Stretchable Sheet Pitch Adjustment for Diaper Manufacturing
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Solution Overview
Problem
In diaper manufacturing lines, the need to change cutter rolls with different arrangement pitches for varying diaper sizes increases facility costs and reduces capacity utilization, as existing processing apparatuses are not adaptable to different product pitches.
Innovation Solution
A manufacturing apparatus and method that includes an upstream and downstream transport mechanism and an extension-ratio adjustment mechanism to adjust the pitch of a stretchable sheet-like member, allowing a single processing apparatus to handle different diaper sizes by adjusting the sheet's extension ratio and transferring it to a downstream transport mechanism for processing at a predetermined pitch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple cutter rolls with different arrangement pitches are used to support different diaper sizes, then the processing apparatus can handle various product pitches, but facility costs increase and capacity utilization decreases
Solution Approach 1:
The cutter roll is designed with adjustable blade arrangement pitch, allowing the same cutter roll to be dynamically reconfigured for different diaper sizes. The blade pitch can be adjusted between a first pitch for L-size diapers and a second pitch for S-size diapers, eliminating the need for multiple fixed cutter rolls and reducing facility costs while maintaining adaptability
Solution Approach 2:
The invention changes the physical parameter of blade arrangement pitch on the cutter roll to accommodate different product pitches. By making the blade pitch adjustable rather than fixed, a single cutter roll can serve multiple product sizes, resolving the contradiction between versatility and device complexity
2Adaptability or versatility
If multiple cutter rolls with different arrangement pitches are installed to support different diaper sizes, then various product pitches can be accommodated, but capacity utilization decreases due to replacement and installation requirements
Solution Approach 1:
The adjustable blade arrangement pitch allows the single cutter roll to be reconfigured for different diaper sizes without replacement. This dynamic adjustment capability eliminates downtime associated with installing and removing different cutter rolls, thereby maintaining high capacity utilization while supporting various product pitches
3Productivity
If a single processing apparatus is shared across different diaper sizes, then cost reduction and productivity improvement can be achieved, but the apparatus must be adaptable to different product pitches
Solution Approach 1:
The cutter roll is designed with universal functionality to handle both L-size and S-size diapers through adjustable blade arrangement pitch. This multi-functionality allows a single processing apparatus to serve multiple product sizes, achieving cost reduction and productivity improvement while maintaining the necessary adaptability
Solution Approach 2:
By enabling parameter adjustment of blade pitch, the single processing apparatus achieves universality across different diaper sizes. The ability to change the blade arrangement pitch parameter allows the apparatus to adapt to varying product pitches without requiring multiple specialized devices
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 solution enables the sharing of processing apparatuses across different diaper sizes, reducing costs and improving productivity by allowing a single apparatus to process diapers of varying sizes efficiently without the need for multiple cutter rolls.
Implementation Method 1
the stretchable sheet-like member sequentially undergoes suitable processes such as attaching an absorbent main body which absorbs liquid, and is finally cut out on product-by-product basis, to produce the diaper. Accompanying with the cutting, the extended state of the stretchable sheet-like member is released and contracts in the transporting direction.
Data Source
AI summary
A manufacturing apparatus for manufacturing an absorbent article, the manufacturing apparatus including: an upstream transport mechanism and a downstream transport mechanism that transports a stretchable sheet-like member along a transporting direction, the stretchable sheet-like member continuing along the transporting direction; an extension-ratio adjustment mechanism that is located between the upstream transport mechanism and the downstream transport mechanism, and that adjusts an extension ratio at which the stretchable sheet-like member extends in the transporting direction; and a processing apparatus that performs the certain process to the stretchable sheet-like member that is being transported by the downstream transport mechanism. When the upstream transport mechanism transports a first stretchable sheet-like member in which parts to be the absorbent article are lined up at a first pitch in the transporting direction, the extension-ratio adjustment mechanism adjusts an extension ratio of the first stretchable sheet-like member so that the parts to be the absorbent article are lined up at a predetermined pitch. When the upstream transport mechanism transports a second stretchable sheet-like member in which the parts to be the absorbent article are lined up at a second pitch in the transporting direction, the second pitch being different from the first pitch, the extension-ratio adjustment mechanism adjusts an extension ratio of the second stretchable sheet-like member so that the parts to be the absorbent article are lined up at the predetermined pitch.