitch, thus streamlining the manufacturing process.
Implementation Method 1
heating a fluid to a temperature sufficient to at least partially melt the first substrate and the second substrate
Implementation Method 2
partially melting at least a portion of at least one of the leading portion and the first trailing portion
Data Source
AI summary
A method and apparatus for mechanically deforming a substrate assembly. The substrate assembly may be advanced in a machine direction at a first velocity toward a bonder apparatus. The bonder apparatus may rotate about an axis of rotation and include a support surface between each of a first and a second member. The first member and the second member may be separated by a repitch angle. The second member may be repositioned such that the first member and the second member are separated by a product angle. The first member may receive a leading portion and second member may receive a trailing portion of the substrate assembly and each member may rotate at the first velocity. The leading portion and the trailing portion are separated by a product arc length, which may be equal to a process product pitch. The substrate assembly may then undergo one or more processes such as bonding, cutting, and/or scoring.