Disposable Worn Article Side Panel Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing disposable worn articles, such as diapers, require complex handling and result in material waste due to the need for side panels to be fastened to a side sheet before being attached to the absorbent body.
Innovation Solution
A method and apparatus that produce side panels directly from a continuous web without using side sheets, where the web is cut into alternating depressed and protruding portions, allowing the panels to be attached to the absorbent body in a way that minimizes material waste and simplifies the production process by enabling point and line symmetry shapes for better fit and wearability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If side panels are fastened to a side sheet before being attached to the absorbent body, then the side panels can be securely attached to the absorbent body, but the handling of the side sheet becomes complicated and the degree of freedom of the production line decreases
Solution Approach 1:
The invention extracts and eliminates the side sheet from the manufacturing process. Instead of fastening side panels to a side sheet before attachment, the method directly attaches the side panels to the absorbent body. This is achieved by carrying the absorbent body and continuous web separately, then fastening the side panels directly to the absorbent body sides, thereby simplifying the production line while maintaining secure attachment.
2Ease of manufacture
If side panels are produced from a continuous web using conventional methods, then side panels can be manufactured, but material waste occurs and the production process becomes complicated
Solution Approach 1:
The invention segments the continuous web into individual side panels through a cutting mechanism. The continuous web is carried along and cut at predetermined intervals to produce separate side panels that are then fastened to the absorbent body. This segmentation approach allows for efficient production while minimizing material waste by optimizing the cutting pattern and web utilization.
Solution Approach 2:
The invention performs preliminary actions by pre-carrying the continuous web and absorbent body in predetermined paths before the fastening operation. The side panels are prepared from the continuous web in advance, and the absorbent body is positioned beforehand, allowing for streamlined production and reduced material waste through optimized material flow and positioning.
3Ease of operation
If the lower edge of the side panel is slanted diagonally to fit around the base of the legs, then wearability is improved, but the upper edge must be horizontal to fit the torso, creating a vertically asymmetric shape that complicates manufacturing
Solution Approach 1:
The invention embraces the vertically asymmetric shape of the side panels as a design feature rather than a manufacturing complication. The side panels are deliberately designed with diagonal lower edges for leg fit and horizontal upper edges for torso fit. The manufacturing process accommodates this asymmetry by using a continuous web that is cut and positioned to create the required asymmetric geometry, turning a potential disadvantage into a wearability advantage.
Data Source
AI summary
A method for manufacturing a disposable worn article, including: severing a continuous web W along a cut-off line L1 having a predetermined wave shape, dividing the continuous web W into a first and second divided webs W1, W2; allowing the first and second divided webs W1, W2 to cross each other in a width direction X so as to reverse positions of the first and second divided webs W1, W2 in the width direction X; reversing the second divided web W2 by twisting the second divided web W2 by 180°; rotating a second side panel which is cut off from the second divided web W2 by 180°, thereby producing a second side panel PR in line symmetry with a first side panel PL which is cut off from the first divided web W1; and placing and fastening the side panels PL, PR to the side portions of the body 20.