Web Material Delivery Module for Continuous Absorbent Article Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing manufacturing processes for disposable absorbent articles face productivity issues due to the need to slow or stop the continuous process to replace exhausted rolls of web materials, leading to increased costs and requiring multiple unwinding devices and controllers for various web materials.
Innovation Solution
An integral web material delivery module that simultaneously unwinds and delivers multiple rolls of web materials to downstream processes using a frame-mounted mandrels and splicers, allowing for continuous operation by splicing and bonding web materials, thereby minimizing downtime and equipment requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate unwinding devices and controllers are used for various web materials, then each web material can be delivered independently, but the device complexity and manufacturing costs increase
Solution Approach 1:
The patent combines multiple separate unwinding devices into a single integrated unwinding apparatus that can handle multiple web materials simultaneously. The frame structure supports multiple mandrels that are all controlled by a single controller, merging the functionality of separate devices while maintaining independent web material delivery capability.
Solution Approach 2:
The single controller is designed to universally control multiple mandrels and unwinding operations. This multi-functional controller can manage different web materials (backsheets, topsheets, absorbent cores, etc.) through a unified control system, eliminating the need for separate controllers for each material type.
2Reliability
If the manufacturing process stops or slows down to replace exhausted rolls, then web material can be replenished, but productivity decreases and costs increase
Solution Approach 1:
The system prepares multiple web material rolls in advance and positions them on the mandrels before they are needed. The splicer is pre-configured and ready to perform automatic splicing operations. This preliminary preparation allows for continuous operation by having backup materials ready to replace exhausted rolls without stopping the manufacturing process.
Solution Approach 2:
The patent implements continuous web material delivery through automatic splicing mechanisms that join exhausted rolls to fresh rolls without interrupting the manufacturing process. The system maintains continuous operation by seamlessly transitioning between different web material rolls, ensuring the manufacturing throughput remains uninterrupted.
3Device complexity
If a single integrated delivery module is used for multiple web materials, then equipment requirements and complexity are reduced, but the ability to independently control each web material delivery may be limited
Solution Approach 1:
The integrated delivery module is segmented into separate mandrels for each web material, with each mandrel capable of independent rotation and tension control. This segmentation allows the system to maintain independent control over each web material delivery while using a single unified controller and frame structure, reducing overall complexity.
Data Source
AI summary
Apparatuses and methods for producing an absorbent article are provided. Generally, the apparatuses and methods allow for continuous delivering of a plurality of web material to downstream equipment during a manufacturing process. In some embodiments, the apparatuses and methods allow for simultaneously unwinding, splicing, and lamination of multiple rolls of web material rotatably mounted to a frame and delivering the web material to various downstream manufacturing processes.