Vacuum Anvil Cutting Stretchable Poly Web Patches
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Solution Overview
Problem
Current methods for applying stretchable poly web materials in diaper manufacturing result in waste due to the need for continuous application along the entire product length, and the slip/cut process often leads to distorted patches due to elasticity issues, making it difficult to cut precise poly patches without snap-back.
Innovation Solution
A method and apparatus utilizing a rotatable anvil with reduced air pressure and vacuum openings, combined with a cutting roll and tension control, to intermittently cut and secure segments of the poly web onto a second web, preventing snap-back and ensuring precise placement and cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous application of poly web is used along the entire product length, then complete coverage is achieved, but material waste increases
Solution Approach 1:
The poly web is divided into discrete patches rather than applied continuously. The cutting roll cuts the poly web into individual patches at predetermined intervals, allowing application only where needed on the diaper chassis, thereby reducing material waste while maintaining complete coverage through systematic segmentation of the application process
Solution Approach 2:
The poly web application is performed periodically rather than continuously. The cutting roll operates at predetermined intervals along the web, creating periodic patches that are applied to specific locations on the chassis. This periodic application pattern ensures complete coverage through strategic placement while minimizing material consumption by applying poly only at necessary intervals
2Ease of manufacture
If slip/cut process is used to cut poly patches, then cutting is achieved, but distortion occurs due to elasticity
Solution Approach 1:
A vacuum anvil serves as an intermediary between the cutting roll and the poly web. The vacuum anvil holds the poly web in place during the cutting process, preventing the elastic material from moving or distorting. This intermediary mechanism allows the cutting roll to efficiently cut patches while the vacuum anvil maintains web stability, eliminating distortion caused by the elasticity of the poly material
Solution Approach 2:
The mechanical holding system is replaced with a vacuum-based holding system. Instead of relying solely on mechanical pressure or friction to hold the elastic poly web during cutting, a vacuum field is applied through the vacuum anvil. This substitution provides more effective and uniform holding of the elastic material, preventing distortion while maintaining ease of cutting through the vacuum-assisted positioning
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 reduces material waste by applying poly web only where necessary, while maintaining the integrity of the cut patches, eliminating distortion and ensuring accurate placement on the diaper chassis.
Implementation Method 1
a rotatable anvil with reduced air pressure and vacuum openings
Implementation Method 2
using the reduced air pressure to hold the segments against the peripheral surface
Data Source
AI summary
Apparatus and methods are provided to allow for cutting a stretchable first web into segments and securing the segments to a second web. The apparatus includes an infeed rate adjustment apparatus, a tension control device, a cutting apparatus, and means for securing the segments to the second web. The infeed rate adjustment apparatus is sized and configured to adjust the speed of the infeed of the first web to the cutting apparatus to space apart the segments.