Web Composition Printing Aligned to Apertures and Phase Shifts
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Solution Overview
Problem
In the manufacturing of disposable absorbent articles, there is a need for a process that can effectively deposit compositions based on specific features of the web, such as apertures, to ensure accurate alignment and functionality, as existing methods often result in printing offsets that impact the intended design and functionality.
Innovation Solution
A system and method for non-contact printing compositions on a web, utilizing an inspection/print station that detects features and generates a print pattern to align composition sites with pre-rendered patterns, allowing for precise deposition of compositions on nonwoven, film, or laminate webs, even after the formation of discontinuities like apertures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional printing methods are used at normal operating speed, then productivity is maintained, but manufacturing precision deteriorates due to printing offsets in machine and cross-machine directions
Solution Approach 1:
The system captures images of the web at multiple positions along the machine direction before printing occurs, and pre-calculates the print pattern with phase shifts applied in advance. This preliminary imaging and pattern generation allows the printing system to compensate for web movement and maintain precision at high speeds without real-time adjustment delays.
Solution Approach 2:
The print pattern is made dynamic by incorporating phase shifts in the machine direction based on detected web position and speed variations. The system continuously adjusts the print pattern phase relative to the captured web images, allowing the printing process to adapt to changing web conditions while maintaining alignment precision at normal operating speeds.
2Manufacturing precision
If printing is based on particular features like apertures, then manufacturing precision is improved, but device complexity increases due to vision systems and registration marks
Solution Approach 1:
The imaging system serves multiple functions: it captures web position information, identifies features like apertures for alignment, and provides data for phase shift calculations. This multi-functional approach eliminates the need for separate registration mark systems and vision processing equipment, reducing overall device complexity while maintaining feature-based printing precision.
Solution Approach 2:
The web features themselves (such as apertures or patterns in the nonwoven material) serve as the alignment references, eliminating the need for separate registration marks. The system uses the web's own features detected by the imaging system to determine print positioning, making the web self-referential for alignment purposes and reducing external complexity.
3Ease of manufacture
If offset printing is applied, then ease of manufacture is improved, but manufacturing precision deteriorates as the entire print design is offset from features
Solution Approach 1:
The print design is segmented into multiple zones with different phase shifts applied in the machine direction. Each segment can be independently positioned relative to detected web features, allowing parts of the design to be offset while maintaining overall feature registration. This segmentation enables selective alignment without requiring the entire design to be uniformly positioned.
Solution Approach 2:
Different phase shifts are applied to different regions of the print pattern based on local web position detection. The system adjusts the print pattern locally in the machine direction to match detected features at each cross-machine position, maintaining manufacturing simplicity while achieving precise local registration between print and web features.
Data Source
AI summary
A method of printing composition(s) on a web is disclosed. The method includes the steps of advancing the web and printing a plurality of composition sites on the web. The method further includes the step of forming one or more discontinuities in the web. The discontinuities correspond to the printed composition sites.