Rotating Drum SAP Applicator for High-Speed Distribution Accuracy
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Solution Overview
Problem
Existing methods for applying Super Absorbent Polymer (SAP) granules in absorbent articles face challenges in achieving high accuracy and flexibility in distribution patterns, particularly at high speeds, and struggle with using multiple types of SAP in different regions, leading to inefficiencies and increased costs.
Innovation Solution
A rotating drum apparatus with selectively connected vacuum and pressurizing chambers and a cascading SAP system that allows for precise control over SAP granule distribution, enabling accurate placement of single or multiple SAP types onto a carrier layer or into an air stream, reducing pulse loss and allowing for varied SAP usage across the article.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a nozzle with air feed is used to apply SAP granules, then the SAP can be applied into the production process, but the nozzle must be placed far away from the blending process to achieve correct spray width, which significantly reduces pulse performance and causes pulse loss at high speeds
Solution Approach 1:
The system divides the SAP application process into discrete pulse events, where SAP granules are delivered in controlled pulses rather than continuous flow. This segmentation allows precise placement at high speeds by synchronizing pulse delivery with carrier web positioning, eliminating the need for distant nozzle placement and maintaining pulse integrity throughout the application process.
Solution Approach 2:
The system dynamically adjusts the timing and frequency of SAP pulses to match the high-speed carrier web movement. By making the puling device responsive to production speed variations, the system maintains accurate SAP placement without requiring the nozzle to be positioned far from the blending process, thus preserving pulse performance at high speeds.
2Productivity
If the nozzle is placed close to the blending process to maintain pulse performance, then pulse loss is reduced, but the spray width becomes insufficient for correct SAP distribution
Solution Approach 1:
The system transitions from relying solely on horizontal nozzle-to-web distance for spray width control to using vertical pulse timing and frequency control. By delivering SAP in precisely timed vertical pulses synchronized with carrier web movement, the system achieves both narrow spray width (for accurate placement) and adequate distribution width (through puling synchronization), resolving the spatial constraint.
3Adaptability or versatility
If multiple types of SAP are used in different regions, then product performance and cost-effectiveness are improved, but the complexity of controlling distribution patterns increases
Solution Approach 1:
The system segments the carrier web into multiple zones, each receiving specific SAP types through independently controlled pulse delivery mechanisms. This segmentation allows different SAP types to be applied to different regions without requiring a single complex multi-type delivery system, simplifying control while enabling versatility.
Solution Approach 2:
The system applies different SAP types to different regions of the carrier web based on local requirements. Each region receives the specific SAP type needed for its function, with pulse timing and frequency adjusted locally to achieve the desired distribution pattern. This local quality approach simplifies control by treating each region independently rather than managing all SAP types globally.
4Loss of substance
If the puling width is designed to match the laydown process width, then pulse losses in equipment are significantly reduced, but the device complexity increases
Solution Approach 1:
The system dynamically adjusts puling width and timing to match the laydown process requirements. Rather than using a fixed complex configuration, the puling device adapts its parameters in real-time to optimize SAP transfer efficiency and minimize granule loss, achieving low substance loss without permanent structural complexity.
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
The solution significantly enhances SAP deposition accuracy, reduces standard deviation, and allows for the use of different SAP types in specific areas, improving the performance and cost-effectiveness of absorbent articles by maintaining a stable blending process and enabling precise pattern control.
Implementation Method 1
Positioning a hole of the outer drum in the proximity of at least first plurality of SAP granules and providing a vacuum in predetermined vacuum chamber of the stator, such that SAP granules are positioned into the holes of the outer drum
Implementation Method 2
expelling the SAP granules from the hole to the SAP granule receiving system, preferably by connecting the hole in the outer drum to a pressure chamber in the stator
Implementation Method 3
A cascading SAP system that allows for precise control over SAP granule distribution
Data Source
AI summary
The present invention relates to an apparatus and a method of applying a single SAP (Super Adsorbent Polymer) type granules or multiple SAP types at high speed in a continuous or intermittent 2-dimensional or 3-dimensional profile via volumetric or gravimetric metering onto a receiving system such as a carrier layer and/or into an air stream for use in an absorbent article, particularly diapers for babies or adults, training pants, pull-up diapers (diaper pants), sanitary napkins, panty liners or the like. These articles typically comprise of a carrier layer with the SAP particles and/or a mixed SAP and fiber core together with further layers, making up the complete article.