Tapered Side Panel Web Segmentation for Bariatric Sanitary Articles
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Solution Overview
Problem
The production of sanitary articles for obese adults poses challenges due to their large size and high production rates, requiring efficient and cost-effective methods to minimize waste and ensure wearability, while existing methods are inefficient and costly for handling and folding of side panels.
Innovation Solution
A process involving the formation of side panels with a tapered configuration from web elements, using oblique cuts and alternating rotation to align panels for efficient application on a central body, reducing waste and improving wearability across various sizes and user types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional cutting and folding operations are used for side panels, then sanitary articles can be produced for newborn babies and small children, but the method becomes inefficient and costly for bariatric articles of large size
Solution Approach 1:
The side panels are pre-formed with a tapered configuration using oblique cuts before being applied to the central body. This preliminary shaping allows the panels to be ready for attachment without requiring complex real-time manipulation during high-speed production, thereby maintaining manufacturing efficiency while enabling production of large-sized bariatric articles
Solution Approach 2:
The web element is segmented into multiple side panels through cutting operations performed in an oblique direction. This segmentation creates individually tapered panels that can be independently handled and applied, reducing the complexity of manipulating large continuous panels while maintaining high production rates
2Productivity
If high production rates are maintained for bariatric articles, then productivity is improved, but manipulation and folding of large side panels becomes very critical and difficult
Solution Approach 1:
Side panels are pre-shaped with tapered configurations through oblique cutting before the high-speed production phase. This preliminary action ensures that panels are already optimized for their final position, eliminating the need for complex real-time folding and manipulation during rapid production of large bariatric articles
Solution Approach 2:
Instead of attempting to fold and manipulate large panels into position during high-speed production, the invention inverts the approach by pre-forming the panels with their final tapered configuration. This reversal of the traditional sequence simplifies the manipulation required during high-rate production
3Ease of operation
If elasticated material is used for side panels to ensure wearability, then comfort is improved, but production cost increases due to material waste
Solution Approach 1:
The side panels are cut with oblique angles to create a tapered configuration that provides different properties at different locations. The wider proximal end ensures comfort and wearability at the waistband area, while the narrower distal end reduces material usage. This local differentiation of panel geometry optimizes both wearability and material efficiency
Solution Approach 2:
The cutting parameters are changed from traditional orthogonal cuts to oblique cuts at specific angles. This parameter change creates the tapered shape that reduces material waste while maintaining the elasticated material's wearability properties throughout the panel
Data Source
AI summary
The process enables production of sanitary articles that can be worn as a pair of pants (such as, for instance, nappies or bariatric pants) comprising a central body (2), which can be set in a concave configuration around the crotch region of the user and at least one pair of side panels (3, 4), which are connected to the central body (2) and are to define at least in part the waistband of the article (1). The process envisages obtaining an intermediate product constituted by one or more assembly webs (1000; 1000a, 1000b) which carries/carry applied thereon, on at least one of its sides, a plurality of said side panels (3, 4), each having a proximal edge (6) applied on said assembly web (1000; 1000a, 1000b). The side panels (3, 4) are connected to the central body (2) by connecting to the central body (2) itself a portion of assembly web (1000; 1000a; 1000b) which carries applied thereon a respective side panel (3, 4).