Vacuum Drum Elastic Substrate Consolidation

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Solution Overview

Problem

Existing manufacturing processes for absorbent articles, such as diapers, face challenges in imparting different amounts of stretch to discrete lengths of elastic substrate at high speeds, leading to increased complexity and cost, and require a simplified method to consolidate regions of stretched elastic substrates while maintaining stretch in specific areas.

Innovation Solution

A method and apparatus utilizing a rotating drum with vacuum compartments and apertures to apply varying vacuum pressures to different regions of a discrete length of elastic substrate, allowing for consolidation of the substrate while maintaining stretch in at least one region, by increasing vacuum pressure in end regions to reduce the length of the substrate while maintaining constant elongation in the central region.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If different amounts of stretch are imparted to discrete lengths of elastic substrate by hand, then the fit and comfort of absorbent articles is improved, but the productivity and manufacturing speed deteriorate

Engineering Contradiction:

Improvefit and comfort of absorbent articlesVSAvoidmanufacturing speed

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent replaces manual mechanical stretching operations with a vacuum-based pneumatic system. The vacuum drum applies controlled vacuum pressure to different regions of the elastic substrate to impart differential stretch automatically, eliminating hand operations while maintaining high manufacturing speed.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention uses vacuum pressure applied through a rotating drum to consolidate and stretch elastic substrate regions. By controlling vacuum pressure in different zones of the drum, the system achieves differential stretching of end regions versus central regions, improving fit and comfort without reducing productivity.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Ease of operation

If different amounts of stretch are imparted by advancing substrate through a series of operations, then the desired stretch distribution is achieved, but the device complexity and manufacturing cost increase

Engineering Contradiction:

Improvestretch distribution controlVSAvoidmanufacturing process complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent combines multiple stretching operations into a single vacuum drum apparatus. Different regions of the substrate receive different vacuum pressures simultaneously as the drum rotates, achieving differential stretch in one integrated process rather than through multiple separate operations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The vacuum drum serves multiple functions: it holds the substrate, applies differential stretch to different regions, and maintains consistent elongation in the central region. This single device performs what would otherwise require multiple specialized operations, reducing overall process complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If uniform stretch is applied to the entire discrete length of elastic substrate, then the manufacturing process is simple, but the fit and comfort of absorbent articles deteriorate

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidfit and comfort of absorbent articles

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The patent applies different vacuum pressures to different regions of the elastic substrate. End regions receive higher vacuum pressure for consolidation and stretch, while the central region maintains constant elongation. This localized differentiation of treatment improves fit and comfort while keeping the overall process relatively simple.

Inventive Principle:

Principle #3Local quality

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

Enables efficient consolidation of elastic substrate regions, reducing the length of the substrate while maintaining stretch in the central region, thereby improving the fit and comfort of absorbent articles without adding complexity or cost to the manufacturing process.

Implementation Method 1

applying vacuum pressure to the first end region, second end region, and central region of the discrete length of elastic substrate

Methodology Applied

Scientific EffectVacuum pressure: Vacuum

Data Source

PatentUS9221195B2Methods and apparatuses for consolidating elastic substrates

Publication Date: 2015.12.29 PROCTER & GAMBLE CO

AI summary

The method includes rotating a drum about an axis of rotation. A discrete length of elastic substrate is positioned on the outer circumferential surface of the rotating drum, wherein the discrete length of elastic substrate is in a stretched state and defines a first length. The discrete length of elastic substrate may be defined by a first end region, a second end region, and a central region separating the first and second end regions. The method may comprise applying vacuum pressure to the first, second, and central regions of the discrete length of elastic substrate. Vacuum pressure may be reduced on the first and second end regions such that the discrete length of elastic substrate consolidates to a second length that is less than the first length.