Tampon String Loop Attachment via Thermal Bonding
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Solution Overview
Problem
The existing methods for manufacturing tampons with stitched withdrawal strings are limited by sewing machine speeds, making it difficult to increase production rates and reduce production times.
Innovation Solution
The withdrawal string is wrapped around the absorbent strip in the form of a loop, with folds formed on either side, and secured through welding or bonding, allowing for higher production speeds and preventing slippage during shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stitching is used to attach the withdrawal string to the absorbent strip, then the string is securely attached, but the production speed is limited by sewing machine speeds
Solution Approach 1:
The patent replaces the mechanical stitching system with a thermal bonding system. The withdrawal string is thermally bonded to the absorbent strip using heated pressing pieces, ultrasound, laser, or other thermal bonding methods, eliminating the need for sewing machines and enabling higher production speeds while maintaining secure attachment.
Solution Approach 2:
The patent changes the attachment method from mechanical (stitching) to thermal (bonding/welding). By applying heat, ultrasound, or other energy forms to bond the string to the strip, the process can be performed much faster than mechanical stitching while achieving reliable attachment.
2Reliability
If stitching is used to attach the withdrawal string, then the string is secured, but production time increases
Solution Approach 1:
The patent replaces the time-consuming mechanical stitching process with rapid thermal bonding or ultrasonic welding. These alternative methods can be performed much faster than sewing machine stitching, significantly reducing the time required to attach the withdrawal string to each tampon.
Solution Approach 2:
The patent performs the attachment operation as part of the continuous forming process rather than as a separate post-processing step. The withdrawal string is positioned and bonded during the tampon formation process itself, eliminating additional handling time and enabling higher overall production rates.
3Productivity
If the withdrawal string is wrapped in a loop around the strip, then high production speeds can be achieved, but the string may slip or disappear during pressing
Solution Approach 1:
The patent uses thermal bonding or ultrasonic welding to permanently secure the looped withdrawal string to the absorbent strip. This replaces the temporary mechanical loop configuration with a permanent chemical/thermal bond, preventing slippage during the pressing operation while maintaining the speed advantages of the loop method.
Solution Approach 2:
The patent changes the string attachment from a temporary mechanical loop to a permanent thermal bond. By applying heat, pressure, and/or ultrasound, the string material is melted or bonded to the strip material, creating a secure attachment that prevents movement during subsequent pressing operations.
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 method enables a significant increase in production rate, allowing for shorter manufacturing times and higher output, with up to 120 tampons per minute per endless web, compared to the prior art.
Implementation Method 1
a welding apparatus which welds the withdrawal string (3) to the absorbent strip (2)
Implementation Method 2
pressing the strip between jaws which can be moved towards one another, forming a fold in the strip on each side of the loop
Data Source
AI summary
A tampon is proposed, with an insertion end and a rear end, made from a pressed absorbent strip (2) and a withdrawal string (3) running out of the rear end. In order to achieve short production times during manufacture of the tampon, the withdrawal string (3) is placed around the strip (2) in the shape of a loop 4, and the strip (2) is provided with a fold (16, 17) at each side of the loop (4).In terms of a method suitable for producing a tampon, the following steps are proposed:a) cutting the absorbent strip (2) to size,b) placing a withdrawal string (3) around the strip (2) in the shape of a loop (4),c) pressing the strip (2) between jaws (7) which can be moved towards one another forming a fold (16, 17) in the strip (2) on each side of the loop (4).