Trapezoidal Ear Web Cutting and Vacuum Application
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Solution Overview
Problem
In the manufacturing of disposable hygiene products like diapers, existing methods result in significant waste due to the inefficiencies in processing and applying web materials, particularly in the production of ear components, where material is often wasted and requires intensive recycling processes.
Innovation Solution
A method and apparatus that utilize a rotary knife or die to create trapezoidal ear webs with minimized waste, involving a synchronized vacuum anvil and ear turner assembly to rotate and orient discrete ear pieces correctly for application to a chassis web, allowing for zero or minimal waste in the incoming ear web material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional slip-and-cut applicators are used to apply ear webs to diapers, then ears can be applied to the diaper, but significant material waste is generated and intensive recycling processes are required
Solution Approach 1:
The incoming ear web is divided into individual ear segments by a rotary knife that cuts between vacuum holes in the anvil. Each vacuum hole holds one ear segment, allowing precise cutting without waste material between segments. This segmentation approach eliminates the need for excessive material and complex recycling processes.
Solution Approach 2:
The vacuum anvil automatically holds and positions each ear segment at the correct location during cutting and transfer. The system self-regulates the positioning and application of ears without requiring additional complex recycling equipment, as the vacuum holes inherently manage material placement and waste elimination.
2Loss of substance
If conventional applicators are used, then ears can be applied to the diaper, but waste materials must be harvested and separated at the end of the process
Solution Approach 1:
The rotary knife extracts and removes waste material between ear segments during the cutting process. By cutting between vacuum holes that hold individual ears, the system automatically extracts waste material at the point of cutting, eliminating the need for separate harvesting and separation steps at the end of the process.
Solution Approach 2:
The cutting and waste removal process occurs continuously during ear application. The rotary knife continuously cuts between vacuum holes while the anvil continuously transfers ears to the diaper, maintaining continuous useful action without interruption for waste harvesting or separation.
3Productivity
If high-speed processing is implemented, then productivity increases, but the mechanical integrity and operational capabilities of applicators must be improved
Solution Approach 1:
The patent replaces complex mechanical positioning and holding systems with a vacuum field system. The vacuum anvil uses suction through holes to hold ear segments, eliminating the need for complex mechanical clamps, springs, or actuators that would compromise reliability at high speeds. This field-based approach maintains mechanical integrity while enabling high-speed operation.
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 approach enables the application of ear components with zero material waste, improving operational efficiency and reducing waste generation in the production process, while maintaining the mechanical integrity and operational capabilities required for high-speed processing.
Implementation Method 1
a synchronized vacuum anvil and ear turner assembly to rotate and orient discrete ear pieces correctly for application
Data Source
AI summary
The present invention provides a method of providing a disposable product with a contoured leg opening. In this method at least one chip is removed from at least one ear of a disposable product. The chip may be removed from an ear prior to attaching the ear to the chassis web. Alternatively, the chip may be removed from the ear after the ear is attached to the chassis web.