U.S. patent application number 14/273836 was filed with the patent office on 2014-11-20 for methods and apparatuses for folding absorbent articles.
This patent application is currently assigned to The Procter & Gamble Company. The applicant listed for this patent is The Procter & Gamble Company. Invention is credited to Andreas Josef Dreher, Todd Douglas Lenser, Peter Wiedmann, Yoichiro Yamamoto, Ricky Reynaldo Yanez, JR..
Application Number | 20140342895 14/273836 |
Document ID | / |
Family ID | 50980372 |
Filed Date | 2014-11-20 |
United States Patent
Application |
20140342895 |
Kind Code |
A1 |
Wiedmann; Peter ; et
al. |
November 20, 2014 |
Methods and Apparatuses for Folding Absorbent Articles
Abstract
The present disclosure relates systems and methods for folding
absorbent articles advancing in a converting line. The folding
processes and apparatuses herein may be configured with tucker
blades that are configured to maximize the period of time wherein
the leading edges of the tucker blades move at maximum speeds
during the folding process.
Inventors: |
Wiedmann; Peter;
(Montgomery, OH) ; Lenser; Todd Douglas; (Liberty
Township, OH) ; Yanez, JR.; Ricky Reynaldo;
(Cincinnati, OH) ; Yamamoto; Yoichiro; (Koeln,
DE) ; Dreher; Andreas Josef; (Cincinnati,
OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Procter & Gamble Company |
Cincinnati |
OH |
US |
|
|
Assignee: |
The Procter & Gamble
Company
Cincinnati
OH
|
Family ID: |
50980372 |
Appl. No.: |
14/273836 |
Filed: |
May 9, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61824013 |
May 16, 2013 |
|
|
|
Current U.S.
Class: |
493/360 ;
493/444 |
Current CPC
Class: |
A61F 13/15747 20130101;
B65H 2801/57 20130101; B65H 45/18 20130101 |
Class at
Publication: |
493/360 ;
493/444 |
International
Class: |
B65H 45/28 20060101
B65H045/28; B65H 45/16 20060101 B65H045/16 |
Claims
1. A method for folding absorbent articles, the method comprising
the steps of: conveying an absorbent article at a first speed, S1,
in a first direction on a first carrier to define an article
transport plane, wherein the absorbent article includes a first
surface and a second surface opposite the first surface, wherein
the absorbent article includes a first end and a second end, and
wherein the absorbent article includes a first end region and a
second end region, and a central region located between the first
and second end regions; advancing the first end region past a nip
defined between the first carrier and a second carrier; rotating a
tucker blade, wherein the tucker blade includes a first surface and
a second surface opposite the first surface, and wherein the tucker
blade includes a leading edge and a trailing edge, wherein the
leading edge and the trailing edge move through the article
transport plane at the nip as the tucker blade rotates; contacting
the first surface of the absorbent article with the leading edge of
the tucker blade thereby creating a fold line across the central
region of the absorbent article; redirecting the central region of
the absorbent article in a second direction into the nip with the
leading edge of the tucker blade; maintaining contact between the
fold line and the leading edge of the tucker blade for a total time
period, Ttot, while portions of the leading edge contacting the
fold line move at speeds, Smax, of at least 0.8*S1 for a time
period, Tmax, of at least 0.5*Ttot; and conveying the folded
absorbent article in the second direction between the first carrier
and the second carrier away from the article transport plane.
2. The method of claim 1, further comprising the step of: cutting
the absorbent article from a continuous length of absorbent
articles, wherein the absorbent article includes a pitch length,
PL, defined by a distance in the machine direction between the
first end and the second end.
3. The method of claim 2, further comprising the step of: advancing
the continuous length of absorbent articles absorbent articles at a
line speed, SL, in a machine direction, wherein SL is less than
S1.
4. The method of claim 1, further comprising the step of folding,
n, absorbent articles with one full revolution of the tucker blade,
wherein n is greater than one.
5. The method of claim 5, wherein n is 2.
6. The method of claim 1, wherein the first carrier comprises a
belt conveyor.
7. The method of claim 1, wherein the second carrier comprises a
belt conveyor.
8. The method of claim 1, wherein the absorbent article comprises a
diaper, and wherein the first end region comprises a front waist
region, and wherein the second end region comprises a rear waist
region.
9. The method of claim 1, wherein the first surface of the
absorbent article comprises a wearer facing surface.
10. The method of claim 1, wherein Smax is at least 0.95*S1, and
Tmax is at least 0.7*Tot.
11. The method of claim 1, wherein Smax is S1, and Tmax is at least
0.9*Tot.
12. A method for folding absorbent articles, the method comprising
the steps of: advancing a continuous length of absorbent articles
absorbent articles at a line speed, SL, in a machine direction;
cutting the continuous length of absorbent articles into discrete
absorbent articles, wherein each discrete absorbent article
includes a first surface and a second surface opposite the first
surface, wherein each discrete absorbent article includes a first
end region and a second end region, and a central region located
between the first and second end regions, and wherein each discrete
absorbent article includes a first end and a second end, and a
having a pitch length, PL, defined by a distance in the machine
direction between the first end and the second end; conveying each
discrete absorbent article at a first speed, S1, in a first
direction on a first carrier to define an article transport plane,
wherein S1 is greater than SL; advancing the first end and the
first end region of each discrete absorbent article past a nip
defined between the first carrier and a second carrier; rotating a
tucker blade through the article transport plane at the nip as the
tucker blade rotates; contacting the first surface of a discrete
absorbent article with a leading edge of the tucker blade thereby
creating a fold line across the central region of the discrete
absorbent article; redirecting the central region of the absorbent
article in a second direction into the nip with the leading edge of
the tucker blade; and maintaining contact between the fold line and
the leading edge of the tucker blade for a total time period, Tot,
while portions of the leading edge contacting the fold line move at
speeds, Smax, of at least 0.8*S1 for a time period, Tmax, of at
least 0.5*Ttot; and conveying the folded absorbent article in the
second direction away from the article transport plane.
13. The method of claim 12, wherein Smax is at least 0.95*S1, and
Tmax is at least 0.7*Tot.
14. The method of claim 12, wherein Smax is S1, and Tmax is at
least 0.9*Tot.
15. The method of claim 12, further comprising the step of folding
more than one discrete absorbent article with one full revolution
of the tucker blade.
16. The method of claim 12, wherein the step of conveying the
folded absorbent article further comprises conveying the folded
absorbent article in the second direction between the first carrier
and the second carrier.
17. The method of claim 12, wherein the first carrier comprises a
belt conveyor, and wherein the second carrier comprises a belt
conveyor.
18. The method of claim 12, wherein the absorbent article comprises
a diaper, and wherein the first end region comprises a front waist
region, and wherein the second end region comprises a rear waist
region, and wherein the first surface of the absorbent article
comprises a topsheet.
19. An apparatus for folding absorbent articles, the apparatus
comprising: a knife adapted to cut discrete absorbent articles from
a continuous length of absorbent articles advancing in a machine
direction at a line speed, SL; a first carrier adapted to convey an
absorbent article in a first direction and a second direction at a
first speed, S1; a second carrier adjacent the first carrier to
define a nip extending in the second direction; a tucker blade
including a leading edge, wherein the leading edge moves through
the article transport plane at the nip as the tucker blade rotates;
and a motor adapted to rotate the tucker blade so as to maintain
contact between the absorbent article and the leading edge of the
tucker blade for a total time period, Ttot, while portions of the
leading edge contacting the absorbent article move at speeds, Smax,
of at least 0.8*S1 for a time period, Tmax, of at least
0.5*Ttot.
20. The apparatus of claim 19, wherein the first speed S1 is
greater than the line speed SL.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/824,013, filed on May 16, 2013, which is hereby
incorporated by reference.
FIELD OF THE INVENTION
[0002] The present disclosure relates to systems and methods for
folding disposable absorbent articles in a nip between first and
second carriers, and more particularly, tucker blades configured to
maximize a period of time wherein the leading edges move at speeds
through the nip that are relatively close to the speeds of the
first and second carriers.
BACKGROUND OF THE INVENTION
[0003] Along an assembly line, diapers and various types of other
absorbent articles may be assembled by adding components to and
otherwise modifying an advancing, continuous web of material. For
example, in some processes, advancing webs of material are combined
with other advancing webs of material. In other examples,
individual components created from advancing webs of material are
combined with advancing webs of material, which in turn, are then
combined with other advancing webs of material. Webs of material
and component parts used to manufacture diapers may include:
backsheets, topsheets, absorbent cores, front and/or back ears,
fastener components, and various types of elastic webs and
components such as leg elastics, barrier leg cuff elastics, and
waist elastics. Once the desired component parts are assembled, the
advancing web(s) and component parts are subjected to a final knife
cut to separate the web(s) into discrete diapers or other absorbent
articles.
[0004] After the final knife cut, the discrete diapers or absorbent
articles may also then be folded prior to being packaged. For
example, some process may be configured to fold absorbent articles
into a U-shape about a lateral centerline, wherein folding blades
engage and force advancing absorbent articles into a nip between
two conveyor belts. For example, in some diaper folding processes,
folding blades may contact the crotch region of the diaper, forcing
the diaper into the folding nip and thereby placing the front and
back waist regions into a facing relationship. As such, the folding
blades rotate at a certain angular velocity, which produces a
sinusoidal shape of the speed of the leading edge through the nip
over time. Thus, there is a relatively narrow time period where the
folded product is propelled into the folding nip at a maximum
leading edge speed.
[0005] In some systems, the conveyor belts move at faster speeds
than the maximum leading speed to avoid a product shearing defect,
which can happen when the folding blades on the inside of a folded
diaper move faster than the belts on the outside of the folded
diaper. As such, the diaper is accelerated by the folding blades to
a certain maximum speed through the nip, and then is quickly
accelerated to surface speeds of the conveyor belts. The timing of
this acceleration may depend on various factors, such as: the
friction between the conveyor belts and the surface of the diapers;
the compressibility of the diapers; and the gap settings between
the conveyor belts. All these factors may vary over time or even
from one diaper to the next, which in turn, causes the acceleration
timing to vary.
[0006] Variations in the acceleration timing in during the folding
process can lead to variability and inconsistencies with respect to
how well the opposing ends of the bi-folded diapers align with each
other, affecting the overall dimensions of the folded diapers. Such
inconsistencies may create negative consumer perceptions and may
also require relatively larger packaging sizes than would otherwise
be necessary. The timing variation can also causes folded diapers
to arrive at the subsequent packaging units at different times,
which can lead to jams at these units, and/or excessive reject
scrap.
[0007] Consequently, it would be beneficial to provide a system for
reliable, high speed folding of absorbent articles that is
configured to maximize the period of time wherein the leading edges
of the folding blades move at maximum speeds during the folding
process, in turn, reducing the timing wherein the folded articles
accelerate to the belt speeds and leading to reduced variability in
the dimensions of the folded articles.
SUMMARY OF THE INVENTION
[0008] The present disclosure relates systems and methods for
folding absorbent articles advancing in a converting line. The
folding processes and apparatuses herein may be configured with
tucker blades that are configured to maximize the period of time
wherein the leading edges of the tucker blades move at maximum
speeds during the folding process.
[0009] In one form, a method for folding absorbent articles
includes the steps of: conveying an absorbent article at a first
speed, S1, in a first direction on a first carrier to define an
article transport plane, wherein the absorbent article includes a
first surface and a second surface opposite the first surface,
wherein the absorbent article includes a first end and a second
end, and wherein the absorbent article includes a first end region
and a second end region, and a central region located between the
first and second end regions; advancing the first end region past a
nip defined between the first carrier and a second carrier;
rotating a tucker blade, wherein the tucker blade includes a first
surface and a second surface opposite the first surface, and
wherein the tucker blade includes a leading edge and a trailing
edge, wherein the leading edge and the trailing edge move through
the article transport plane at the nip as the tucker blade rotates;
contacting the first surface of the absorbent article with the
leading edge of the tucker blade thereby creating a fold line
across the central region of the absorbent article; redirecting the
central region of the absorbent article in a second direction into
the nip with the leading edge of the tucker blade; maintaining
contact between the fold line and the leading edge of the tucker
blade for a total time period, Ttot, while portions of the leading
edge contacting the fold line move at speeds, Smax, of at least
0.8*S1 for a time period, Tmax, of at least 0.5*Ttot; and conveying
the folded absorbent article in the second direction between the
first carrier and the second carrier away from the article
transport plane.
[0010] In another form, a method for folding absorbent articles
includes the steps of: advancing a continuous length of absorbent
articles absorbent articles at a line speed, SL, in a machine
direction; cutting the continuous length of absorbent articles into
discrete absorbent articles, wherein each discrete absorbent
article includes a first surface and a second surface opposite the
first surface, wherein each discrete absorbent article includes a
first end region and a second end region, and a central region
located between the first and second end regions, and wherein each
discrete absorbent article includes a first end and a second end,
and a having a pitch length, PL, defined by a distance in the
machine direction between the first end and the second end;
conveying each discrete absorbent article at a first speed, S1, in
a first direction on a first carrier to define an article transport
plane, wherein S1 is greater than SL; advancing the first end and
the first end region of each discrete absorbent article past a nip
defined between the first carrier and a second carrier; rotating a
tucker blade through the article transport plane at the nip as the
tucker blade rotates; contacting the first surface of a discrete
absorbent article with a leading edge of the tucker blade thereby
creating a fold line across the central region of the discrete
absorbent article; redirecting the central region of the absorbent
article in a second direction into the nip with the leading edge of
the tucker blade; and maintaining contact between the fold line and
the leading edge of the tucker blade for a total time period, Tot,
while portions of the leading edge contacting the fold line move at
speeds, Smax, of at least 0.8*S1 for a time period, Tmax, of at
least 0.5*Ttot; and conveying the folded absorbent article in the
second direction away from the article transport plane.
[0011] In yet another form, an apparatus for folding absorbent
articles includes: a knife adapted to cut discrete absorbent
articles from a continuous length of absorbent articles advancing
in a machine direction at a line speed, SL; a first carrier adapted
to convey an absorbent article in a first direction and a second
direction at a first speed, S1; a second carrier adjacent the first
carrier to define a nip extending in the second direction; a tucker
blade including a leading edge, wherein the leading edge moves
through the article transport plane at the nip as the tucker blade
rotates; and a motor adapted to rotate the tucker blade so as to
maintain contact between the absorbent article and the leading edge
of the tucker blade for a total time period, Ttot, while portions
of the leading edge contacting the absorbent article move at
speeds, Smax, of at least 0.8*S1 for a time period, Tmax, of at
least 0.5*Ttot.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a top plan view of a disposable absorbent article
that may include one or more substrates and/or components
constructed and folded in accordance with the present
disclosure.
[0013] FIG. 2 is a schematic representation of an absorbent article
converting line and folding system.
[0014] FIG. 3 is a detailed schematic representation of a folding
system.
[0015] FIG. 3A is a view of two tucker blades from FIG. 3 taken
along line 3A-3A.
[0016] FIG. 4 is a detailed schematic representation the folding
system showing absorbent articles advancing in a first direction
toward a nip between a first carrier and a second carrier.
[0017] FIG. 5 is a detailed schematic representation the folding
system showing an absorbent article with a first end and first end
region advanced past the nip.
[0018] FIG. 5A is a view of two tucker blades from FIG. 5 taken
along line 5A-5A.
[0019] FIG. 6 is a detailed schematic representation the folding
system showing the tucker blades redirecting a central region of
the absorbent article in a second direction into the nip.
[0020] FIG. 7 is a detailed schematic representation the folding
system showing opposing end regions of a folded absorbent article
contacting opposing sides of the tucker blades.
[0021] FIG. 8 is a detailed schematic representation the folding
system showing the folded absorbent article advancing in the second
direction through the nip.
[0022] FIG. 8A is a view of two tucker blades from FIG. 8 taken
along line 8A-8A.
[0023] FIG. 9 shows a generic graphical representation of carrier
surface speeds and leading edge contact portion speeds during a
total contact time period, Tot.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The following term explanations may be useful in
understanding the present disclosure:
[0025] "Absorbent article" is used herein to refer to consumer
products whose primary function is to absorb and retain soils and
wastes. "Diaper" is used herein to refer to an absorbent article
generally worn by infants and incontinent persons about the lower
torso. The term "disposable" is used herein to describe absorbent
articles which generally are not intended to be laundered or
otherwise restored or reused as an absorbent article (e.g., they
are intended to be discarded after a single use and may also be
configured to be recycled, composted or otherwise disposed of in an
environmentally compatible manner).
[0026] An "elastic," "elastomer" or "elastomeric" refers to
materials exhibiting elastic properties, which include any material
that upon application of a force to its relaxed, initial length can
stretch or elongate to an elongated length more than 10% greater
than its initial length and will substantially recover back to
about its initial length upon release of the applied force.
[0027] As used herein, the term "joined" encompasses configurations
whereby an element is directly secured to another element by
affixing the element directly to the other element, and
configurations whereby an element is indirectly secured to another
element by affixing the element to intermediate member(s) which in
turn are affixed to the other element.
[0028] "Longitudinal" means a direction running substantially
perpendicular from an end edge, such as a waist edge to a
longitudinally opposing end edge, or waist edge of an absorbent
article when the article is in a flat out, uncontracted state, or
from a waist edge to the bottom of the crotch, i.e. the fold line,
in a bi-folded article. Directions within 45 degrees of the
longitudinal direction are considered to be "longitudinal."
"Lateral" refers to a direction running from a longitudinally
extending side edge to a laterally opposing longitudinally
extending side edge of an article and generally at a right angle to
the longitudinal direction. Directions within 45 degrees of the
lateral direction are considered to be "lateral."
[0029] The term "substrate" is used herein to describe a material
which is primarily two-dimensional (i.e. in an XY plane) and whose
thickness (in a Z direction) is relatively small (i.e. 1/10 or
less) in comparison to its length (in an X direction) and width (in
a Y direction). Non-limiting examples of substrates include a web,
layer or layers or fibrous materials, nonwovens, films and foils
such as polymeric films or metallic foils. These materials may be
used alone or may comprise two or more layers laminated together.
As such, a web is a substrate.
[0030] The term "nonwoven" refers herein to a material made from
continuous (long) filaments (fibers) and/or discontinuous (short)
filaments (fibers) by processes such as spunbonding, meltblowing,
carding, and the like. Nonwovens do not have a defined woven or
knitted filament pattern.
[0031] The term "machine direction" (MD) is used herein to refer to
the direction of material flow through a process. In addition,
relative placement and movement of material can be described as
flowing in the machine direction through a process from upstream in
the process to downstream in the process.
[0032] The term "cross direction" (CD) is used herein to refer to a
direction that is generally perpendicular to the machine
direction.
[0033] The present disclosure relates to methods and apparatuses
for manufacturing absorbent articles, and more particularly,
systems and methods for folding absorbent articles advancing in a
converting line. As discussed in more detail below, the folding
processes and apparatuses herein may be configured with tucker
blades that are configured to maximize the period of time wherein
the leading edges of the tucker blades move at maximum speeds
during the folding process. During the converting process, various
continuous substrates and/or discrete components may be combined
with each other to form a continuous length of absorbent articles.
At a downstream portion of the converting process, the continuous
length of absorbent articles may be subjected to a final knife and
cut to create separate and discrete absorbent articles in the form
of diapers. Each discrete absorbent article includes a first
surface and a second surface opposite the first surface, and each
discrete absorbent article includes a first end and a second end,
as well as a first end region and a second end region separated
from each other by a central region. From the final knife, the
discrete absorbent articles may then advance to a folding system.
More particularly, the folding system includes a first carrier that
advances the absorbent articles in a first direction to define an
article transport plane. A second carrier is located adjacent the
first carrier to define a nip extending in a second direction, and
one or more tucker blades are rotated adjacent the nip. As
discussed in more detail, each tucker blade includes a leading edge
that moves through the article transport plane as the tucker blade
rotates. The first carrier then advances the first end region of
each discrete absorbent article past the nip. The discrete
absorbent articles are then folded by redirecting the central
region of each absorbent article in a second direction into the nip
with the leading edge of the tucker blade, thereby creating a fold
line across the central region of the absorbent article.
[0034] As discussed in more detail below, the first carrier
includes a first carrier surface, and the second carrier includes a
second carrier surface, each moving at a first speed S1. Thus, the
first carrier conveys the absorbent articles at the first speed,
S1, to the nip. A leading edge of a tucker blade is rotated into
contact with the first surface of the absorbent article thereby
creating a fold line across the central region of the absorbent
article. As the tucker blade redirects the absorbent article into
and through the nip, portions of the leading edge of the tucker
blade maintain contact with the fold line for a total time period,
Ttot. And the portion of the leading edge of the tucker blade that
is in contact with the fold line move at maximum speeds Smax for a
time period Tmax. The folded article is then conveyed in the second
direction at the first speed S1 between the first carrier and the
second carrier away from the article transport plane. As discussed
below, Smax and Tmax may have various values. For example, in some
configurations, Smax may be at least: 0.8*S1; 0.95*S1; or S1. In
addition, in some configurations, Tmax may be at least: 0.5*Ttot;
0.7*Tot; or 0.9*Tot.
[0035] In some embodiments, the tucker blades may also be
configured with an extended trailing edge that prevent the first
and the second end regions of the absorbent articles from colliding
with each other during the folding process. More particularly, the
tucker blades each include a first surface and a second surface
opposite the first surface. And the tucker blades may be configured
such that as the leading edge continues to push the article along
the fold line in the second direction through the nip, the first
surface of the first end region of the absorbent article is brought
into a facing relationship with the first surface of the tucker
blade. At the same time, the first surface of the second end region
of the absorbent article is brought into a facing relationship with
the second surface of the tucker blade. And the first end and the
second end of the folded absorbent article are separated by tucker
blade. As such, the first and second end regions of the absorbent
article may be brought into contact with opposing sides of the
tucker blade.
[0036] It is to be appreciated that although the methods and
apparatuses herein may be configured to fold various types of
products, the methods and apparatuses herein are discussed below in
the context of manufacturing absorbent articles. In particular, the
methods and apparatuses are discussed in the context of folding
advancing diapers during production. For the purposes of a specific
illustration, FIG. 1 shows one example of a disposable absorbent
article 100, such as described in U.S. Patent Publication Nos.
US2008/0132865 A1 and US2011/0247199 A1, in the form of a diaper
102 that may be constructed from substrates and components
monitored according to the systems and methods disclosed herein. In
particular, FIG. 1 is a plan view of one embodiment of a diaper 102
including a chassis 104 shown in a flat, unfolded condition, with
the portion of the diaper 102 that faces away from the wearer
oriented towards the viewer. A portion of the chassis structure is
cut-away in FIG. 1 to more clearly show the construction of and
various features that may be included in embodiments of the
diaper.
[0037] As shown in FIG. 1, the diaper 102 includes a chassis 104
having a first ear 106, a second ear 108, a third ear 110, and a
fourth ear 112. To provide a frame of reference for the present
discussion, the chassis 104 is shown with a longitudinal axis 114
and a lateral axis 116. The chassis 104 is shown as having a first
waist region 118, a second waist region 120, and a crotch region
122 disposed intermediate the first and second waist regions. In
some configurations, the first waist region 118 may correspond with
a front waist region, and the second waist region 120 may
correspond with a rear waist region. The periphery of the diaper is
defined by a pair of longitudinally extending side edges 124, 126;
a first outer edge 128 extending laterally adjacent the first waist
region 118; and a second outer edge 130 extending laterally
adjacent the second waist region 120. As shown in FIG. 1, the
chassis 104 includes an inner, body-facing surface 132, and an
outer, garment-facing surface 134. A portion of the chassis
structure is cut-away in FIG. 1 to more clearly show the
construction of and various features that may be included in the
diaper. As shown in FIG. 1, the chassis 104 of the diaper 102 may
include an outer covering layer 136 including a topsheet 138 and a
backsheet 140. An absorbent core 142 may be disposed between a
portion of the topsheet 138 and the backsheet 140. As discussed in
more detail below, any one or more of the regions may be
stretchable and may include an elastomeric material or laminate as
described herein. As such, the diaper 102 may be configured to
adapt to a specific wearer's anatomy upon application and to
maintain coordination with the wearer's anatomy during wear.
[0038] The absorbent article may also include an elastic waist
feature 143 shown in FIG. 1 in the form of a waist band 144 and may
provide improved fit and waste containment. The elastic waist
feature 143 may be configured to elastically expand and contract to
dynamically fit the wearer's waist. The elastic waist feature 143
can be incorporated into the diaper and may extend at least
longitudinally outwardly from the absorbent core 142 and generally
form at least a portion of the first and/or second outer edges 128,
130 of the diaper 102. In addition, the elastic waist feature may
extend laterally to include the ears. While the elastic waist
feature 143 or any constituent elements thereof may comprise one or
more separate elements affixed to the diaper, the elastic waist
feature may be constructed as an extension of other elements of the
diaper, such as the backsheet 140, the topsheet 138, or both the
backsheet and the topsheet. In addition, the elastic waist feature
143 may be disposed on the outer, garment-facing surface 134 of the
chassis 104; the inner, body-facing surface 132; or between the
inner and outer facing surfaces. The elastic waist feature 143 may
be constructed in a number of different configurations including
those described in U.S. Patent Publication Nos. US2007/0142806A1;
US2007/0142798A1; and US2007/0287983A1, all of which are hereby
incorporated by reference herein.
[0039] As shown in FIG. 1, the diaper 102 may include leg cuffs 146
that may provide improved containment of liquids and other body
exudates. In particular, elastic gasketing leg cuffs can provide a
sealing effect around the wearer's thighs to prevent leakage. It is
to be appreciated that when the diaper is worn, the leg cuffs may
be placed in contact with the wearer's thighs, and the extent of
that contact and contact pressure may be determined in part by the
orientation of diaper on the body of the wearer. The leg cuffs 146
may be disposed in various ways on the diaper 102.
[0040] The diaper 102 may be provided in the form of a pant-type
diaper or may alternatively be provided with a re-closable
fastening system, which may include fastener elements in various
locations to help secure the diaper in position on the wearer. For
example, fastener elements 148 may be located on the first and
second ears 110, 112 and may be adapted to releasably connect with
one or more corresponding fastening elements located in the first
or second waist regions. It is to be appreciated that various types
of fastening elements may be used with the diaper.
[0041] FIG. 2 shows a schematic representation of an absorbent
article converting process including a converting line or machine
300 configured to manufacture absorbent articles 100. It is to be
appreciated that the systems and methods disclosed herein are
applicable to work with various types of converting processes
and/or machines. As shown in FIG. 2, the converting line 300 may
include one or more motors 302 that drive transport systems, such
as a nip roll 304, to move diaper substrates and component
materials through the manufacturing process. For example, FIG. 2
shows a base substrate 306 and two auxiliary substrates and/or
components 308 of material used to construct portions of the
diapers. The substrates may be provided as rolls and fed into the
converting line 300. It is to be appreciated that material of the
auxiliary substrates may be supplied in various ways. For example,
FIG. 2 shows a first auxiliary substrate 310 in the form of a
continuous substrate 312, and a second auxiliary substrate 314 in
the form of individual components 316. It is to be appreciated that
the auxiliary substrates 310 may be transferred to the base
substrate through various types of transfer mechanisms. For
example, the individual components 316 are shown as being
transferred to the base substrate via a transfer mechanism 318 in
the form of a servo patch placer mechanism 320, such as disclosed
in U.S. Pat. Nos. 6,450,321; 6,705,453; 6,811,019; and 6,814,217.
It is also to be appreciated that the various substrates can be
used to construct various components of the absorbent articles,
such as backsheets, topsheets, ears, leg cuffs, elastic waist
features, and absorbent cores. Exemplary descriptions of absorbent
article components are provided above with reference to FIG. 1.
[0042] Referring back to FIG. 2, as the base substrate 306 advances
through the converting line 300, the base substrate 306 is combined
with the auxiliary substrates 308 and/or discrete components 316 to
create a continuous length of absorbent articles 400. At a
downstream portion of the converting process 300, the continuous
length of absorbent articles 400 is subjected to a final knife 324
and cut to create separate and discrete absorbent articles 100 in
the form of diapers 102. An inspection system 600 may identify the
defective absorbent articles 100R. In turn, defective articles 100R
may be subject to a rejection system 500 and removed from the
process. For example, FIG. 2 shows defective articles 100R being
channeled to a reject bin 502. It is to be appreciated that various
types of inspection system 600 configurations may be utilized, such
as for example disclosed in U.S. Pat. No. 8,145,338, and may
include various types of sensors 602 connected with a controller
604 over a communication network 606. Articles 100 that are not
deemed to be defective may be subject to further processing steps,
such as folding and packaging. For example, FIG. 2 shows diapers
102 advancing from the final knife 324 to a folding system 700.
[0043] It is to be appreciated that the term "reject bin" is used
herein generically to designate the location where rejected diapers
may be conveyed. As such, the reject bin 502 may include various
systems. For example, the reject bin may 502 may include additional
systems such as conveyors and/or pneumatic systems to provide
additional transport or conveyance of rejected diapers to other
locations.
[0044] As mentioned above, the converting apparatus includes a
folding system adapted to fold absorbent articles 100 advancing
through the converting process. FIGS. 3-4 show a detailed schematic
a downstream portion of a converting apparatus 300 that includes a
folding system 700 adapted to fold discrete absorbent articles 100
advancing in a machine direction MD from a final knife 324. The
folding system 700 may include a first carrier 702 adjacent the
final knife 324, wherein the first carrier 702 advances absorbent
articles 100 from the final knife 324 in a first direction 704 to
define an article transport plane 706. A second carrier 708 is
located adjacent the first carrier 702 to define a nip 710
extending in a second direction 712. More particularly, the first
carrier 702 may be in the form of belt conveyor including a first
belt 714 defining a first carrier surface 716. As shown in FIG. 3,
the first belt 714 may be routed in an endless loop around three
rollers 718. The second carrier 708 may be in the form of belt
conveyor including a second belt 720 defining a second carrier
surface 722. The second belt 720 may be routed in an endless loop
around two rollers 724. As such, the nip 710 extends in the second
direction between the first carrier surface 716 and the second
carrier surface 722. As discussed in more detail below, the first
carrier 702 advances discrete absorbent articles 100 in the first
direction 704 from the final knife 324. And the first carrier 702
and the second carrier 708 advance folded absorbent articles 100 in
the second direction 712 through the nip 710.
[0045] With continued reference to FIG. 3, the folding system 700
may also include one or more tucker blades 726 that are rotated
adjacent the nip 710. As discussed in more detail below, the tucker
blades 726 rotate to engage absorbent articles 100 advancing on the
first carrier 702. In turn, the absorbent articles 100 are folded
while being forced in the second direction 712 and into the nip 710
by the tucker blades 726.
[0046] It is to be appreciated that the folding system 700 may be
configured with various numbers of tucker blades 726. For example,
as shown in FIG. 3A, the folding system may include a first tucker
blade 726a and a second tucker blade 726b. The tucker blades 726a,
726b may be operatively connected with various types of drive
mechanisms 728 configured to rotate the tucker blades 726a, 726b
around respective axes of rotation 730a, 730b. As shown in FIG. 3A,
the first tucker blade 726a is configured to rotate in a direction,
A, and the second tucker blade 726b is configured to rotate in an
opposite direction, B. In some configurations, the drive mechanisms
728 may include one or more motors directly or indirectly connected
with the tucker blades 726a, 726b. In some configurations, a motor
may be connected with the tucker blades 726a, 726b through various
types of transmission, belt, and/or gear arrangements. In addition,
the motors may be configured as servo motors that may operate with
constant or variable speeds. Various examples of drive mechanism
arrangements that may be used to rotate the tucker blades 726a,
726b are disclosed in U.S. Pat. No. 7,617,656. It is to be
appreciated that the drive mechanism 728 may be configured to
rotate the tucker blades 726 at a constant angular velocity. In
some embodiments, the angular velocity of the tucker blades 726 may
be varied on a cyclic basis with a drive mechanism 728 that may
include a servo motor.
[0047] With continued reference to FIGS. 3 and 3A, each tucker
blade includes a first surface 738 and an opposing second surface
740. And each tucker blade 726 includes at least one leading edge
732 and at least one trailing edge 734 connected with each other by
an outer circumferential edge 736. As discussed in more detail,
during the folding operation, the leading edge 732 and the trailing
edge 734 move through the article transport plane 706 as the tucker
blade 726 rotates. As shown in FIG. 3A, the tucker blades 726a,
726b are configured to fold two absorbent articles 100 for each
complete revolution. Thus, the tucker blades 726a, 726b each
include two leading edges 732 and two trailing edges 734. It is to
be appreciated that tucker blades 726 can be configured to include
more or less than two leading edges 732 and trailing edges 734. It
should also be appreciated that embodiments of the folding systems
700 herein may also be configured to fold every other absorbent
article 100, thereby providing a method of separating a continuous
stream of products into two streams.
[0048] It is to be appreciated that the tucker blades may be
positioned in various ways with respect to the first and/or second
carriers 702, 708. For example as shown in FIG. 3A, the axis of
rotation 730a of the first tucker blade 726a may be separated in
the cross direction CD from the axis of rotation 730b of the second
tucker blade 726b. In some configurations, the axes of rotation
730a, 730b may be separated by equal cross directional distances on
opposing sides of a machine direction centerline, CL. The machine
direction centerline CL may be defined by a longitudinal centerline
114 of an absorbent article 100, 102 advancing in the first
direction 704 on the first carrier 702. The axes 730a, 730b may
also positioned in various elevations with respect to the first
carrier 702. For example, the axes 730a, 730b may be at elevations
that are aligned with or offset from the article transport plane
706. As shown in FIG. 3A, the article transport plane 712 is offset
in the second direction 712 from a line 742 connecting the axes
730a, 730b.
[0049] To provide additional context to the above discussion, the
following provides a description of one example implementation of
the folding systems and processes herein with respect to FIGS.
3-8.
[0050] As shown in FIGS. 3 and 4, a continuous length of absorbent
articles 400 advances in a machine direction MD to a final knife
324 that cuts the continuous length of absorbent articles 400 into
discrete absorbent articles 100. The final knife 324 may be
configured in various ways. For example, the final knife 324 may
include a knife roll 324a and an anvil roll 324b. Each discrete
absorbent article 100 may be in the form of a diaper 102, such as
described above with reference to FIG. 1, and includes a first
surface 402 and a second surface 404 opposite the first surface
402. In some configurations, where the absorbent articles 100 are
in the form of diapers 102, the first surface 402 may correspond
with the inner, body-facing surface 132 and/or topsheet 138, and
the second surface 404 may correspond with the outer,
garment-facing surface 134 and/or backsheet 140. In other
configurations, the first surface 402 may correspond with the
outer, garment-facing surface 134 and/or backsheet 140, and the
second surface 404 may correspond with the inner, body-facing
surface 132 and/or topsheet 138. Each discrete absorbent article
100 also includes a first end 405, a first end region 406, a second
end 407, a second end region 408, and a central region 410
intermediate the first and second regions 406, 408. In some
configurations, where the absorbent articles 100 are in the form of
diapers 102, the first end region 406 may correspond with the first
waist region 118; the second end region 408 may correspond with the
second waist region 120; and the central region 410 may correspond
with the crotch region 122. In addition, the first end 405 may
correspond with the first outer edge 128, and the second end 407
may correspond with the second outer edge 130. In other
configurations, the first end region 406 may correspond with the
second waist region 120, and the second end region 408 may
correspond with the first waist region 118. As shown in FIG. 4, the
distance between the first end 405 and the second end 407 of the
absorbent article 100 along the machine direction MD or first
direction 704 defines a pitch length PL.
[0051] With continued reference to FIG. 4, the discrete absorbent
articles 100 advance to the first carrier 702 from the final knife
324. The absorbent articles 100 are oriented such that the second
surface 404 is in a facing relationship with and in contact with
the first carrier surface 716. The first carrier 702 advances the
absorbent articles 100 in the first direction 704 such that the
first end 405 of each absorbent article 100 is a leading end and
the second end 407 is a trailing end. It is to be appreciated that
the first direction 704 may correspond with the machine direction
MD. The continuous length of absorbent articles 400 may advance to
the final knife 324 at a line speed, SL. And the first carrier 702
may advance the discrete absorbent articles 100 from the final
knife 324 at a first speed, S1. In some configurations, the first
speed S1 may be the same as the line speed SL. In other
configurations, the first speed S1 may be greater than the line
speed SL. And as such, the first carrier 702 may accelerate the
discrete absorbent articles 100 advancing from the final knife 324
to the first speed S1, which in turn, causes consecutive absorbent
articles 100 on the first carrier 702 to be spaced apart from each
other along the first direction 704. As shown in FIG. 4, the
advancement of the discrete absorbent articles 100 in the first
direction 704 on the first carrier 702 defines an article transport
plane 706 along which the absorbent articles 100 are
transported.
[0052] As shown in FIGS. 4 and 5, the first carrier 702 conveys
each discrete absorbent article 100 along the article transport
plane 706 such that the first end 405 and the first end region 406
of each absorbent article 100 advances in the first direction 704
past the nip 710 and the rotating tucker blades 726. With reference
to FIGS. 5 and 5A, the tucker blades 726a, 726b are rotated such
that leading edges 732 of the tucker blades 726a, 726b contact the
first surface 402 of the absorbent article 100 in the central
region 410, thereby creating a fold line 412 extending in a cross
direction CD across the central region 410 of the absorbent article
100. Referring now to FIG. 6, as the tucker blades 726a, 726b
continue to rotate, the leading edges 732 move through the article
transport plane 706 and redirect the central region 410 of the
absorbent article 100 in the second direction 712 and into the nip
710. It is to be appreciated that the folding system 700 may be
configured such that the leading edges 732 of the tucker blades 726
contact the absorbent articles 100 so as create fold lines 412 that
are equidistant from the first end 405 and the second end 407. As
such, in some configurations, the fold lines 412 may be positioned
so as to bisect the article 100. It is also to be appreciated that
the folding systems and methods herein may be configured to
bi-fold, tri-fold, and/or quad-fold various types of absorbent
articles 100. As such, the fold line 412 may be positioned in
various locations other than the geometric center of the absorbent
articles 100.
[0053] With continued reference to FIG. 6, as the central region
410 of the absorbent article is redirected into the nip 710 by the
tucker blades 726a, 726b, the second end 407 of the absorbent
article 100 continues to move in the first direction 704 toward the
second surface 740 of the tucker blades 726. At the same time,
movement of the first end 405 of the absorbent article 100 reverses
and moves in a third direction 744 toward the first surfaces 738 of
the tucker blades 726. As mentioned above, the tucker blades may be
configured with extended trailing edges that prevent the first and
second end regions 406, 408, and first and second ends 405, 407, of
the absorbent article 100 from colliding with each other. Instead,
the first and second end regions 406, 408, and first and second
ends 405, 407, of the absorbent article 100 are brought into
contact with opposing sides 738, 740 of the tucker blades 726
during the folding process. For example, as shown in FIG. 7, the
leading edges 732 of the tucker blades 726 continue to push the
absorbent article 100 along the fold line 412 in the second
direction 712 through the nip 710, the first surface 402 of the
first end region 406 of the absorbent article 100 is brought into a
facing relationship with the first surfaces 738 of the tucker
blades 726. At the same time, the first surface 402 of the second
end region 408 of the absorbent article 100 is brought into a
facing relationship with the second surfaces 740 of the tucker
blades 726. And when the absorbent article 100 is completely
folded, the first end 405 and the second end 407 of the absorbent
article 100 are separated by first and second surfaces 738, 740 of
the tucker blades 726. It is to be appreciated that the tucker
blades 726 herein may also be configured with trailing edges 734
that do not prevent the first and second end regions 406, 408, and
first and second ends 405, 407, of the absorbent article 100 from
colliding with each other during the folding process.
[0054] As shown in FIG. 8, the folded absorbent articles 100 are
conveyed in the second direction 712 through the nip 712 between
the first carrier 702 and the second carrier 708 and away from the
article transport plane 706 and from the tucker blades 726. And the
tucker blades 726 continue to rotate as a subsequently advancing
absorbent article 100 is conveyed in the first direction 704 by the
first carrier 702 toward the nip 710 and tucker blades 726. As
shown in FIGS. 8 and 8A, the tucker blades 726 continue to rotate
such that the trailing edges 734 move through the article transport
plane 706 far enough to allow first end region 406 of the
subsequently advancing absorbent article 100 to advance past the
nip 710 without colliding with the second surface 740 of the tucker
blades 726. As shown in FIG. 8A, the trailing edges 734 of the
tucker blades 726 may also be configured with straight edges that
are oriented to be parallel with the article transport plane 706 at
least once during a complete rotation of the tucker blades as a
subsequently advancing absorbent article 100 to advances toward the
nip 710.
[0055] As previously mentioned, the tucker blades 726 may be
configured to maximize the period of time wherein the leading edges
732 of the tucker blades 726 move at maximum speeds during the
folding process while in contact with the fold line 412. As
discussed above with reference to FIGS. 3-8A, the first carrier 712
conveys the absorbent articles 100 at the first speed, S1, to the
nip 710. And the first carrier 712 and the second carrier 708
convey the folded absorbent article 100 away from the from the
article transport plane 706 and from the tucker blades 726 the
first speed, S1. Thus, the first carrier surface 716 and the second
carrier surface 722 may be configured to move at the first speed
S1. With particular reference to FIGS. 5 and 5A, the fold line 412
is created across the central region 410 of the absorbent article
100 when the leading edges 732a, 732b of the tucker blades 726a,
726b are rotated into contact with the first surface 702 of the
absorbent article 100. As the tucker blades 726a, 726b redirects
the absorbent article 100 into and through the nip 710, portions
746 of the leading edges 732a, 732b (which may be referred to
herein as leading edge contact portions 746a, 746b) of the tucker
blades 726a, 726b maintain contact with the fold line 412 for a
total contact time period, Ttot.
[0056] FIG. 9 shows a generic graphical representation of carrier
surface speeds and leading edge contact portion speeds during the
total contact time period, Ttot. As shown in FIG. 9, the leading
edge contact portions 746a, 746b may move at an initial speed, Si,
when the leading edges 732 of the tucker blades 726 first make
contact with the absorbent article 100. And as the tucker blades
continue to rotate, the leading edge contact portions 746a, 746b
accelerate to maximum speeds, Smax at time, t1. The leading edge
contact portions 746a, 746b may maintain maximum speeds, Smax, for
a time period Tmax, which is calculated by subtracting t1 from
Ttot. And the leading edge contact portions 746a, 746b remain in
contact with fold line 412 of the absorbent article 100 until the
folded article is conveyed away from the tucker blades 726 in the
second direction at the first speed S1 by the first carrier surface
716 and the second carrier surface 722.
[0057] It is to be appreciated that the leading edges 732 of the
tucker blades 726 may be configured to provide various relative
values of S1, Smax, Tot, and Tmax. For example, in one
configuration, Smax may be values of at least 0.8*S1 or greater. In
another configuration, Smax may be values of at least 0.95*S1 or
greater. In yet another configuration, Smax may be values equal to
S1. In some configurations, Tmax may be at least 0.5*Ttot or
greater. In yet other configurations, Tmax may be at least 0.7*Tot
or greater. In yet another configuration, Tmax may be at least
0.9*Tot or greater.
[0058] Although the present disclosure is provided in the context
of manufacturing absorbent articles, and diapers in particular, it
is to be appreciated that the systems and methods disclosed herein
may be applied to the manufacture of various types of articles and
products involving the monitoring of various different types of
substrates and/or components. Examples of other products include
absorbent articles for inanimate surfaces such as consumer products
whose primary function is to absorb and retain soils and wastes
that may be solid or liquid and which are removed from inanimate
surfaces such as floors, objects, furniture and the like.
Non-limiting examples of absorbent articles for inanimate surfaces
include dusting sheets, pre-moistened wipes or pads, paper towels,
dryer sheets. Additional examples of products include absorbent
articles for animate surfaces whose primary function is to absorb
and contain body exudates and, more specifically, devices which are
placed against or in proximity to the body of the user to absorb
and contain the various exudates discharged from the body.
Non-limiting examples of incontinent absorbent articles include
diapers, adult incontinence briefs and undergarments, feminine
hygiene garments such as panty liners, absorbent inserts, and the
like, toilet paper, tissue paper, facial wipes or cloths, toilet
training wipes. Still other examples of products include packaging
components and substrates and/or containers for laundry detergent,
which may be produced in pellets or pouches and may be manufactured
in a converting or web process or even discreet products produced
at high speed such as high-speed bottling lines or cosmetics. Still
other examples of products include a web substrate containing
labels to be placed on bottles and/or containers for laundry
detergent, fabric enhancers, hair and beauty care products, and
cleaning products. Further, it is to be appreciated that although
the present disclosure often refers to monitoring or viewing
substrates and/or webs, it is to be appreciated that the inspection
systems discussed herein can be used to monitor and/or view
combinations of webs and individual components as well as parts
added as a continuous web of material and parts added as a
discontinuous web of material.
[0059] It is also to be appreciated that various components of the
converting apparatus 300 may have various configurations. For
example, although the first carrier 702 and the second carrier 708
are depicted as belt conveyors, it is to be appreciated that the
first carrier 702 and/or the second carrier 708 may be configured
in various ways. For example, in some embodiments, the first
carrier 702 and/or second carrier 708 may be configured as a
rotating drum. In order to help mitigate problems associated with
uncontrolled movement of the discrete diapers 100 during
conveyance, the first carrier 702 and/or second carrier 708 may
also include a vacuum system in communication with a porous and/or
apertured belt or other foraminous carrier surface 716, 722 that
allows the suction force of the vacuum system to be exerted on
absorbent articles 100. In some embodiments, additional belt
conveyors may be located adjacent the first and/or second carriers
702, 708 to create additional nips extending along the first
direction 704, wherein absorbent articles 100 are maintained in a
flattened state while advancing in the first direction 704.
[0060] The dimensions and values disclosed herein are not to be
understood as being strictly limited to the exact numerical values
recited. Instead, unless otherwise specified, each such dimension
is intended to mean both the recited value and a functionally
equivalent range surrounding that value. For example, a dimension
disclosed as "40 mm" is intended to mean "about 40 mm."
[0061] Every document cited herein, including any cross referenced
or related patent or application and any patent application or
patent to which this application claims priority or benefit
thereof, is hereby incorporated herein by reference in its entirety
unless expressly excluded or otherwise limited. The citation of any
document is not an admission that it is prior art with respect to
any invention disclosed or claimed herein or that it alone, or in
any combination with any other reference or references, teaches,
suggests or discloses any such invention. Further, to the extent
that any meaning or definition of a term in this document conflicts
with any meaning or definition of the same term in a document
incorporated by reference, the meaning or definition assigned to
that term in this document shall govern.
[0062] While particular embodiments of the present invention have
been illustrated and described, it would be obvious to those
skilled in the art that various other changes and modifications can
be made without departing from the spirit and scope of the
invention. It is therefore intended to cover in the appended claims
all such changes and modifications that are within the scope of
this invention.
* * * * *