U.S. patent application number 14/747255 was filed with the patent office on 2016-12-29 for methods for transferring discrete articles.
The applicant listed for this patent is The Procter & Gamble Company. Invention is credited to Daniel Patrick FINDLEY, Clifford Theodore PAPSDORF, Uwe SCHNEIDER.
Application Number | 20160376109 14/747255 |
Document ID | / |
Family ID | 56297129 |
Filed Date | 2016-12-29 |
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United States Patent
Application |
20160376109 |
Kind Code |
A1 |
SCHNEIDER; Uwe ; et
al. |
December 29, 2016 |
METHODS FOR TRANSFERRING DISCRETE ARTICLES
Abstract
The present disclosure is directed to a method of transferring
discrete articles between a transfer assembly and an apparatus
comprising a head. The transfer assembly comprises a frame defining
a first rotation axis and a transfer member comprising a transfer
surface configured to receive one of the discrete articles. The
method comprises rotating the transfer member of the transfer
assembly about the first rotation axis at a substantially constant
angular velocity, maintaining the transfer surface at a
substantially constant minimum distance away from a surface of the
head at a point of discrete article transfer, and rotating the head
of the apparatus about a second rotation axis at a plurality of
angular velocities. A first angular velocity of the head is
substantially constant at the point of discrete article
transfer.
Inventors: |
SCHNEIDER; Uwe; (Cincinnati,
OH) ; PAPSDORF; Clifford Theodore; (Loveland, OH)
; FINDLEY; Daniel Patrick; (Finneytown, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Procter & Gamble Company |
Cincinnati |
OH |
US |
|
|
Family ID: |
56297129 |
Appl. No.: |
14/747255 |
Filed: |
June 23, 2015 |
Current U.S.
Class: |
198/377.02 |
Current CPC
Class: |
B65H 39/14 20130101;
B65H 2406/365 20130101; B65G 29/02 20130101; B65H 2406/3454
20130101; B65H 2301/4472 20130101; B65H 2403/51 20130101; B65H
2301/33216 20130101; B65G 47/848 20130101; B65H 29/241 20130101;
A61F 13/15764 20130101; B65G 47/244 20130101; B65H 2406/33
20130101; B65H 2301/4472 20130101; B65H 2220/01 20130101; B65H
2220/02 20130101 |
International
Class: |
B65G 47/244 20060101
B65G047/244; A61F 13/15 20060101 A61F013/15; B65G 29/02 20060101
B65G029/02 |
Claims
1. A method of transferring discrete articles between a transfer
assembly and an apparatus comprising a head, wherein the transfer
assembly comprises a frame defining a first rotation axis and a
transfer member comprising a transfer surface configured to receive
one of the discrete articles, the method comprising: rotating the
transfer member of the transfer assembly about the first rotation
axis at a substantially constant angular velocity; maintaining the
transfer surface at a substantially constant minimum distance away
from a surface of the head at a point of discrete article transfer;
and rotating the head of the apparatus about a second rotation axis
at a plurality of angular velocities, wherein a first angular
velocity of the head is substantially constant at the point of
discrete article transfer.
2. The method of claim 1, wherein a tangential velocity of the
transfer surface is substantially constant at the point of discrete
article transfer.
3. The method of claim 2, wherein a tangential velocity of the
surface of the head is substantially the same as the substantially
constant tangential velocity of the transfer surface at the point
of discrete article transfer.
4. The method of claim 3, comprising rotating the head about the
second rotation axis at a second angular velocity when the head is
outside of a zone of discrete article transfer, wherein the second
angular velocity is different than the first angular velocity.
5. The method of claim 4, wherein the discrete articles are
transferred from the transfer surface to the surface of the head,
the method comprising rotating the head about the second rotation
axis at a third, different angular velocity when the surface of the
head is transferring the discrete articles to a discrete article
conveying device, and wherein a second tangential velocity of the
surface of the head substantially matches a tangential velocity or
linear speed of the discrete article conveying device at a second
point of discrete article transfer.
6. The method of claim 5, comprising rotating the head about the
second rotation axis between the first, second, and third angular
velocities in one revolution of the head.
7. The method of claim 1, wherein the surface of the head comprises
an arcuate portion, and wherein the transfer surface is
substantially flat.
8. The method of claim 1, wherein the discrete articles are
transferred from the transfer surface of the transfer assembly to
the surface of the head of the apparatus.
9. The method of claim 1, wherein the discrete articles are
transferred from the surface of the head of the apparatus to the
transfer surface of the transfer assembly.
10. The method of claim 1, wherein the transfer surface is a
substantially flat transfer surface, the method comprising moving
the substantially flat transfer surface radially inwardly and
radially outwardly relative to the first rotation axis at the point
of discrete article transfer to maintain the substantially constant
minimum distance.
11. The method of claim 1, comprising rotating the transfer surface
about a third rotation axis between a first position and a second
position, wherein the first rotation axis extends in a first
direction, and wherein the third rotation axis extends in a second,
different direction.
12. The method of claim 11, wherein the first rotation axis is
substantially parallel to the second rotation axis, and wherein the
third rotation axis is substantially perpendicular to the first and
second rotation axes.
13. The method of claim 11, wherein the transfer surface is rotated
between about 80 degrees and about 100 degrees about the third
rotation axis between the first position and the second
position.
14. The method of claim 1, comprising using a radial displacement
mechanism operably engaged with a portion of the transfer member to
maintain the transfer surface at the substantially constant minimum
distance away from the surface of the head of the apparatus at the
point of discrete article transfer.
15. The method of claim 1, comprising maintaining a substantially
constant pressure between the transfer surface and the surface of
the head of the apparatus at the point of discrete article
transfer.
16. A method of transferring discrete articles between a transfer
assembly and an apparatus comprising a head, wherein the transfer
assembly comprises a frame defining a first rotation axis and a
transfer member comprising a transfer surface configured to receive
one of the discrete articles, the method comprising: rotating the
transfer member of the transfer assembly about the first rotation
axis at a substantially constant angular velocity; maintaining the
transfer surface at a substantially constant minimum distance away
from a surface of the head at a point of discrete article transfer,
wherein a tangential velocity of the transfer surface is
substantially constant at the point of discrete article transfer;
and rotating the head of the apparatus about a second rotation axis
at a variable angular velocity, wherein a first angular velocity of
the head is substantially constant at the point of discrete article
transfer, and wherein a tangential velocity of the surface of the
head is substantially the same as the substantially constant
tangential velocity of the transfer surface at the point of
discrete article transfer.
17. The method of claim 16, wherein the transfer surface is
substantially flat, wherein the surface of the head comprises an
arcuate portion, and wherein the surface of the head is configured
to receive one of the discrete articles.
18. The method of claim 16, wherein the first rotation axis is
substantially parallel to the second rotation axis, the method
comprising rotating the transfer member about a third rotation axis
between a first position and a second position, wherein the
transfer member is rotated between about 80 degrees and about 100
degrees about the third rotation axis between the first position
and the second position, and wherein the first rotation axis is
substantially perpendicular to the third rotation axis.
19. A method of transferring discrete articles between a transfer
assembly and an apparatus comprising a head, wherein the transfer
assembly comprises a frame defining a first rotation axis and a
transfer member comprising a transfer surface configured to receive
one of the discrete articles, wherein the transfer surface is
substantially flat, the method comprising: rotating the transfer
member of the transfer assembly about the first rotation axis at a
substantially constant angular velocity; maintaining the transfer
surface at a substantially constant minimum distance away from a
surface of the head in a zone of discrete article transfer; and
rotating the head of the apparatus about a second rotation axis at
a variable angular velocity.
20. The method of claim 19, wherein a first angular velocity of the
head is substantially constant in the zone of discrete article
transfer, and wherein the surface of the head is arcuate.
21. The method of claim 19, wherein the first rotation axis is
substantially parallel to the second rotation axis.
22. The method of claim 19, comprising rotating the transfer member
about a third rotation axis between a first position and a second
position, wherein the first rotation axis extends in a first
direction, wherein the third rotation axis extends in a second,
different direction, and wherein the transfer member is rotated
about the third rotation axis between about 80 degrees and about
100 degrees between the first position and the second position.
23. The method of claim 19, wherein a first tangential velocity of
the transfer surface is substantially constant in the zone of
discrete article transfer, wherein a second tangentially velocity
of the surface of the head is substantially constant in the zone of
discrete article transfer, and wherein the first and second
tangentially velocities are substantially the same in the zone of
discrete article transfer.
24. The method of claim 19, wherein the transfer surface or a
surface of the head comprises a resilient material.
25.-39. (canceled)
40. A method of transferring discrete articles between a transfer
assembly and an apparatus comprising a head, wherein the transfer
assembly comprises a frame defining a first rotation axis and a
transfer member comprising a transfer surface configured to receive
one of the discrete articles, the method comprising: rotating the
transfer member of the transfer assembly about the first rotation
axis at a substantially constant angular velocity; maintaining the
transfer surface at a substantially constant minimum distance away
from a surface of the head at a point of discrete article transfer,
wherein the transfer surface is a substantially flat transfer
surface; moving the substantially flat transfer surface radially
inwardly and radially outwardly relative to the first rotation axis
at the point of discrete article transfer to maintain the
substantially constant minimum distance; and rotating the head of
the apparatus about a second rotation axis at a plurality of
angular velocities, wherein a first angular velocity of the head is
substantially constant at the point of discrete article
transfer.
41. A method of transferring discrete articles between a transfer
assembly and an apparatus comprising a head, wherein the transfer
assembly comprises a frame defining a first rotation axis and a
transfer member comprising a transfer surface configured to receive
one of the discrete articles, the method comprising: rotating the
transfer member of the transfer assembly about the first rotation
axis at a substantially constant angular velocity; maintaining the
transfer surface at a substantially constant minimum distance away
from a surface of the head at a point of discrete article transfer;
moving the transfer surface radially inwardly and radially
outwardly relative to the first rotation axis at the point of
discrete article transfer to maintain the substantially constant
minimum distance; and rotating the head of the apparatus about a
second rotation axis at a plurality of angular velocities, wherein
a first angular velocity of the head is substantially constant at
the point of discrete article transfer.
Description
FIELD
[0001] The present disclosure generally relates to methods for
transferring discrete articles and, more particularly, relates to
methods for transferring discrete articles to or from an apparatus
comprising one or more heads.
BACKGROUND
[0002] Absorbent articles, such as taped diapers or pant diapers,
for example, may be manufactured by a process where discrete
articles, such as a chassis of a taped diaper or a pant diaper
comprising a topsheet, a backsheet, and an absorbent core, for
example, are applied to one or more moving webs of components, such
as webs of front and rear belt portions, for example. To achieve
this, a transfer assembly may be provided that comprises one or
more transfer members and a frame defining a rotation axis. The
transfer member(s) may orbit about the rotation axis. Each of the
transfer members may comprise a transfer surface that is configured
to engage one or more of the discrete articles. The transfer
members may pick up the discrete articles at a pick-up location and
place the discrete articles at a drop-off location within the
orbit. In certain instances, the transfer assembly may rotate the
discrete articles about 90 degrees, or other suitable angles,
between the pick-up location and the drop-off location about a
second rotation axis that is perpendicular, or substantially
perpendicular, to the rotation axis. Transfer assemblies that
rotate and transfer discrete articles are known in the art as "turn
and repitch" units because the units turn the discrete articles and
repitch them (i.e., change the spacing or "pitch" between them)
between the pick-up location and the drop-off location. The
repitching capability of these units, however, is somewhat limited
and frequent change-outs of the entire transfer assemblies, or
portions thereof, typically must be done to transfer discrete
articles having different sizes (e.g., different MD widths and/or
different CD lengths). This is owing to the fact that the transfer
members of typical transfer assemblies orbit about the rotation
axis at a constant angular velocity, thereby reducing or
eliminating any pitch variation at the drop-off location.
Differently sized discrete articles may require different drop off
pitches at the drop-off location.
[0003] What is needed are methods for transferring discrete
articles that overcome the repitching limitations and frequent
change-outs of related art discrete article transfer methods.
SUMMARY
[0004] The present disclosure provides for transfer assemblies that
transfer discrete articles to or from an apparatus comprising one
or more heads. The transfer assemblies may comprise a frame
defining a rotation axis and one or more transfer members. Each
transfer member is configured to orbit about the rotation axis at a
constant, or substantially constant, angular velocity. The transfer
members each comprise a transfer surface configured to receive one
or more of the discrete articles. The transfer surface may be flat,
substantially flat, or may comprise a portion that is flat or
substantially flat. The transfer assembly may transfer the discrete
articles to and/or from the apparatus comprising the one or more
heads. Stated another way, the apparatus comprising the one or more
heads may be positioned on the input side of the transfer assembly,
on the output side of the transfer assembly, or on both the input
and output sides of the transfer assembly. The one or more heads of
the apparatus rotate about a rotation axis of the apparatus at a
variable angular velocity or at a plurality of angular velocities.
By rotating the heads at a variable angular velocity, a
significantly expanded range of input or output pitches of the
discrete articles are provided by the combination of the transfer
assembly and the apparatus(es) compared to only using the related
art transfer assemblies. By providing such an apparatus(es) in
combination with a transfer assembly that rotates its transfer
members at a constant angular velocity, the transfer assembly does
not need to be changed out as frequently and can run more than one
size of discrete articles because of the increased pitch range that
the combination provides.
[0005] In a form, the present disclosure is directed, in part, to a
method of transferring discrete articles between a transfer
assembly and an apparatus comprising one or more heads. The
transfer assembly may comprise a frame defining a first rotation
axis and at least one transfer member each comprising a transfer
surface configured to receive one of the discrete articles. The
method may comprise rotating the at least one transfer member of
the transfer assembly about the first rotation axis at a constant,
or substantially constant, angular velocity, maintaining the
transfer surface at a substantially constant minimum distance away
from a surface of the head at a point or zone of discrete article
transfer, and rotating the at least one head of the apparatus about
a second rotation axis at a plurality of angular velocities. A
first angular velocity of the head may be constant, or
substantially constant, at the point or zone of discrete article
transfer.
[0006] In another form, the present disclosure is directed, in
part, to a method of transferring discrete articles between a
transfer assembly and an apparatus comprising one or more heads.
The transfer assembly may comprise a frame defining a first
rotation axis and at least one transfer member each comprising a
transfer surface configured to receive one or more of the discrete
articles. The method may comprise rotating the at least one
transfer member of the transfer assembly about the first rotation
axis at a constant, or substantially constant, angular velocity and
maintaining the at least one transfer surface at a constant, or
substantially constant, minimum distance away from a surface of the
at least one head at a point or zone of discrete article transfer.
A tangential velocity of the at least one transfer surface may be
constant, or substantially constant, at the point or zone of
discrete article transfer. The method may further comprise rotating
the at least one head of the apparatus about a second rotation axis
at a variable angular velocity. A first angular velocity of the at
least one head may be constant, or substantially constant, at the
point or zone of discrete article transfer. A tangential velocity
of the surface of the head may be substantially the same as the
constant, or substantially constant, tangential velocity of the at
least one transfer surface at the point or zone of discrete article
transfer.
[0007] In still another form, the present disclosure is directed,
in part, to a method of transferring discrete articles between a
transfer assembly and an apparatus comprising one or more heads.
The transfer assembly may comprise a frame defining a first
rotation axis and at least one transfer member each comprising a
transfer surface configured to receive one of the discrete
articles. The transfer surface may be flat, substantially flat, or
may comprise a flat, or substantially flat, portion. The method may
comprise rotating the at least one transfer member of the transfer
assembly about the first rotation axis at a constant, or
substantially constant, angular velocity, maintaining the transfer
surface at a constant, or substantially constant, minimum distance
away from a surface of the at least one head at a point or zone of
discrete article transfer, and rotating the at least one head of
the apparatus about a second rotation axis at a variable angular
velocity.
[0008] In still another form, the present disclosure is directed,
in part, to a method of transferring discrete articles from a
transfer assembly to an apparatus comprising one or more heads. The
transfer assembly may comprise a frame defining a first rotation
axis and at least one transfer member each comprising a transfer
surface configured to receive one or more of the discrete articles.
The method may comprise rotating the at least one transfer member
of the transfer assembly about the first rotation axis and
maintaining the transfer surface at a constant, or substantially
constant, minimum distance away from a surface of the at least one
head at a point or zone of discrete article transfer. The transfer
surface may be moved at a first constant, or substantially
constant, tangential velocity at the point or zone of discrete
article transfer. The method may further comprise rotating the at
least one head of the apparatus about a second rotation axis. The
surface of the at least one head may be moved at a second constant,
or substantially constant, tangential velocity at the point or zone
of discrete article transfer. The second, constant, or
substantially constant, tangential velocity of the head may be
greater than the first substantially constant tangential velocity
of the transfer surface to tension the discrete articles being
transferred at the point or zone of discrete article transfer.
[0009] In yet another form, the present disclosure is directed, in
part, to a method of transferring discrete articles from a transfer
assembly to an apparatus comprising one or more heads. The transfer
assembly may comprise a frame defining a first rotation axis and
one or more transfer members each comprising a transfer surface
configured to receive one of the discrete articles. The method may
comprise rotating the at least one transfer member of the transfer
assembly about the first rotation axis at a constant, or
substantially constant, angular velocity and maintaining the
transfer surface at a constant, or substantially constant, minimum
distance away from a surface of the at least one head at a point or
zone of discrete article transfer. The transfer surface may be
moved at a first constant, or substantially constant, tangential
velocity at the point or zone of discrete article transfer. The
method may further comprise rotating the at least one head of the
apparatus about a second rotation axis at a variable angular
velocity. The surface of the at least one head may be moved at a
second constant, or substantially constant, tangential velocity at
the point or zone of discrete article transfer. The second
constant, or substantially constant, tangential velocity of the
head may be greater than the first constant, or substantially
constant, tangential velocity of the transfer surface.
[0010] In yet another form, the present disclosure is directed, in
part, to a method of transferring discrete articles from a transfer
assembly to an apparatus comprising one or more heads. The transfer
assembly may comprise a frame defining a first rotation axis and at
least one transfer member each comprising a transfer surface
configured to receive one or more of the discrete articles. The
transfer surface may be substantially flat, flat, or may comprise a
flat portion. The method may comprise rotating the at least one
transfer member of the transfer assembly about the first rotation
axis and maintaining the transfer surface at a constant, or
substantially constant, minimum distance away from a surface of the
at least one head at a point or zone of discrete article transfer.
The transfer surface may be moved at a first constant, or
substantially constant, tangential velocity at the point or zone of
discrete article transfer. The method may further comprise rotating
the at least one head of the apparatus about a second rotation
axis. The surface of the at least one head may be moved at a second
constant, or substantially constant, tangential velocity at the
point or zone of discrete article transfer. The second constant, or
substantially constant, tangential velocity of the at least one
head may be greater than the first constant, or substantially
constant, tangential velocity of the transfer surface to tension
the discrete articles being transferred at the point or zone of
discrete article transfer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The above-mentioned and other features and advantages of the
present disclosure, and the manner of attaining them, will become
more apparent and the disclosure itself will be better understood
by reference to the following description of non-limiting
embodiments of the disclosure taken in conjunction with the
accompanying drawings, wherein:
[0012] FIG. 1 is a front perspective view of a transfer assembly
configured to transfer a discrete article from a first apparatus
comprising a head to a second apparatus comprising a head in
accordance with the present disclosure;
[0013] FIG. 2 is a perspective view of a pant in accordance with
the present disclosure;
[0014] FIG. 3 is a schematic illustration of an absorbent article
capable of being formed into the pant of FIG. 2 in accordance with
the present disclosure;
[0015] FIG. 4 is a front view of the transfer assembly and the
apparatuses comprising the heads of FIG. 1 in accordance with the
present disclosure;
[0016] FIG. 5 is a top view of the transfer assembly and the
apparatuses comprising the heads of FIG. 1 in accordance with the
present disclosure;
[0017] FIG. 6 is a rear perspective view of the transfer assembly
and the apparatuses comprising the heads of FIG. 1 in accordance
with the present disclosure;
[0018] FIG. 7 is a rear view of a portion of the transfer assembly
of FIG. 1 in accordance with the present disclosure;
[0019] FIG. 8 is a rear perspective view of a portion of the
transfer assembly of FIG. 1 in accordance with the present
disclosure;
[0020] FIG. 9 is a simplified, front perspective view of a transfer
assembly and portions of apparatuses comprising heads for
transferring discrete articles in accordance with the present
disclosure;
[0021] FIG. 10 is a rear view of two tracks, a transfer member and
a rotation assembly movably engaged with the two tracks, and
portions of two apparatuses comprising heads in accordance with the
present disclosure;
[0022] FIGS. 10A-10C are rear views of a portion of the transfer
assembly having a transfer member and transfer surface, wherein the
progression of movement of the transfer surface relative to a
second apparatus comprising a head is illustrated, in accordance
with the present disclosure;
[0023] FIG. 11 is a side view of a portion of transfer member
comprising a flat, or substantially flat, transfer surface in
accordance with the present disclosure;
[0024] FIG. 12 is a front view of the portion of the transfer
member of FIG. 11 having the flat, or substantially flat, transfer
surface in accordance with the present disclosure;
[0025] FIG. 13 is a front perspective view of two tracks, a
rotation assembly, the apparatuses comprising heads, and a transfer
member in a pick-up zone, with a transfer surface in a first
position, in accordance with the present disclosure;
[0026] FIGS. 13A-13C are rear views of a portion of the transfer
assembly having a transfer member and transfer surface, wherein the
progression of movement of the transfer surface relative to a first
apparatus comprising a head is illustrated, in accordance with the
present disclosure;
[0027] FIG. 14 is a front view of the two tracks, the rotation
assembly, the apparatuses comprising heads, and a transfer member,
wherein portions of the transfer member are moving from a first
position into a second position in accordance with the present
disclosure;
[0028] FIG. 15 is a front perspective view of the two tracks, the
rotation assembly, the apparatuses comprising the heads, and the
transfer member, wherein a portion of the transfer member is in a
drop-off zone in a second position, in accordance with the present
disclosure;
[0029] FIGS. 16-18 are perspective views of a transfer member
engaged with a rotation assembly in accordance with the present
disclosure;
[0030] FIG. 19 is a cut away perspective view of the rotation
assembly and the transfer member illustrating first and second
gears in accordance with the present disclosure;
[0031] FIG. 20 is a cut away side view of the rotation assembly and
the transfer member illustrating the first and second gears in
accordance with the present disclosure;
[0032] FIG. 21 is a perspective view of an example apparatus
comprising a head in accordance with the present disclosure;
[0033] FIG. 22 is a front view of the example apparatus comprising
the head of FIG. 21 in accordance with the present disclosure;
[0034] FIG. 23 is a perspective view of another example apparatus
comprising two heads in accordance with the present disclosure;
[0035] FIG. 24 is a side view of the example apparatus comprising
the two heads of FIG. 23 in accordance with the present
disclosure;
[0036] FIG. 25 is a perspective view of a portion of the apparatus
comprising the two heads of
[0037] FIG. 23 in accordance with the present disclosure;
[0038] FIG. 26 is a rear view of the portion of the apparatus
comprising the two heads of FIG. 25 in accordance with the present
disclosure;
[0039] FIG. 27 is a cross-sectional view of the portion of the
apparatus comprising the two heads taken about line 27-27 of FIG.
25 in accordance with the present disclosure;
[0040] FIG. 28A is a schematic illustration of an example apparatus
comprising a head, wherein the head is being rotated about a
rotation axis at a first angular velocity, AV1, and at a first
tangential velocity, TV1 in accordance with the present
disclosure;
[0041] FIG. 28B is a schematic illustration of the example
apparatus comprising the head of FIG. 28A, wherein the head is
being rotated about the rotation axis at a second angular velocity,
AV2, and at a second tangential velocity, TV2, in accordance with
the present disclosure;
[0042] FIG. 28C is a schematic illustration of the example
apparatus comprising the head of FIG. 28A, wherein the head is
being rotated at a third angular velocity, AV3, and at a third
tangential velocity, TV3, in accordance with the present
disclosure;
[0043] FIGS. 29A-29C are illustrative examples of a discrete
article being transferred from a transfer surface of a transfer
member of a transfer apparatus to a surface of a head of an
apparatus, with the angular velocity, AV1, of the transfer surface
being constant, or substantially constant, and with the angular
velocity, AV2, of the surface being the same as or substantially
the same as the angular velocity, AV1 of the transfer surface at
the point of discrete article transfer and/or within the zone of
discrete article transfer in accordance with the present
disclosure;
[0044] FIGS. 30A-30C are illustrative examples of a discrete
article being transferred from a transfer surface of a transfer
member of a transfer apparatus to a surface of a head of an
apparatus, with the tangential velocity, TV1, of the transfer
surface being constant, or substantially constant, and with the
tangential velocity, TV2, of the surface being the same as or
substantially the same as the tangential velocity, TV1, of the
transfer surface at the point of discrete article transfer and/or
within the zone of discrete article transfer in accordance with the
present disclosure;
[0045] FIGS. 31A-31C are illustrative examples of a discrete
article being transferred from a transfer surface of a transfer
member of a transfer apparatus to a surface of a head of an
apparatus, with the tangential velocity, TV1, of the transfer
surface being constant, or substantially constant, and with the
tangential velocity, TV2, of the surface being constant, or
substantially constant, wherein the constant, or substantially
constant, tangential velocity, TV2, of the head is greater than the
constant, or substantially constant, tangential velocity, TV1, of
the transfer surface at the point of discrete article transfer
and/or within the zone of discrete article transfer in accordance
with the present disclosure;
[0046] FIGS. 32A-32C are illustrative examples of a discrete
article being transferred from a surface of a head of an apparatus
to a moving or rotating carrier member in accordance with the
present disclosure; and
[0047] FIGS. 33A-33C are illustrative examples of a discrete
article being transferred from a surface of a head of an apparatus
to a generally linear conveyor in accordance with the present
disclosure.
DETAILED DESCRIPTION
[0048] Various non-limiting forms of the present disclosure will
now be described to provide an overall understanding of the
principles of the structure, function, manufacture, and use of the
methods for transferring discrete articles disclosed herein. One or
more examples of these non-limiting forms are illustrated in the
accompanying drawings. Those of ordinary skill in the art will
understand that the methods for transferring discrete articles
described herein and illustrated in the accompanying drawings are
non-limiting example forms and that the scope of the various
non-limiting forms of the present disclosure are defined solely by
the claims. The features illustrated or described in connection
with one non-limiting form may be combined with the features of
other non-limiting forms. Such modifications and variations are
intended to be included within the scope of the present
disclosure.
[0049] The term "absorbent article(s)" refers herein to consumer
products whose primary function is to absorb and retain bodily
exudates and wastes. Absorbent articles as used herein may refer to
pants, taped diapers, and/or sanitary napkins (e.g., feminine
hygiene products). The term "absorbent articles" also specifically
includes adult incontinence products, in any form. In some
instances, absorbent articles may comprise or be formed into pants,
taped diapers, or sanitary napkins. The terms "diaper" and "pants"
are used herein to refer to absorbent articles generally worn by
infants, children, and/or incontinent persons about the lower
torso.
[0050] 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).
[0051] The term "nonwoven" or "nonwoven material" 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 woven or knitted filament pattern.
[0052] The term "machine direction" (MD) refers herein to the
primary direction of material, web, or article flow through a
process. In various manufacturing and converting processes, such as
a bi-fold process, it may be possible to have more than one machine
direction when an article is undergoing simultaneous processes. In
other words, a manufacturing line may have an overall machine
direction, but a material or an article may travel in directions
other than the overall machine direction as it passes through
various processes along the manufacturing line. For example, a
discrete article having a trailing end portion and a leading end
portion, each portion being attached to the surface of a different
roll and/or conveyor may travel in two different directions
simultaneously. In this example, both directions of travel may be
considered the machine direction.
[0053] The term "cross direction" (CD) refers herein to a direction
that is perpendicular to the machine direction.
[0054] The term "taped diaper" refers herein to disposable
absorbent articles having an initial front waist region and an
initial rear waist region that are not fastened, pre-fastened, or
connected to each other as packaged, prior to being applied to the
wearer. A taped diaper may be folded about its lateral central axis
with the interior of one waist region in surface to surface contact
with the interior of the opposing waist region without fastening or
joining the waist regions together. Example taped diapers in
various configurations are disclosed in U.S. Pat. Nos. 5,167,897,
5,360,420, 5,599,335, 5,643,588, 5,674,216, 5,702,551, 5,968,025,
6,107,537, 6,118,041, 6,153,209, 6,410,129, 6,426,444, 6,586,652,
6,627,787, 6,617,016, 6,825,393, and 6,861,571.
[0055] The term "pant" refers herein to disposable absorbent
articles having a continuous perimeter waist opening and continuous
perimeter leg openings designed for infant, child, or adult
wearers. A pant may be configured with a continuous or closed waist
opening and at least one continuous, closed, leg opening prior to
the article being applied to the wearer. A pant may be preformed by
various techniques including, but not limited to, joining together
portions of the absorbent article using any refastenable and/or
permanent closure member (e.g., seams, heat bonds, pressure welds,
adhesives, cohesive bonds, mechanical fasteners, etc.). A pant may
be preformed anywhere along the circumference of the absorbent
article in the waist region (e.g., side fastened or seamed, front
waist fastened or seamed, rear waist fastened or seamed). A pant
may be opened about one or both of the side seams and then
refastened. Example pants in various configurations are disclosed
in U.S. Pat. Nos. 5,246,433, 5,569,234, 6,120,487, 6,120,489,
4,940,464, 5,092,861, 5,897,545, 5,957,908, and U.S. Patent
Publication No. 2003/0233082.
[0056] The term "discrete article(s)" refers herein to absorbent
articles, pants, taped diapers, sanitary napkins, bandages, medical
pads and dressings, and any other suitable articles, in any
industry, capable of being transferred using the transfer
apparatuses and methods of the present disclosure. Discrete
articles may also refer herein to portions of the absorbent
articles, pants, taped diapers, sanitary napkins, bandages, medical
pads and dressings, and other suitable articles. The discrete
articles may be flexible. In one example, discrete articles may
refer herein to a chassis of a taped diaper or a pant. The chassis
may comprise a topsheet, a backsheet, an optional single or dual
layer acquisition system, and an absorbent core disposed between at
least a portion of the topsheet and the backsheet. The chassis may
also comprise stretched elastic elements such as leg elastics and
inner barrier leg cuff elastics, for example.
[0057] In various forms, referring to FIG. 1, the present
disclosure provides, in part, transfer assemblies (e.g., 100) and
transfer members associated with the transfer assemblies, in
combination with one or more apparatuses 101 and 101' each
comprising one or more heads, for transferring discrete articles
and/or flexible discrete articles. A transfer assembly and at least
one of the apparatuses may be referred to herein as the "overall
transfer apparatus." An apparatus comprising one or more heads may
be positioned at the input side of the transfer assembly (on the
side of element 104), at the output side of the transfer assembly
(on the side of element 106), or at both the input and output
sides. The one or more heads of the apparatuses may be rotated at
variable angular velocities about a rotation axis of the
apparatuses such that the apparatuses may provide a greater input
pitch range and/or a greater output pitch range to the overall
transfer apparatus, as is described in further detail herein. By
providing an apparatus at the input and/or output sides of the
transfer assembly, the same transfer assembly may be used to
transfer an increased size range (e.g., MD and CD sizes) of
discrete articles without frequently and costly change-outs of the
transfer assemblies. Typically, transfer members of transfer
assemblies have a constant angular velocity, thereby limiting their
input and output pitch ranges. By providing an apparatus comprising
one or more heads in combination with the transfer assembly greater
input and output pitch ranges can be achieved at a pick-up location
or a drop-off location.
[0058] The present disclosure also provides, in part, methods for
transferring the discrete articles using the transfer assemblies
and the one or more apparatuses each comprising one or more heads.
A chassis of a pant or a taped diaper, for example, may be picked
up by a transfer member of the transfer assembly at a pick-up
location while moving at a first speed and may be transferred to a
head of an apparatus. The apparatus may then place the chassis onto
a moving or rotating carrier member, a linear conveyor, or another
head at drop-off location at a second speed that is different than
or the same as the first speed. Alternatively, a head of an
apparatus may provide the chassis to a transfer member of the
transfer assembly at the pick-up location at a first speed and the
transfer member may then place the chassis onto a moving or
rotating carrier member at a drop-off location at a second,
different speed. Again alternatively, a head of an apparatus may
provide the chassis to a transfer member at the pick-up location.
The transfer member may then place the discrete article onto a head
of another apparatus and the head may then place the discrete
article onto a moving or rotating carrier member, a linear
conveyor, other type of conveyor, or another head, at a drop-off
location. As discussed above, by providing the apparatus on the
input and/or output sides of the transfer assembly, the input
and/or output pitch ranges can be significantly increased compared
to using only a transfer assembly and two moving or rotating
carrier members. These increased pitch ranges are at least
partially contributable to the variable angular velocity of the
heads of the apparatuses.
[0059] The discrete articles may be transferred from the pick-up
location (e.g., output of roll 104) to the drop-off location (e.g.,
input of roll 106) by the overall transfer apparatus to change the
speed and/or pitch of the discrete articles and/or to turn the
discrete articles, for example. Components, such as webs of front
and rear belts or discrete front and rear belts, either of which
may be configured to together form a portion of a belt in a pant,
for example, may be moving over a moving or rotating carrier
member, a linear conveyor, or other conveyor in the drop-off
location. The moving or rotating carrier member or linear conveyor
in the drop-off location may have a first portion carrying the web
of front belts and a second portion carrying a web of rear belts.
In other instances, the moving or rotating carrier member or linear
conveyor may comprise two separate moving or rotating carrier
members or linear conveyor; one carrying the web of front belts and
the other carrying the web of rear belts. If webs of front and rear
belts are provided on the moving or rotating carrier member or the
linear conveyor, the chassis may be placed on the transfer member
(either from moving carrier member 104 or head of the apparatus
101, if present), turned, then transferred to a head of the
apparatus 101'. The apparatus 101' may then apply the chassis to
the moving or rotating carrier member or linear conveyor in the
drop-off location so as to apply the waist regions of the chassis
to the first and second webs of front and rear belts. A first waist
region of the chassis may be applied to the web of first belts and
a second waist region of the chassis may be applied to the web of
second belts to form an intermediate absorbent article that can be
formed into a pant or a taped diaper, for example. The waist
regions of the chassis may be glued to the webs of belts or
otherwise attached to the webs of belts. Further details regarding
this example transfer are provided herein.
[0060] The overall transfer apparatus of the present disclosure may
be able to turn the discrete articles intermediate the pick-up
location and the drop-off location for placement onto one or more
webs of components or discrete components traveling over the moving
or rotating carrier member or linear conveyor (hereafter sometimes
referred to as a "moving carrier member") or onto the moving
carrier member without being placed on discrete components. In one
example, a portion of a transfer member of a transfer assembly may
receive a discrete article, such as a taped diaper or pant chassis,
for example, from a moving carrier member and turn it between a
first position and a second position (e.g., a 90 degree turn to the
discrete article). Then, the discrete article may be transferred by
the transfer member to a head of the apparatus 101'. After which,
the apparatus 101' may apply the discrete article onto webs of
front and rear belts traveling on the moving carrier member to form
an absorbent article that may be formed into a taped diaper or a
pant, for example.
[0061] As discussed above, the overall transfer apparatuses may
also be configured to repitch the discrete articles between the
pick-up location and the drop-off location. This "repitching" is
changing the machine direction spacing between midpoints of the
discrete articles relative to each other. In an instance, the
machine direction pitch of the discrete articles in the pick-up
location may be smaller or larger than the machine direction pitch
of the discrete articles in the drop-off location. The apparatus
(or apparatuses) comprising the head(s) of the present disclosure
aids in providing an overall transfer apparatus that may provide a
greater range of input and/or output pitches compared to transfer
assemblies used without the apparatus. This is owing to the
variable angular velocity of the heads. In other instances, the
pitch of the discrete articles may not be changed between the
pick-up and drop-off locations. In various forms, the overall
transfer apparatus of the present disclosure may not turn the
discrete articles between the pick-up and drop-off locations,
although they may have the ability to do so. In other instances,
the overall transfer apparatuses may not have the ability to turn
the discrete articles during a transfer between the pick-up and
drop-off locations.
[0062] It is to be appreciated that the methods and apparatuses of
the present disclosure may also be suitable for any other uses that
require transfer of a discrete article or a discrete component from
a pick-up location to a drop-off location, regardless of the
desired speed of the discrete articles at the pick-up location and
at the drop-off location, and regardless of whether the discrete
articles or discrete components need to be turned and/or repitched.
These other uses may comprise various manufacturing processes for
any product, or intermediate product, in any industry.
[0063] FIG. 2 illustrates an example of a pant 20 that may be at
least partially formed or manufactured using the overall transfer
apparatuses of the present disclosure. FIG. 3 illustrates an
absorbent article 10 that can be formed into the pant 20 of FIG. 2.
Those of skill in the art will recognize that FIGS. 2 and 3 are
merely examples of one absorbent article that may be formed, or at
least partially manufactured, using the overall transfer
apparatuses of the present disclosure. Many other products,
including other absorbent articles, pants, taped diapers, sanitary
napkins, cleaning pad or substrates, dusting pads or substrates,
wipes, or portions thereof, may be formed, or at least partially
manufactured, using the overall transfer apparatuses of the present
disclosure. The absorbent article 10 has a longitudinal central
axis L1 and a lateral central axis L2 (see FIG. 3). The pant 20 has
an outer surface 22, an inner surface 24 opposed to the outer
surface 22, a front waist region 26, a rear waist region 28, a
crotch region 30, and seams 32 which join the front waist region 26
and the rear waist region 28 to form two leg openings 34 and a
waist opening 36. The seams 32 may be permanent or refastenable.
When referring to "pant 20" herein, it will be understood that the
absorbent article 10, although not yet formed into the pant 20, may
be considered a "pant". It will be understood that the pant 20 is
disclosed as an example, but that a taped diaper may also be formed
from the absorbent article 10 merely by adding fastening elements
and/or landing zones to one or both of the front and rear belts 84
and 86.
[0064] Referring to FIGS. 2 and 3, the pant 20 may comprise an
absorbent chassis 38 to cover a crotch region of a wearer and a
belt 40 extending transversely about the waist opening 36. The pant
20 may also optionally comprise an outer cover layer 42 to cover
the chassis 38. The belt 40 may define the waist opening 36 in the
pant 20. The belt 40, the chassis 38, and/or the outer cover layer
42 may jointly define the leg openings 34. In some circumstances,
the pant 20 may have a patch sheet 44 printed with a graphic 46
thereon, which may be disposed in the front waist region 26, the
rear waist region 28, or any other suitable portion of the pant 20.
The belt 40 may be formed from a front belt 84 in the front waist
region 26 and a rear belt 86 in the rear waist region 28. The front
belt 84 may form a front waist edge 35 in the front waist region 26
and the rear belt 86 may form a rear waist edge 37 in the rear
waist region 28. The front and rear waist edges 35 and 37 may be
laterally opposed about the lateral central axis L2. The belt 40
may form a portion of an outer surface 22 or an inner surface 24 of
the pant 20. In other instances, the belt 40, or portions thereof,
may be disposed intermediate other layers of the chassis 38, such
as a topsheet and a backsheet, for example.
[0065] The absorbent chassis 38 may absorb and contain body
exudates or wastes disposed on the chassis 38. Referring to FIG. 3,
the chassis 38 may have a generally rectangular shape having left
and right longitudinally extending side edges 48 (hereinafter may
be referred to as "longitudinal side edge") and front and rear
laterally extending end edges 50 (hereinafter may be referred to as
"lateral end edge"). The chassis may also have any other suitable
shape, such as an hourglass shape. The chassis 38 may also comprise
waist panels (i.e., a front waist panel 52 positioned in the front
waist region 26 and a rear waist panel 54 positioned in the rear
waist region 28) and a crotch panel 56 in the crotch region 30
between the front and rear waist panels 52, 54.
[0066] The pant 20 may comprise front and rear belts 84 and 86
intended to encircle at least a portion of the waist of the wearer.
The front and rear belts 84 and 86 together form at least a portion
of, or all of, the belt 40 when joined. The front and rear belts 84
and 86 may be connected by the chassis 38 forming the crotch region
30 of the pant 20. The front and rear belts 84 and 86 may each be
formed from a first belt layer 82 possibly forming a portion of the
outer surface 22 of the pant 20 and a second belt layer 83 possibly
forming a portion of the inner surface 24 of the pant 20. The first
and second belt layers 82 and 83 may be comprised of any known
materials. Various suitable materials may comprise films, plastic
films, apertured plastic films, woven or nonwoven webs of natural
materials (e.g., wood or cotton fibers), synthetic fibers (e.g.,
polyolefins, polyamides, polyester, polyethylene, or polypropylene
fibers), or a combination of natural and/or synthetic fibers,
stretchable nonwovens, or coated woven or nonwoven webs. The belt
40 may comprise an inner hydrophobic, nonwoven material and an
outer hydrophobic, nonwoven material. The front and rear belts 84
and 86 may also comprise a plurality of elastic elements 85
disposed at least partially between the first and second belt
layers 82 and 83 thereof and attached to at least one of the first
and second belt layers 82 and 83 using adhesives or bonding, for
example. The elastic elements 85 may comprise one or more elastic
strands, elastic materials, elastomeric films, elastomeric ribbons,
elastomeric nonwovens, elastomeric filaments, elastomeric
adhesives, elastomeric foams, scrims, or combinations thereof.
[0067] The chassis 38 of the pant 20 may comprise a portion of the
outer surface 22, a backsheet 60, a portion of the inner surface
24, a topsheet 58, and an absorbent core 62 disposed between at
least a portion of the topsheet 58 and the backsheet 60. In
addition, the chassis 38 may comprise elasticized barrier leg cuffs
64 disposed at or adjacent the side edges 48 of the chassis 38. The
barrier leg cuffs 64 may provide improved containment of liquids
and other body exudates or wastes in the crotch region 30 and may
comprise a single layer of material which may be folded to form a
barrier leg cuff having two layers. The barrier leg cuffs 64 may
extend from the side of the chassis 38 at or adjacent the
longitudinal side edge 48 toward the longitudinal central axis L1.
The barrier leg cuffs 64 may be folded along the folding lines 66
back toward the longitudinal side edges 48. The front and rear
belts 84 and 86 may overlap at least a portion of the chassis 38
and one or both of the front and rear belts 84 and 86 may be
disposed on the outer surface 22 of the chassis 38, on the inner
surface 24 of the chassis 38, or disposed intermediate various
portions of the chassis 38.
[0068] A portion of, or the whole of, the chassis 38 may be made
extensible to a degree greater than the inherent extensibility of
the material or materials from which the chassis 38 is made, e.g.,
the backsheet 60. The additional extensibility may be desirable in
order to allow the chassis 38 to conform to the body of a wearer
during movement by the wearer and or to provide adequate body
coverage. The additional extensibility may also be desirable, for
example, in order to allow the user of a pant including the chassis
38 having a particular size before extension to extend the front
waist region 26, the rear waist region 28, or both of the waist
regions of the chassis 38 to provide additional body coverage for
wearers of differing size, i.e., to tailor the pant to the
individual wearer. Such extension of the waist region or regions
may give the chassis 38 a generally hourglass shape, so long as the
crotch region 30 is extended to a relatively lesser degree than the
waist region or regions, and may impart a tailored appearance to
the pant 20 when it is donned or worn. In addition, the additional
extensibility may be desirable in order to minimize the cost of the
pant 20. For example, an amount of material that would otherwise be
sufficient only to make a relatively smaller pant lacking this
extensibility may be used to make an article capable of being
extended to adequately cover a wearer that is larger than the
unextended smaller pant would fit.
[0069] A portion of the chassis 38, for example, a portion of the
chassis 38 in one or both of the waist regions 26 and 28 may be
made laterally extensible to a maximum extensibility greater than a
maximum extensibility of another portion of the chassis 38 in the
crotch region 30 such that a lateral extension of each of the
portions to its maximum extensibility imparts an hourglass shape to
the chassis 38. The portion of the chassis 38 underlying,
overlying, and/or immediately adjacent one or both of the front and
rear extensible belts 84 and 86 may be made laterally extensible to
a maximum extensibility greater than a maximum extensibility of
another portion of the chassis 38, for example the crotch region
30, such that a lateral extension of each of the portions to its
maximum extensibility facilitates application of the pant 20 onto
the body of a wearer by enabling the waist regions 26 and 28 to be
extended to fit over the wearer's hips and in addition, opening and
orienting the leg openings enabling the wearer to place the legs
through the openings more effectively.
[0070] The liquid pervious topsheet 58 may be positioned adjacent
the body-facing surface of the absorbent core 62 and may be joined
thereto and/or to the backsheet 60 by any attachment methods known
to those of skill in the art. The liquid impervious backsheet 60
may generally be that portion of the pant 20 positioned adjacent
the garment-facing surface of the absorbent core 62 and may
prevent, or at least inhibit, the bodily exudates and wastes
absorbed and contained in the absorbent core 62 from soiling
garments that may contact the outer surface 22 of the pant 20.
[0071] The topsheet 58, the backsheet 60, and the absorbent core 62
may be manufactured of any known materials. Suitable topsheet
materials may comprise porous foams; reticulated foams; apertured
plastic films; or woven or nonwoven webs of natural fibers (e.g.,
wood or cotton fibers), synthetic fibers (e.g., polyester or
polypropylene fibers), or a combination of natural and synthetic
fibers. Suitable backsheet materials may include breathable
materials that permit vapors to escape from the pant 20 while still
preventing, or at least inhibiting, bodily exudates or wastes from
passing through the backsheet 60. Such materials may include
nonwoven materials, woven materials, films, and/or laminates
comprising a combination of one or more of these materials. In one
embodiment, the backsheet 60 may be a film and nonwoven laminate,
wherein the nonwoven of the laminate forms the outer cover layer
42.
[0072] A suitable absorbent core 62 for use in the pant 20 may
comprise any absorbent material which is generally compressible,
conformable, non-irritating to the wearer's skin, and capable of
absorbing and retaining liquids such as urine and other certain
body exudates. Absorbent material may comprise a superabsorbent
material, a cellulosic material, or combinations thereof. In some
instances, the absorbent core may comprise one or more adhesives
and a superabsorbent material and may be free of, or at least
mostly free of, a cellulosic material. In addition, the
configuration and construction of the absorbent core 62 may also be
varied (e.g., the absorbent core(s) or other absorbent structure(s)
may have varying caliper zones, hydrophilic gradient(s), a
superabsorbent gradient(s), or lower average density and lower
average basis weight acquisition zones; or may comprise one or more
layers or structures). In some forms, the absorbent core 62 may
comprise a fluid acquisition component, a fluid distribution
component, and/or a fluid storage component. An example of a
suitable absorbent core having a fluid acquisition component, a
fluid distribution component, and a fluid storage component is
described in U.S. Pat. No. 6,590,136.
[0073] The outer cover layer 42 may be disposed on the outer
surface 22 of the pant 20 and may cover the crotch panel 56 of the
absorbent chassis 38. The outer cover layer 42 may extend into and
cover the front waist panel 52 and the rear waist panel 54 of the
chassis 38. The outer cover layer 42 may form a portion of the
backsheet 60 and/or the chassis 38. In a form, the outer cover
layer 42 may be directly joined to and cover a portion of, or all
of, the liquid impervious backsheet 60 of the chassis 38. The outer
cover layer 42 may be disposed between the front and rear belts 84
and 86.
[0074] The outer cover layer 42 may comprise a material separate
from the first and second belt layers 82 and 83 forming the belts
84 and 86. The outer cover layer 42 may comprise two or more layers
of materials of any known materials including the materials used
for the first and second belt layers 82 and 83. The outer cover
layer 42 may comprise a single layer of a nonwoven web of synthetic
fibers. The outer cover layer 42 may comprise a single layer of
hydrophobic, non-stretchable nonwoven material. In some instances,
the outer cover layer 42 may comprise a film, a foam, a nonwoven, a
woven material, or the like and/or combinations thereof such as a
laminate of a film and a nonwoven.
[0075] The belt 40 may be at least partially formed, or fully
formed, when the front and rear belts 84 and 86 are permanently or
refastenably connecting together to form the seams 32. Any suitable
seams may be formed, as known to those of skill in the art. The
belt 40 may be ring-like and elastic. The ring-like elastic belt 40
may extend about the waist opening 36 of the pant 20 and act to
dynamically create fitment forces and to distribute the forces
dynamically generated during wear.
[0076] Referring to FIGS. 1 and 4-6, an overall transfer apparatus
comprising a transfer assembly 100 and at least one apparatus 101
or 101'comprising at least one head 105 or 105' is illustrated. As
explained above, an apparatus may be provided on the input and
output sides of the transfer assembly 100 or may only be provided
on the input side or on the output side of the transfer assembly
100. An apparatus on the input side of the transfer assembly is
labeled 101 and an apparatus on the output side is labeled 101'
(with its various components also being numbered with primes). The
apparatus 101 may be the same or different than the apparatus 101'.
The differences may be in size, shape, and/or speed, for example.
The overall transfer assembly is configured to transfer discrete
articles from a pick-up location to a drop-off location, as
explained herein. FIG. 1 is a front perspective view of the overall
transfer apparatus comprising the transfer assembly 100, the
apparatus 101, and the apparatus 101'. FIG. 4 is a front view of
the overall transfer apparatus of FIG. 1. FIG. 5 is a top view of
the overall transfer apparatus of FIG. 1. FIG. 6 is a rear
perspective view of the overall transfer apparatus of FIG. 1. The
overall transfer apparatus may transfer discrete articles 102 from
a first moving carrier member 104 to a second moving carrier member
106. The moving carrier members 104 and 106 from and to which the
discrete articles 102 may be transferred may be rolls, drums,
curved conveyors, linear conveyors, and/or discrete heads following
a curvilinear path, for example. The moving carrier members may be
rotating carrier members, such as rolls or cylindrical rolls. The
output side of the first moving carrier member 104 may represent
the pick-up location and the input side of the second moving
carrier member 106 may represent the drop-off location in certain
instances. An apparatus 101 may be provided intermediate the
transfer assembly 100 and the first moving carrier member 104, and
likewise, an apparatus 101' may be provided intermediate the
transfer assembly 100 and the second moving carrier member 106. The
first and second moving carrier members 104 and 106 may be moving
at a different surface velocity or at the same surface velocity.
Surfaces of the first and second moving carrier members 104 and 106
may have different or the same tangential velocities. Typically,
surfaces of the first and second moving carrier members 104 and 106
have constant, or substantially constant, tangential velocities,
but the tangential velocities may also be variable in certain
instances. A transfer member 112 of the transfer assembly 100 or
the head 105 of the apparatus 101 (if the apparatus is provided on
the input side of the transfer assembly 100) may pick up the
discrete article 102 at a first velocity, V1, from the first moving
carrier member 104. The transfer member 112 will then convey the
discrete article 102 to the output side of the transfer assembly
100. Next, the transfer member 112 or the head 105' of the
apparatus 101' (if the apparatus is provided on the output side)
may apply the discrete article 102 at a second velocity, V2, to the
second moving carrier member 106. The first velocity, V1, and the
second velocity, V2, at the point or zone of discrete article
transfer to and from the first and second moving carrier members
104 and 106 may be tangential or linear velocities.
[0077] A continuous web of articles 108 may be fed on a roll or
other conveying mechanism toward the first moving carrier member
104 and, optionally, the apparatus 101. Once a portion of the web
of discrete articles 108 long enough to form a discrete article 102
is engaged with the first moving carrier member 104, is engaged
with a portion of a transfer member 112 of the transfer assembly
100, or optionally, is engaged with a portion of a head 105 of the
apparatus 101, a knife integral to the first moving carrier member
104 may cut the web 108 into discrete articles 102 against an anvil
roll 114. The knife may be a flex knife, a die cutter, a shear
knife, or any other suitable knife or cutting device or mechanism.
Knife and anvil roll technology is generally known in the art. In
other instances, previously cut discrete articles 102 may be fed on
a conveyor toward the first moving carrier member 104. In some
instances, discrete articles 102 may be engaged directly with the
head 105 of the apparatus 101 directly without the moving carrier
member 104 and anvil roll 114 being present.
[0078] Portions of the transfer members 112 of the present
disclosure may also turn between a first position 116 and at least
a second position 118 when transferring the discrete articles 102
from an input side of the transfer assembly 100 to an output side
of the transfer assembly 100. As a result, the discrete articles
102 may be turned between a first position 116 and a second
position 118. The portions of the transfer members 112 may be
turned using rotation assemblies engaged with a portion of each
transfer member 112, as described in further detail below. The
discrete articles 102 may be turned between about 30 degrees and
about 180 degrees, between about 40 degrees and about 150 degrees,
between about 60 degrees and about 120 degrees, between about 75
degrees and about 105 degrees, about 45 degrees (e.g., +/-5
degrees), about 90 degrees (e.g., +/-5 degrees), 45 degrees, 90
degrees, about 180 degrees (e.g., +/-5 degrees), or 180 degrees,
specifically reciting each 0.5 degree increment within the
above-recited ranges and all ranges formed therein or thereby.
Optionally, the discrete articles 102 may also not be turned at all
and the transfer assembly may be used for conveying and/or
repitching the discrete articles 102 without turning them.
[0079] Again referring to FIGS. 1 and 4-6, continuous webs of
components 120 may be moving towards, over, and away from the
second moving carrier member 106 on a roller, conveyor, or other
mechanism. In one example, these webs of components 120 may be
front belts 124 and rear belts 126, although in other examples, the
webs of components 120 may be various other components or even
discrete components that have been previously cut from a continuous
web. An adhesive may be applied to the webs of components 120 or
discrete components using adhesive dispensers 128. The adhesive
dispensers 128 are optional in some circumstances. The adhesive may
be applied to portions of the webs of components 120 prior to those
portions being moved over the second moving carrier member 106. As
a result, a discrete article 102 being transferred to the second
moving carrier member 106, by either a transfer member 112 or a
head 105' of the apparatus 101', may be adhesively attached to the
webs of components 120 when transferred onto the second moving
carrier member 106. In one example, the discrete article 102 may be
a chassis 38 and the front waist panel 52 of the chassis 38 may be
adhesively attached to the continuous web of front belts 124 and
the rear waist panel 54 of the chassis 38 may be adhesively
attached to the continuous web of rear belts 126. This may form a
web of absorbent articles. The web of absorbent articles may then
be cut or separated into discrete absorbent articles, such as the
absorbent article 10 of FIG. 2.
[0080] Referring to FIGS. 1 and 4-10, the transfer assembly 100 may
comprise a frame 130 defining a rotation axis 132 and a track 134
(also referred to herein as a first track or the outer track)
having a circumferential shape surrounding the rotation axis 132.
FIG. 7 is a partial rear perspective cross-sectional view of the
transfer assembly 100 and FIG. 8 is a partial rear perspective
cross-sectional view of the transfer assembly 100. In both of FIGS.
7 and 8, the frame 130 and various other components have been
removed to more clearly illustrate various features. FIG. 9 is a
front perspective view of the transfer assembly 100 with multiple
transfer members 112 removed for clarity in illustration. FIG. 10
is a rear view of portions of the transfer assembly 100
illustrating the track 134, the transfer member 112, and other
components for clarity. The apparatuses 101 and 101' are also
illustrated in FIGS. 1, 4-6, 9, and 10. The distance between the
rotation axis 132 and various points on the track 134 may vary. The
track 134 may be a cam track. The track 134 may comprise one or
more separation points 135 in the event the track 134 needs to be
disassembled for maintenance or other reasons. The transfer
assembly 100 may comprise one or more transfer members 112 movably,
rollably, and/or slidably engaged with the track 134. Each transfer
member 112 may comprise a transfer surface 136 on an end of the
transfer member 112 most distal from the rotation axis 132. The
transfer surface 136 may be configured to receive one or more of
the discrete articles 102. The transfer surfaces 136 of the
transfer members 112 may be configured to retain the discrete
articles 102 thereto using a fluid pressure, such as vacuum,
magnets, or an adhesive, for example. The transfer assembly 100 may
also comprise a wheel 138 supported by the frame 130 and configured
to rotate about the rotation axis 132. The wheel 138 may or may not
be round about its perimeter. The wheel 138 may be engaged with
portions of the transfer members 112 such that as the wheel 138
rotates about the rotation axis 132, the transfer members 112
circumnavigate about a path about the rotation axis 132 in
correspondence with the track 134. The shape of the track 134 may
cause the transfer members 112 to move radially inwardly and
radially outwardly relative to the rotation axis 132 while the
transfer surfaces 136 are maintained a constant or a substantially
constant distance or minimum distance away from the first and
second moving carrier members 104 and 106 or surfaces of the heads
105 and 105' of the apparatuses 101 and 101' at the point or zone
of discrete article transfer onto and off of the transfer surfaces
136. The substantially constant minimum distance or minimum
distance may vary typically from 0-6 mm or may have a tolerance of
typically +/-0.1 to 1 mm, although a wide range of targets are
achievable. In an instance, the minimum distance may be constant,
then not constant, then constant again at the point or zone of
discrete article transfer as the transfer surface 136 is moved past
the point or zone of discrete article transfer. Such a profile may
be employed if, for instance, it is desired to only maintain the
substantially constant gap at the leading and/or trailing edge of
the discrete article transfer. The profile may also be adjusted to
account for thickness variations in the discrete article being
transferred. In some cases, the gap or minimum distance may be
profiled to be larger in the region with the absorbent core, for
example.
[0081] Referring again to FIGS. 1 and 4-10, the frame 130 may be
mounted to a base or stand 140 for the transfer assembly 100. The
apparatuses 101 and 101' may also be mounted to a base or stand.
The track 134 may be formed with or in the frame 130 or be mounted
to the frame 130. The track 134 may be a projection that extends
from a plane of the frame 130 or may be a groove (not illustrated)
defined in the frame 130. The track 134 may have a constant, or
substantially constant, width, or a varying width, regardless of
whether it is a projection or a groove. In the event the track 134
is a groove, a follower member 142 extending from each of the one
or more transfer members 112 may be movably, slidably, and/or
rollably engaged with the groove. The follower member 142 may be
biased toward the track 134. In the event the track 134 is a
projection as illustrated, a follower member 142 extending from
each of the one or more transfer members 112, or portions thereof,
may be movably, slidably, and/or rollably engaged with a surface of
the projection that extends generally perpendicular to a front
planer surface of the frame 130 from which the projection extends.
In an instance, when the track 134 is a projection, two or more
follower members 142 may extend from each transfer member 112, or
portions thereof, such that one follower member 142 engages a first
surface 144 of the projection and another follower member 142
engages the opposite surface 146 of the projection. The follower
members 142 may be rollers or cam followers that slide or roll
about the track 134 as the transfer member 112 circumnavigates
about a path around the rotation axis 132. The follower members 142
may comprise materials such as metals, plastics, and/or polymers,
for example, or coatings thereof, to permit rolling or sliding
movement between the follower members 142 and the track 134.
[0082] In the event that the track 134 is a groove, the follower
members 142 may comprise two stacked concentric cylindrical cam
followers, each following one side of the groove. This may
constrain the cam followers to rotate in one direction and
eliminate, or at least inhibit, the issue of cam follower reversal
as with a single cam follower following a groove. The stacked cam
followers may also be configured with eccentricity between the axes
of their rotation. Adjusting the eccentric may adjust the clearance
between the cam groove and the cam followers. An elastic element,
such as a spring or pneumatic cylinder, for example, may also be
used to keep the cam follower loaded against one surface of the
groove. This has the potential to only use one surface of the
groove.
[0083] In the event that the track 134 is a projection, the
follower members 142 may comprise two conjugate cylindrical
follower members on each side of the track projection 134. This
arrangement may naturally cause each follower member to rotate in
one direction. The axis of rotation of one of the follower members
may be adjusted to control the clearance between the follower
members and the track projection 134. A single follower member may
be employed in conjunction with an elastic or inertial force to
keep the follower member in contact with the track projection 134.
The follower member may be spring loaded or loaded by pneumatic
cylinder, for example.
[0084] Referring to FIGS. 16-18 for clarity, the transfer members
112 may comprise a fluid manifold attached to or formed with a base
141 and the follower members 142 may be mounted, or rotatably
mounted, to the base 141. The base 141 may be slidably or movably
engaged with a plate 155 such that the transfer members 112 may be
moved radially relative to the wheel 138 and the plate 155 by the
track 134. The plate 155 may be used to mount portions of the
transfer members 112 and portions of the rotation assembly (as
described below) to projections 156 on the wheel 138, as described
in further detail herein.
[0085] Referring to FIGS. 1 and 4-10, the wheel 138 may be engaged
with the frame 130 such that the wheel 138 is permitted to rotate
relative to the frame 130 about the rotation axis 132. The frame
130 may locate bearings that support the drive shaft 148 and/or the
wheel 138. This permits rotation of wheel 138 and the drive shaft
148 about the first rotation axis 132. This also locates the axial
position of the wheel 138 and the drive shaft 148. The first
rotation axis 132 may be located generally centrally, although not
necessarily at the midpoint of the track 134, within the
circumference of the track 134. A drive shaft 148 that has a
rotation axis common to the rotation axis 132 may be driven by one
or more actuators 150 through the use of a drive belt or chain 152,
for example. The drive shaft 148 may be engaged with the wheel 138
to cause the wheel 138 to rotate. Other methods of rotating the
drive shaft 148 will be envisioned by those of skill in the art and
will not be discussed in detail for brevity. The one or more
actuators 150 may cause the drive shaft 148 to rotate in either the
clockwise or counter-clockwise direction. The drive shaft 148 may
rotate in either direction and at any speed about the rotation axis
132 to drive or rotate the wheel 138. The wheel 138 may rotate in a
direction generally parallel with the plane of the frame 130 from
which the track 134 extends or is defined in. The wheel 138 may be
fixedly attached to the drive shaft 148 such that upon activation
of the one or more actuators 150, the drive shaft 148 and, thereby,
the wheel 138 may rotate.
[0086] The wheel 138 may have one or more recesses 154 defined in a
perimeter thereof. Fluid conduits and/or other components may
extend through the recesses 154 to portions of the transfer members
112. Also, by providing the recesses 154 in the wheel 138, the
wheel 138 may be lighter and have less rotational inertia.
[0087] Referring again to FIGS. 1 and 4-10, the wheel 138 may be
engaged with one or more of the transfer members 112 through the
use of the plate 155. The wheel 138 may have projections 156
extending therefrom in a direction toward the frame 130. Portions
of the plate 155 extending intermediate a portion of the transfer
member 112 and a torque transmitting assembly (as discussed below),
for example, may be mounted to the projections 156 on the wheel 138
to provide support to the rotating assembly which includes the
transfer member 112. The plate 155 may be movably engaged with the
base 141 as described in greater detail herein. Portions of the
transfer members 112 may also be engaged with shafts or shaft
assemblies comprising a spline, for example, to allow the transfer
members 112 to be movable in radial directions relative to the
first rotation axis 132. The shaft or shaft assemblies may also
allow portions of the transfer members 112 to be turned relative to
the wheel 138 about a second rotation axis 164 that may be
positioned generally perpendicular, or transverse, to first
rotation axis 132. The shaft or shaft assemblies and the transfer
members 112 may rotate with the wheel 138. Transfer members 112 may
have a constant relative angular position about the first rotation
axis 132 and may share the same angular velocity about the first
rotation axis 132. Stated another way, the transfer members 112 may
orbit about the rotation axis 132 at a constant angular velocity or
a substantially constant angular velocity.
[0088] The wheel 138 may be engaged with one to sixteen or more
transfer members 112, for example. All or some of the transfer
members 112 may be used to transfer discrete articles 102 in
various manufacturing operations. In some instances, every other,
or every third, transfer member 112 may be used to transfer
discrete articles 102 in a particular manufacturing operation, for
example.
[0089] Referring to FIGS. 7, 8, 10, and 16, the one or more
follower members 142 may extend from the base 141 or other portion
of the transfer members 112 such that they may engage the track 134
and move the transfer members 112 radially. The follower members
142 may be attached to portions of the transfer members 112 or may
be formed with the transfer members 112. The "transfer members 112"
may refer to not only the portion comprising the transfer surface
136 but all of the radially movable assembly at the second end 204
of the shaft or shaft assembly 200. Radially moving assemblies
comprise the fluid manifold, the spline receiving member, the base
141, the follower members 142, the housing, and the transfer
surface 136, for example. Some of these components are discussed in
more detail below. The shaft, the spline, and the second end of the
shaft (as are all discussed below) may not be radially moving. In
certain instances, more than two follower members 142 may be
desired on a particular track 134 or if more than one track 134 is
provided on the frame 130. In an example, two tracks (not
illustrated) for the follower members 142 may be provided on a
frame and one or more follower members may be movably engaged with
each of the tracks. The follower members 142 being movably engaged
with the track 134 causes the transfer members 112 to
circumnavigate about a path about the rotation axis 132 in
correspondence with the track 134.
[0090] The shape of the track 134 may be such that it causes the
follower members 142 and, thereby, the transfer members 112, and
the transfer surfaces 136 of the transfer members 112, to be moved
radially inwardly and outwardly when the transfer members 112 are
rotating about the path of the rotation axis 132 in correspondence
with the track 134. This path can be seen in FIGS. 7, 8, and 10,
for example. The path may be said to be about the rotation axis
132. The track 134 may comprise a first projection 158 extending
radially outwardly from the rotation axis 132 proximate to the
first moving carrier member 104 and a second projection 160
extending radially outwardly from the rotation axis 132 proximate
to the second carrier member 106. This radial extension of the
projections 158 and 160 is discussed with reference to a
non-projection portion 162 of the track 134. The projections 158
and 160 may have any suitable shape which generally extends
radially outwardly from the rotation axis 132. The shape of the
projections 158 and 160, among other things, may dictate the
tangential velocity of a portion of the transfer surface 136 at the
point or zone of discrete article transfer from or to one of the
moving carrier members 104 and 106 or from or to one of the heads
105 and 105' of the apparatuses 101 and 101'. The shape of the
projections 158 and 160 may also contribute to or cause the gap
between the transfer surfaces 136 and surfaces of the first and
second moving carrier members 104 and 106 or the surfaces of the
heads 105 and 105' of the apparatuses 101 and 101' to remain
constant or substantially constant at the point or zone of discrete
article transfer. These projections 158 and 160 may be positioned
at any locations on the track 134 that are proximate to an incoming
first moving carrier member 104 or incoming head 105 or an outgoing
moving second carrier member 106 or an outgoing head 105'. The
track 134 may only have one projection 158 or 160 positioned
proximate to one of the moving carrier members 104 and 106 or one
of the heads 105 and 105'. The first projection 158 may be
generally across the track 134 from the second projection 160 or
otherwise situated relative to the second projection 160 depending
on the positioning of the incoming first moving carrier member 104
or incoming head 105 and the outgoing second moving carrier member
106 or the outgoing head 105'. The radius of the track 134 relative
to the rotation axis 132 may increase and decrease about the track
134, even in the non-projection portions 162 of the track 134. In
an instance, the radius of the track 134 may increase at least when
portions of the transfer members 112 are partially rotated between
the first position 116 and the second position 118 to allow two
adjacently positioned transfer surfaces of the transfer members 112
to clear each other (i.e., not contact each other) during rotation
of the transfer members 112 about the second rotation axis 164. The
increased radius of the track 134 at these locations forces the
transfer members 112 radially outwardly relative to the rotation
axis 132, thereby providing adequate clearance of a first transfer
surface 136 and an adjacent second transfer surface 136 to rotate
between the first position 116 and the second position 118. The
second rotation axis 164 may be perpendicular, substantially
perpendicular, or transverse to the rotation axis 132. In other
instances, the rotation axis 132 may extend in a first direction
and the second rotation axis 164 may extend in a second, different
direction. The second, different direction may be parallel or
substantially parallel (e.g., +/-0.5 to fifteen degrees) to a plane
of the frame 130 from which the rotation axis 132 extends, wherein
the plane extends generally perpendicular to the rotation axis 132.
The rotation of the portions of the transfer members 112 and an
example rotation assembly configured to accomplish this rotation
will be discussed in further detail below.
[0091] The track 134 may not increase the radial distance of the
transfer members 112 from the rotation axis 132 during movement of
the transfer surfaces 136 between a first position and a second
position. In such an instance, the transfer surfaces 136 may be
shaped (e.g., ovate, round) or spaced such that they can be turned
between the first position and the second position without
contacting each other.
[0092] Referring to FIGS. 1 and 4-12, the transfer members 112 may
each comprise the transfer surface 136 on the distal most portion
thereof relative to the rotation axis 132, as referenced above. The
transfer surface 136 may be flat, substantially flat, or may
comprise one or more flat portions in one or more directions. FIG.
11 illustrates the flat, or substantially flat, transfer surface in
a first direction, while FIG. 12 illustrates the flat, or
substantially flat, surface in a second direction. Substantially
flat, as used herein, means the transfer surface 136 used to
support and transport a discrete article 102 conforms to a plane
within about 0-10 mm, and alternatively about 0-5 mm, not including
fluid ports and bolt holes, as discussed below. Example transfer
surfaces 136 are illustrated as rectangular, but it is to be
understood that other transfer surfaces for use with the transfer
members 112 of the present disclosure may be formed of other
suitable shapes, such as squares, circles, or ovals, for example. A
portion of each transfer surface 136 may be flat, or substantially
flat, while other portions may be arcuate. Although not
illustrated, some of the transfer surfaces of the transfer members
of a transfer assembly may be flat, or substantially flat, while
other transfer surfaces may be arcuate. The portions of the
transfer members 112 supporting the transfer surfaces 136 (e.g.,
the portions attached to the distal end of the housing 278 as
described below) may be flat, substantially flat, or arcuate. In
some instances, the transfer members 112 may be arcuate in one or
more directions.
[0093] By providing flat, or substantially flat, transfer surfaces
136, a significant advantage may be achieved in that the flatness
of the transfer surfaces 136 is the same, or substantially the
same, whether the transfer surface 136 is in the first position 116
or rotated into the second position 118 about the second rotation
axis 164. In an instance, a transfer surface 136 may have a flat,
or substantially flat leading portion, an arcuate middle portion,
and a flat, or substantially flat, trailing portion. This geometry
of a transfer surface 136 may be employed for substantially
constant gap transfer at the leading and trailing portions (and not
the middle portion), for example. On related art transfer
assemblies, having arcuate transfer surfaces with the arc extending
generally in the longitudinal direction of the transfer surface,
once the transfer member is rotated into the second position (a
position which is generally 90 degrees from the first position),
transfer of the discrete articles may become an issue because of
the arc being in the wrong direction for transfer to a second
moving carrier member 106 or a head 105' of the apparatus 101'.
Stated another way, if the arc is suitable for picking up a
discrete article from a first moving carrier member 104 or a head
105 of the apparatus 101, it generally may not be suitable for
dropping off a discrete article onto a second moving carrier member
106 or the head 105' of the apparatus 101' because the outer edges
of the transfer surface may be more distal from the second moving
carrier member 106 or the head 105' of the apparatus 101',
potentially leading to inefficient transfers. The flat, or
substantially flat, transfer surface 136 solves that problem by
providing the same, or substantially the same, distance or gap
between all or most portions of the transfer surface 136 and the
second moving carrier member 106 or heads 105' after the transfer
surface 136 is rotated from the first position 116 into the second
position 118 about the second rotation axis 164. This can lead to
improved discrete article transfers and increased speed of the
transfers.
[0094] One problem that may arise, however, in related art transfer
assemblies using flat, or substantially flat, transfer surfaces
that do not have the ability to move their transfer members
radially inwardly and radially outwardly with respect to the
rotation axis of the transfer assemblies, may be that there will be
a significant gap at the point of discrete article transfer while
portions of the flat, or substantially flat, transfer surface pass
through the discrete article transfer point or transfer zone. In
such an instance, the leading edges and trailing edges of the flat
transfer surface may be positioned quite close to the moving
carrier member or head, while the middle portion of the transfer
surface, owing to its flat, or substantially flat, configuration,
may be positioned more distal from the moving carrier member or
heads. This gap between the middle portion of the flat, or
substantially flat, transfer member and a moving carrier member or
head and/or gap variation may result in poor or unacceptable
transfers, especially during high speed transfers, which are
desired in absorbent article manufacturing. The poor transfer may
result in folding of portions of the discrete article over itself,
for example.
[0095] Referring to FIGS. 7, 8, and 10C, the transfer assembly 100
solves this gap problem, among others, in the middle portion of a
related art transfer surface by providing the track 134 with the
projections 158 and 160 therein at or proximate to the moving
carrier members 104 and 106 or the heads 105 and 105'. By providing
the projections 158 and 160, the transfer surfaces 136 of the
transfer members 112 of the present disclosure may maintain a
constant, or substantially constant (e.g., 0.1-2 mm or 0.1-3 mm),
distance or minimum distance between themselves and the moving
carrier members 104 and 106 or the heads 105 and 105' at the point
or zone of discrete article transfer. FIGS. 10A-10C illustrate the
progression of the transfer surface 136 when moving past the head
105' in the direction of arrow A. FIGS. 13A-13C illustrate the
progression of the transfer surface 136 when moving past the head
105 in the direction of arrow B. Similar constant, or substantially
constant, distances or minimum distances, as illustrated in FIGS.
10A-10C and 13A-13, would also apply to moving carrier members 104
and 106 if an apparatus 101 or 101' was not provided on the input
or output sides of the transfer assembly 100 and the discrete
articles were transferred directly from a moving carrier member 104
or 106 to the transfer member 112. In some forms, the distance may
be constant, or substantially constant, then not constant, and then
constant, or substantially constant again at the point or zone of
discrete article transfers as the transfer surface 136 moves past
one of the moving carrier members or one of the heads. The point or
zone of discrete article transfer may be the point or zone at which
a portion of the discrete article 102 leaves the first moving
carrier member 104 or head 105 and transfers to the transfer
surface 136. The point or zone of discrete article transfer may
also be the point or zone at which a portion of the discrete
article 102 leaves the transfer surface 136 and transfers to the
second moving carrier member 106 or head 105'. The point or zone of
discrete article transfer may also be where the moving carrier
members, heads, and/or transfer surfaces are closest to each other
in their respective rotations. Since the transfer surfaces 136 of
the present disclosure are flat, or substantially flat, the
transfer surfaces 136 generally may need to be moved radially
outwardly and radially inwardly as portions of the transfer
surfaces 136 pass through the discrete article transfer point or
zone with the moving carrier members 104 and 106 or the heads 105
and 105'. The projections 158 and 160 constrain such radial
movement of the transfer members 112 since the transfer members 112
are movably engaged with the track 134 and rotate about a path
about the rotation axis 132 in correspondence with the track 134.
As such, each of the transfer members 112 and, thereby, the
transfer surfaces 136 may be moved or cammed consistently or
variably radially outwardly relative to the rotation axis 132 from
when, or about when, the leading edge of the transfer surface 136
is at or proximate to the point or zone of discrete article
transfer until when, or about when, a midpoint or mid portion (in
the machine direction of travel) of the transfer surface 136 is at
or proximate to the point or zone of discrete article transfer. At
such a time, the transfer surface 136 may then be moved or cammed
consistently or variably radially inwardly until the trailing edge
of the transfer surface 136 is at or past the point or zone of
discrete article transfer or until the transfer member 112 has
travelled over the projection 158 or 160 and back onto a
non-projection portion 162 of the track 134.
[0096] In various forms, the angular velocity of the rotation about
the first rotation axis 132 of the transfer members 112 may be or
is constant, or substantially constant, in that the rotation of the
drive shaft 148 and the wheel 138 may be constant. That being said,
the tangential velocity of the transfer surfaces 136 changes when
the transfer members 112 are moved radially outwardly and inwardly.
Generally, if the transfer members 112 are moved radially
outwardly, the tangential velocity of transfer surfaces 136 will
increase, while if the transfer members 112 are moved radially
inwardly, the tangential velocity of the transfer surfaces 136 will
decrease owing to the transfer members 112 being rotated about the
rotation axis 132. The tangential velocity of the transfer surfaces
136 at the point or zone of discrete article transfer may be
constant, or substantially constant (e.g., within 0.1%-2%) and
matched to the tangential velocity of the first or second moving
carrier members 104 or 106 or the heads 105 or 105' during
transfer. This is accomplished by maintaining a substantially
constant radial displacement between the zone of discrete article
transfer and the first rotation axis 132. The radial displacement
of the transfer surface 136 is adjusted as the follower members 112
travel over the projections 158 and 160. By providing constant, or
substantially constant, tangential velocities of the transfer
surfaces 136 at the point or zone of discrete article transfer,
smoother and matched speed discrete article transfers may be
accomplished. The projections 158 and 160 may be designed so that a
first projection provides a transfer surface 136 with a first
tangential velocity at a first point or zone of discrete article
transfer (i.e., pick-up location) and a second projection provides
the same transfer surface 136 with a second tangential velocity at
a second point of discrete article transfer (i.e., drop-off
location). As such, the transfer assembly 100 may pick up a
discrete article 102 from the first moving carrier member 104 or
the head 105 having a first velocity or tangential velocity at a
first point or zone of discrete article transfer and may drop off
the discrete article 102 onto the second moving carrier member 106
or the head 105' having a second velocity or tangential velocity at
a second point or zone of discrete article transfer. In an
instance, the transfer assembly 100 may be configured to pick up
the discrete articles from the second moving carrier member 106 or
head 105' and transfer them to the first moving carrier member 104
or head 105. In such an instance, the direction of rotation of the
transfer members 112 about the rotation axis 132 may be clockwise
or counterclockwise.
[0097] Although the angular velocity and tangential velocity of the
heads 105 and 105' may be variable, the angular velocity and
tangential velocity of the heads 105 and 105' may be constant, or
substantially constant at the point or zone of discrete article
transfer. The angular velocity or tangential velocity of the heads
105 and 105' may be the same as, or substantially the same as, the
angular or tangential velocity of the transfer members 112 at the
point or zone of discrete article transfer. In other instances, the
angular or tangential velocity of the heads 105 and 105' may be
different than, greater than, or less than, the angular or
tangential velocity of the transfer members 112 at the point or
zone of discrete article transfer, as will be discussed in greater
detail below.
[0098] The transfer assembly 100 may be used to transfer discrete
articles 102 from the first moving carrier member 104 or the head
105 at a first pitch (i.e., spacing of discrete articles) to a
second moving carrier member 106 or the head 105' at a second pitch
(i.e., repitching). The transfer assembly 100 is capable of
achieving suitable transfer of the discrete articles 102 as the
pitch increases, decreases, or remains the same between the first
and second moving carrier members 104 and 106 or between the heads
105 and 105'.
[0099] Transferring the discrete articles 102 from the head 105' to
the second moving carrier member 106 or from the transfer member
112 directly to the second moving carrier member 106 may provide
suitable and efficient bonding of the discrete articles 102 to the
webs of front and rear belts 124 and 126 or to front and rear
belts. In an instance where the transfer member 112 place the
discrete articles 102 directly onto the second moving carrier
member 106, the constant gap clearance, or substantially constant
gap clearance, may be adjusted to provide uniform, or substantially
uniform, bonding pressure between the transfer surface 136 and the
second moving carrier member 106. The head 105' and the second
moving carrier member 106 may also be adjusted to interfere with
the discrete article 102 and create bonding pressure that will be
constant, or substantially constant, across the area of the
discrete article 102 or the area of a portion of the discrete
article 102. This may be useful for creating suitable bonds between
the discrete article 102 and the webs of front and rear belts 124
and 126 when a hot melt adhesive or other pressure sensitive
adhesive is employed.
[0100] The transfer assembly 100, with a variable radius transfer
member mechanism, may also be employed to improve transfer from
transfer surfaces that are not flat. For example, a transfer
surface that is arcuate may benefit from adjusting the radial
position of the transfer surface during transfer from the first
moving carrier member 104 or the head 105 or to the second moving
carrier member 106 or the head 105'. Likewise, a transfer surface
that has any non-flat surface can be adjusted radially to improve
the transfer from the first moving carrier member 104 or the head
105 to the second moving carrier member 106 or the head 105'. A
person of ordinary skill in the art will recognize that the
variable radius techniques described herein may be used with
related art transfer assemblies as well as the transfer assemblies
disclosed herein. As such, those concepts are encompassed by the
present disclosure.
[0101] Referring to FIGS. 13-18, a rotation assembly 170 for one or
more of, or all of, the transfer members 112 of the transfer
assemblies 100 discussed herein may be provided. Portions of the
transfer assembly 100, some transfer members, and other components
are eliminated in FIGS. 13-18 for clarity in illustrating the
rotation assembly 170. The rotation assembly 170 can be viewed on
the transfer assembly 100 in FIGS. 7 and 8. The rotation assembly
170 may be simpler and less costly to manufacture than a barrel
cam-type rotation assembly, may have extended follower member life,
and may reduce the pressure angle of the track 134. As discussed
above, the transfer assembly 100 may comprise a frame 130 defining
a first rotation axis 132, wherein the one or more transfer members
112 may rotate about the first rotation axis 132 (see e.g., FIGS.
3, 4, and 6-8). The rotation assembly 170 may rotate portions of
the transfer member 112 about the second rotation axis 164 between
the first position 116 and at least a second position 118. The
first rotation axis 132 may be perpendicular, or substantially
perpendicular (e.g., 0.5 to fifteen degrees), or transverse to the
second rotation axis 164. In other instances, the first rotation
axis 132 may extend in a first direction and the second rotation
164 axis may extend in a second, different direction. The first
rotation axis 132 may or may not intersect the second rotation axis
164.
[0102] Referring to FIGS. 13-20, the rotation assembly 170 may
comprise a torque transmitting assembly 174 comprising an input
member (or input portion) 176 and an output member (or output
portion) 178. The torque transmitting assembly 174 may comprise a
90 degree gearbox or another type of gearbox. In other instances,
the torque transmitting assembly may not comprise a gearbox and
instead may be another mechanism for achieving torque transmission
between perpendicular, or substantially perpendicular, shafts, such
as worm gearing, bevel gearing, hypoid gearing, helical gearing,
belt drives, chain drives, hydraulic drives, and/or
three-dimensional space mechanisms, for example. The input member
176 and the output member 178 may be an input shaft and an output
shaft, respectively. The shafts may have any suitable length and/or
dimensions. The input member 176 may extend in a direction parallel
to or substantially parallel to the first rotation axis 132 and the
output member 178 may extend in a direction parallel to,
substantially parallel to, or coaxial to the second rotation axis
164.
[0103] Referring to FIGS. 19 and 20, the torque transmitting
assembly 174 may comprise two or more gears. FIG. 19 is a partially
cut away perspective view of the torque transmitting assembly 174,
among other components, and FIG. 20 is a partially cut away top
view of the torque transmitting assembly 174, among other
components. The gears may each comprise teeth (not illustrated)
meshingly engaged with each other. If two gears are provided, a
first gear 180 may be operably engaged with the second gear 182 and
may have a rotation axis 184 that is transverse, perpendicular, or
substantially perpendicular to rotation axis 186 of the second gear
182. The torque transmitting assembly 174 may be a speed increasing
assembly, such as a 1 to 1.5, 1 to 2, 1 to 2.5, or 1 to 3 gearbox,
for example. Those of skill in the art will recognize that other
speed increasing assemblies may also be used and that the speed may
be increased any suitable amount. One example of a speed increasing
assembly 174 is discussed in further detail below. In a form, the
torque transmitting assembly 174 may be a speed decreasing or equal
speed assembly, such as a 2 to 1, or a 1 to 1, gearbox, for
example. Those of skill in the art will recognize that other speed
decreasing assemblies may also be used and that the speed may be
decreased any suitable amount.
[0104] The rotation assembly 170 may also comprise a link or bar
188 comprising a first end 190 operably coupled or fixedly attached
to the input member 176 and a second end 192 comprising a follower
member 194. The input member 176 may be operably coupled to the
link 188 using a key 172 or other mechanical component or assembly
configured to cause the input member 176 to rotate when the link
188 is rotated about its first end 190. Stated another way, the
input member 176 may be non-rotatably attached to the link 188,
such that when the link 188 is rotated about its first end 190, the
input member 176 rotates in unison with the first end 190 of the
link 188. The link 188 may be rotated about its first end 190 when
the follower member 194 is moved radially relative to the first
rotation axis 132 by a track 198, as discussed in greater detail
herein. The follower member 194 may be a cam follower, which, in
one form, may comprise a roller rotatably attached to or engaged
with the second end 192 of the link 188. In various forms, the
follower member may not be a roller and may be attached to or
formed with the second end 192 of the link 188. The one or more of
the follower members 194 may comprise materials such as metals,
plastics, and/or polymers, for example, or coatings thereof, to
permit relative movement between the one or more follower members
194 and the track 198 194 (also referred to as a second track 198)
for the follower members. The follower members 142 and the track
134 may comprise similar features. This second track 198 may
surround the first rotation axis 132 and be surrounded by the first
track 134 described above. In any event, the "inner" track 198 may
be engaged with the follower member(s) 194 of the rotation assembly
170. The track 198 may comprise or be coated with the same, similar
materials, or different materials as the follower members 170, for
example.
[0105] Referring again to FIGS. 13-18, the rotation assembly 170
may comprise a shaft or a shaft assembly 200 comprising a first end
202 engaged with or operably coupled to the output member 178 of
the torque transmitting assembly 174 and a second end 204 engaged
with or operably coupled to a portion of the transfer member 112.
The first end 202 of the shaft 200 may be operably coupled to the
output member 178 using the key 172 so that when the output member
178 is rotated, the shaft 200 may be rotated at least partially
about the second rotation axis 164. Stated another way, the
rotation of the output member 178 may drive the rotation of the
shaft 200. A portion of, or all of, the shaft 200 may have a slot
or groove (not illustrated) defined therein in a direction
extending parallel to, or substantially parallel, to its
longitudinal axis. A key (not illustrated) may extend from a
portion of the transfer member 112 or from the output member 178 at
or proximate to the point of coupling to the shaft 200. The key may
allow the transfer member 112 to be moved radially inwardly and
outwardly relative to the first rotation axis 132 as portions of
the transfer member 112 rotate about the first rotation axis 132
about a path in correspondence with the first track 134, as
discussed above. The shaft 200 may extend into a portion of the
transfer member 112, such as the fluid manifold 256 and the housing
278, or the torque transmitting assembly 174 so that the distance
between a shaft receiving portion of the transfer member 112 and
the output member 178 (i.e., the length of the portion of the shaft
200 intermediate the shaft receiving portion of the transfer member
112 and the torque transmitting assembly 174) may be varied. The
key may also allow the shaft 200 to be turned about the second
rotation axis 164 by the output member 178. In essence, the
key/slot feature allows the shaft 200 to be rotated about the
second rotation axis 164 and to vary the distance of the portion of
the shaft 200 intermediate the shaft receiving portion of the
transfer member 112 and the torque transmitting assembly 174.
[0106] The shaft may comprise a shaft assembly 200 comprising a
spline 206 and a spline receiving member 208. The spline receiving
member 208 may be positioned on or engaged with a portion of the
transfer member 112 or the output member 178 at or proximate to the
point of engagement with an end portion of the spline 206. If the
spline receiving member 208 is positioned on the output member 178,
the output member 178 may be hollow such that the spline may extend
therethrough. The spline 206 may be slidably engaged with the
spline receiving member 208 such that the distance between the most
proximal portion of the transfer member 112 and the output member
178 may be varied as the transfer member 112 is moved radially
relative to the first rotation axis 132. The end of the spline 206
not engaged with the spline receiving member 208 may be engaged
with or operably coupled to the output member 178 or to a portion
of the transfer member 112. In such a form, as the transfer member
112 is moved radially outwardly or radially inwardly as it
circumnavigates about the path of the first track 134, the length
of the portion of the spline 206 intermediate the transfer member
112 and the output shaft 178 may be varied. The spline 206 and the
spline receiving member 208 may allow the output member 178 to
rotate the spline 206 about the second rotation axis 164 while the
transfer member 112 is moved radially relative to the first
rotation axis 132. Those of skill in the art will recognize that
other shaft assemblies that allow adjustment of the length of the
portion of the shaft between the transfer member 112 and the output
member 178 are within the scope of the present disclosure.
[0107] Although not illustrated, a shaft assembly may comprise a
shaft portion and a shaft receiving portion. The shaft may be
slidably engaged with the shaft receiving portion in a telescoping
fashion (not illustrated) to allow axial expansion and contraction
of the shaft assembly relative to the first rotation axis. The
shaft may be non-rotatably engaged with the shaft receiving portion
such that the output member 178 may rotate the shaft and the shaft
receiving portion.
[0108] Referring to FIGS. 7, 8, 10, and 13-15, the rotation
assembly 170 may be engaged with the track or second track 198
positioned on or in the frame 130 and surrounding the first
rotation axis 132. The second track 198 may be surrounded by the
first track 134 such that the second track 198 may be an inner
track and the first track 134 may be an outer track relative to the
first rotation axis 132. The inner track and the outer track may be
referred to as a track, a first track, or a second track depending
on which of the tracks is recited first. Referring to FIG. 14, a
first point 210 at a first location on the second track 198 may be
first distance, D1, away from the first rotation axis 132 and a
second point 212 at a second location on the second track 198 may
be a second distance, D2, away from the first rotation axis 132.
The first distance, D1, may be different than the second distance,
D2. Other points on the second track 198 may be other distances
away from the first rotation axis 132. This distance variation of
various points on the second track 198 relative to the first
rotation axis 132 may allow the shaft or shaft assembly 200 to
rotate about the second rotation axis 164, thereby moving a portion
of the transfer member 112 between the first position 116 and at
least the second position 118.
[0109] The second track 198 may be a cam track or a radial cam, for
example. In an instance, although not the illustrated form, but
similar to the first cam track 134, the second track 198 may extend
outwardly from a front plane of the frame 130 and form a projection
that surrounds the first rotation axis 132. In such a form, the
second track 198 may be formed with the frame 130 or may be
attached to the frame 130. The projection may comprise a first side
surface, a second side surface, and a top surface. The first side
surface may be positioned parallel to, or substantially parallel to
(e.g., 0.5 to 15 degrees), the second side surface. The top surface
of the projection may extend in a direction parallel to, or
substantially parallel to, the plane of the frame 103 and in a
direction perpendicular to, or substantially perpendicular to, the
first and second side surfaces. The distance between the first side
surface and the second side surface may be constant, substantially
constant, or variable about the projection. Two follower members
may be engaged with, attached to, or formed with the second end 192
of the link 188 and may each be movably engaged with one of the
side surfaces of the projection. Two links, each comprising a
follower member on their second end, may be provided if two
follower members are provided, as will be recognized by those of
skill in the art. The follower members may be biased toward the
side surfaces of the projection.
[0110] Referring to FIGS. 13-15, the second track 198 may be a cam
track or groove defined in a front plane of the frame 130 and
surrounding the first rotation axis 132. The cam track or groove
may optionally be surrounded by a projection 214 positioned more
radially outward from the first rotation axis 132 than the groove.
The projection 214 may have a constant width or may have a variable
width throughout its circumference. By providing the projection
214, the groove may be partially, or fully, defined in a front
plane of the frame 130. The groove may also be formed intermediate
the projection 214 and another projection 215 extending from the
front plane of the frame 130. If the projection 214 is not
provided, the groove may be fully defined in a front plane of the
frame 130. In various forms, one or more of the follower members
194 may be at least partially positioned with the cam track or
groove 198 and may engage side walls of the second cam track or
groove 198 as the transfer member 112 rotates about the first
rotation axis 132. Any of the follower members 194, regardless of
whether the second track 198 is a projection or a groove, may be
moveably engaged with the second track 198 and may circumnavigate
about the first rotation axis 132 about a path in correspondence
with the second track 198.
[0111] Referring to FIGS. 13-15, the groove of the second track 198
may have a first surface 216 and a second surface 218 on a portion
of the groove most proximal to the rotation axis 132. The
projection 214 may also have a first surface 220 and a second
surface 222 on a portion of the projection most proximal to the
rotation axis 132. The first surface 216 and the second surface 218
may extend different distances from the first rotation axis 132.
Likewise, the first and second surfaces 220 and 222 may be
positioned at different distances from the first rotation axis 132.
A distance between the first surface 216 and the first surface 220
may be the same, or substantially the same, and, likewise, a
distance between the second surface 218 and the second surface 222
may be the same, or substantially the same. Stated another way, the
first surface 216 may be offset from the second surface 218 and the
first surface 220 may be offset from the second surface 222. In
such a form, the second end 198 of the link 188 may comprise a
first follower member 194 and a second follower member 194. The
follower members 194 may be rotatably engaged with the second end
198 of the link 188 using a pin, bolt, or other attachment
mechanism or component. The follower members 194 may be positioned
adjacent to each other and may each rotate about the pin or bolt,
for example. The first follower member 194 may be engaged with the
first surface 216 and the second follower member 194 may be engaged
with the second surface 222. Surfaces 218 and 220 may not be
engaged by the follower members 194 due to the offset of the
surfaces 218 and 220 relative to the surfaces 216 and 222. By
providing essentially two cam tracks in the groove and two follower
members 194, each follower member may only turn in one direction.
In other forms, the second track 198 may only have one surface on
each side of the groove and only one follower member 194 may ride
within the track 198.
[0112] Referring to FIGS. 7, 8, 10, and 13-20, when the one or more
follower members 194 are moved radially relative to the first
rotation axis 132 as they circumnavigate about the path in
correspondence with the second track 198, the link 188 may be
rotated in a clockwise or counterclockwise direction about its
first end 190 thereby imparting a rotational force or torque to the
input member 176. The torque transmitting assembly 174 may then
impart the rotational force to the output member 178 and, thereby
the shaft or the shaft assembly 200 owing to the gearing
arrangement within the torque transmitting assembly 174. In a form,
the input member 176 may be rotated with the first end 190 of the
link 188 a first rotational distance and may impart a second
rotational distance to the output member 178 and, thereby the shaft
or shaft assembly 200, owing to the gearing arrangement within the
torque transmitting assembly 174. The second rotational distance
may be greater than the first rotational distance. The rotation of
the shaft or the shaft of the shaft assembly 200 may cause the
transfer member 112 to move between the first position 116 and the
second position 118 about the second rotation axis 164. At least a
portion of this rotation between the first position 116 and the
second position 118 may occur when the first track 134 has radially
expanded the distance between the transfer member 112 and the
output member 178 or when the transfer member 112 has been moved
radially outwardly by the first track 134 relative to the first
rotation axis 132. The second rotation axis 164 may be an axis
formed about a longitudinal axis of the shaft or the shaft of the
shaft assembly 200. In one revolution of the transfer member 112
about the first rotation axis 132, the shaft or the shaft of the
shaft assembly 200 may be rotated from the first position 116 into
the second position 118 and back into the first position 116. The
transfer surfaces 136 may be rotated between about 45 degrees to
about 180 degrees, about 60 degrees to about 150 degrees, about 75
degrees to about 105 degrees, about 90 degrees (e.g., plus or minus
3 degrees), or 90 degrees, specifically reciting all 0.5 degree
increments within the above-specified ranges and all ranges formed
therein or thereby, when the transfer member 112 is moved between
the first position 116 and the second position 118.
[0113] The second track 198 may vary the angle of the transfer
member 112 rotating about the second rotation axis 164 due to the
changing radius of the follower member 194. The second track 198
may also have dwell regions therein where the radius of the
follower members 194 and the rotation angle of the transfer members
112 remain constant, or substantially constant. These dwell regions
may be useful when the transfer member is in the first position 116
and in the second position 118 during the transfer of the discrete
articles 102 from the first moving carrier member 104 or the head
105 to the second moving carrier member 106 or the head 105'.
[0114] Although the rotation assembly 170 is illustrated in use
with the transfer assembly 100 as an example, the rotation assembly
170 may be applied to other transfer assemblies known to or
developed by those of skill in the art and may function
independently of the transfer assembly 100. Other transfer
assemblies than the rotation assembly 170 of the present disclosure
may be used with may not have transfer members that move radially
relative to the first rotation axis 132. In one example, the
rotation assembly 170 may be used with transfer members that have a
varying angular position about the first rotation axis 132, for
example.
[0115] The transfer members 112 may be cammed or moved radially
outwardly to provide clearance for rotation of the transfer members
112 about the second rotation axis 164 with adjacent transfer
members 112. In other instances, the spacing or shape of the
transfer members 112 may not require increasing their radial
position for rotation about the second rotation axis 164. In
another form, the radius of the transfer members 112 may decrease
to provide clearance for transfer member rotation about the second
rotation axis 164. In another instance, the transfer members 112,
or portions thereof, may tilt relative to first rotation axis 132
to allow clearance with adjacent transfer members 112 during
rotation about the second rotation axis 164.
[0116] A method of transferring one or more discrete articles from
a first moving carrier member or head of an apparatus to a second
moving carrier member or head of an apparatus using a transfer
assembly is provided. The transfer assembly may comprise a frame
defining a first rotation axis and one or more transfer members
each comprising a transfer surface configured to receive one or
more of the discrete articles. The method may comprise rotating the
one or more transfer members about the first rotation axis and
selectively varying the radial distance of the one or more transfer
surfaces relative to the first rotation axis as the one or more
transfer member rotate about the first rotation axis. The method
may also comprise rotating the one or more transfer surfaces, and
other portions of the transfer members, about a second rotation
axis between a first position and at least a second position using
a track that surrounds the first rotation axis, one or more
follower members circumnavigating about a path in correspondence
with the track while the transfer member rotates about the first
rotation axis, a torque transmitting assembly, a link comprising a
first end operably coupled to a first portion of the torque
transmitting assembly and a second end comprising the one or more
follower members, and a shaft assembly operably engaged with a
second portion of the torque transmitting assembly on a first end
and engaged with a portion of the transfer member on a second end.
The first portion or input portion of the torque transmitting
assembly may be positioned parallel to, or substantially parallel
to, the first rotation axis and the second portion or output shaft
of the torque transmitting assembly may be positioned parallel to,
or substantially parallel to, the second rotation axis. The method
may comprise expanding and contracting the length of the shaft
assembly between each transfer member and each output portion
during the selectively varying of the radial distance of the one or
more transfer surfaces relative to the first rotation axis. The
method may also comprise rotating the one or more transfer surfaces
at least partially between the first and second positions when the
length of the shaft assemblies between the transfer members and the
output portions are expanded and turning the discrete article
through the rotation of the transfer surfaces between the first
position and the second position. The transfer surfaces, and other
portions of the transfer members, may be rotated from the first
position into the second position in a first direction of rotation
and may be rotated from the second position into the first position
in a second direction of rotation. The first direction of rotation
may be opposite to the second direction of rotation. In other
instances, the first direction of rotation may be the same as the
second direction of rotation. One or more of the discrete articles
may be retained to or pushed from the transfer surfaces using a
fluid pressure, such as a negative or a positive fluid pressure,
for example.
[0117] The various discrete articles 102 (e.g., a chassis of an
absorbent article) or flexible discrete articles 102 may be
retained to the various transfer surfaces 136 of the transfer
members 112 or the surfaces of the heads 105 and 105' of the
present disclosure in many ways, including but not limited to,
fluid pressure, mechanical attachment via pins or grippers,
adhesives, such as pressure sensitive or low tack adhesives, static
attraction, and/or magnetic attraction, for example. Fluid
pressures and/or other forces may also be used to force or move the
discrete articles 102 from the transfer surfaces 136 or surfaces of
the heads 105 and 105' onto a moving carrier member, such as the
second moving carrier member 106.
[0118] Referring to FIGS. 1, 4-6, 8, 9, 16, and 18, for example,
the transfer assembly 100 may comprise a fluid system configured to
retain the discrete articles 102 to one or more of the transfer
surfaces 136 of the transfer members 112. Each of or one of the
transfer members 112 may have one or more fluid ports 230 defined
through the transfer surface 136 thereof, or through portions or
zones of the transfer surface 136. The fluid ports 230 may have any
suitable shape, such as elongate slots, circular or ovate openings,
and/or rectangular, square, or triangular openings, for example.
The fluid ports 230 may also have mesh, screen, or other porous
materials extending thereover. The fluid ports 230 may be linear or
non-linear, continuous or non-continuous. In a form, a first
transfer member may have a transfer surface having a first pattern
of fluid ports and a second transfer member may have a transfer
surface having a second pattern of fluid ports. In other instances,
the patterns on all of the transfer surfaces 136 may be the same. A
positive or a negative (vacuum) fluid pressure may be applied to
the fluid ports 230 through various fluid conduits and fluid lines.
Some fluid ports, at various times, may not have any fluid pressure
being applied thereto. The fluid pressures may initiate in one or
more fluid movement devices or sources 232, 234, such as one or
more fluid pumps, vacuum pumps, pressure blowers, or fans. The
fluid may be air or other gas, for example. Some fluid ports 230
may be configured to provide a positive pressure, while at the same
time, other fluid ports 230 of the same transfer member 112 may be
configured to provide a negative pressure or no fluid pressure. In
various instances, some of the fluid ports 230 may be configured to
provide a first fluid pressure (positive or negative), while at the
same time, other fluid ports 230 of the same transfer member 112
may be configured to provide a second fluid pressure (positive or
negative). The first fluid pressure may be greater than or less
than the second fluid pressure. In other instances, the fluid ports
230 in one transfer member 112 may have a different fluid pressure
as the fluid ports 230 in another transfer member 112 on the same
transfer assembly 100 owing to factors like the number of the fluid
ports 230 or the areas of the fluid ports 230 on a particular
transfer surface 136. For example, one fluid pressure may be
applied at a pick-up location and another fluid pressure may be
applied at a drop-off location. In other instances, the fluid
pressure applied to the fluid ports 230 may vary in different fluid
ports 230 or zones of the fluid ports 230 in a transfer member 112
at the pick-up location and at the drop-off location.
[0119] Referring to FIGS. 1 and 4-9, the fluid system used to
provide the fluid pressure to the fluid ports 230 may comprise the
first fluid movement device 232 and the second fluid movement
device 234. The first and second fluid movement devices 232 and 234
may supply a positive fluid pressure and/or a negative fluid
pressure to first and second fluid lines 236 and 238. The first and
second fluid movement devices 232 and 234 may be controlled
independently or controlled together for various applications. In
an instance, only one fluid movement device may be provided. That
single fluid movement device may be configured to supply the first
and second fluid lines 236 and 238 with positive and/or negative
fluid pressures. The fluid pressure and flow rates applied to the
first and second fluid lines 236 and 238 may be equal or different.
In an instance, the single fluid movement device may supply a
positive pressure to the first fluid line 236 and a negative
pressure to the second fluid line 238, for example.
[0120] Referring now to FIGS. 1 and 4-6, the apparatuses 101 and
101' will be discussed in greater detail. As stated herein, in
certain instances, only one apparatus may be provided on either the
input side or output side of the transfer assembly 100. If the
apparatus 101 is provided only on the input side of the transfer
assembly 100, the discrete articles 102 may be transferred from the
first moving carrier 104 to a head 105 of the apparatus 100, then
from the head 105 of the apparatus 101 to the transfer member 112,
and then from the transfer member 112 directly to the second moving
carrier member 106. If the apparatus 101' is provided only on the
output side of the transfer assembly 100, the discrete articles 102
may be transferred directly from the first moving carrier member
104 to the transfer member 112, then from the transfer member 112
to the head 105' of the apparatus 101', and then from the head 105'
to the second moving carrier member 106. In certain operations,
more than one apparatus may also be provided on either the input
side or the output side of the transfer assembly, or both. In other
certain instances, the first and/or second moving carrier members
104 and 106 may be eliminated and only the apparatus 101 and/or
101' may be used.
[0121] Each of the apparatuses 101 and 101' may comprise one or
more heads 105 and 105', respectively. Each apparatus 101 and 101'
may have a rotation axis 107 and 107', respectively. The heads 105
and 105' may be rotated about the rotation axis 107 and 107',
respectively, at a variable angular velocity or at a plurality of
angular velocities. For example, each of the heads 105 and 105' may
be rotated about a first, second, third, fourth or more angular
velocities within one revolution of the head about the rotation
axis 107 and 107', respectively.
[0122] Referring to FIGS. 21 and 22, an example apparatus
comprising a single head is illustrated. The apparatus 101 may
comprise a motor 161 for transmitting rotational energy to a
transfer device 171. The motor 161 may be operably linked or
operably engaged with the transfer device 171 using any technique
known to those skilled in the art such as, for example, a gear to
gear connection, transmission belting and pulleys, gearboxes,
direct couplings, and the like or any combinations thereof. For
example, in FIG. 21 the transfer device 171 may comprise a driven
gear 173 that is connected to a driving gear 163, which transmits
rotational energy to the driven gear 173. In use, the driving gear
163 may engage and rotate the driven gear 173 which, in turn, may
rotate a head 105 of the apparatus 101 about rotation axis 107. The
apparatus 101' and the head 105' may be generally the same as, or
very similar to, that described for the apparatus 101 and the head
105. In other instances, the apparatus 101' and/or the head 105'
may be different in size, speed, and/or configuration, for
example.
[0123] In some instances, the transfer device 171 may be formed
with a portion of the head 105. The head 105 may comprise a surface
153 configured to receive a discrete article 102. The head 105 may
be connected to the transfer device 171 by any technique known to
those skilled in the art such as, for example, bolts, screws, pins,
keys and matching key ways, connector parts such as shafting or
brackets, adhesive bonding or gluing, welding and the like or
combinations thereof. For instance, the head 105 shown in FIG. 21
may be connected directly to the driven gear 173 by fitting the end
of the head 105 into a mating hole in the driven gear 173 and
locking it into position with a pin. In other instances, the head
105 may be formed with the transfer device 171.
[0124] The dimensions of the head 105 may vary depending upon the
desired output of the apparatus 101 and the size and shape of the
discrete articles 102 being transferred. The head 105 may comprise
a crescent-shaped member having an outer, peripheral arc length
spanning from about 5 degrees to about 355 degrees, an outer radius
ranging from about 10 mm to about 1,000 mm or about 25 mm to about
500 mm, and a width ranging from about 25 mm to about 1,000 mm or
about 50 mm to about 750 mm, specifically reciting all 0.1
increments within the above-specified ranges and all ranges formed
therein or thereby. Other suitable dimensions are also within the
scope of the present disclosure. As the transfer device 171
rotates, the head 105 may travel in the direction indicated by
arrow 93 as shown in FIG. 22. The head 105 may pass through a
pick-up zone and a drop-off zone as it rotates about the rotation
axis 107. In the pick-up zone, the head 105 may receive a discrete
article 102 from the first moving carrier member 104 (if present)
(on the input side of the transfer apparatus 100) and the head 105'
may receive the discrete article 102 from the transfer member 112
(on the output side of the transfer apparatus 100). In the drop-off
zone, the head 105 may provide a discrete article 102 to a transfer
member 112 (on the input side of the transfer apparatus 100) and
the head 105' may provide the discrete article 102 to the second
moving carrier member (if present) (on the output side of the
transfer apparatus 100).
[0125] The motor 161 may be configured to move the head 105 at a
plurality of angular velocities throughout one full revolution of
the head about the rotation axis 107.
[0126] One illustrated example of the motor 161 comprises, or is
operably linked to, a rotatable circular driving gear 163 operably
connected to an input shaft 165. In this example, the input shaft
165 is the output shaft of the motor 161. The transfer device 171
may be placed parallel to the motor 161 such that the driving gear
163 meshes with the driven gear 173 using gear set-ups known to
those skilled in the art. In use, the motor 161 may rotate the
input shaft 165, which rotates the driving gear 163, which, in
turn, rotates the driven gear 173 and, thereby, rotates the head
105 about the rotation axis 107. A similar method of operation
would apply to the apparatus 101' and the head 105'.
[0127] In other forms, the transfer device 171 may comprise any
mechanism or mechanisms known to those skilled in the art by which
rotational energy may be conducted from one shaft to another such
as, for example, v-belts, timing belts, continuous chains and the
like or combinations thereof. Further, the transfer device 171 may
comprise any mechanism or mechanisms known to those skilled in the
art by which input velocity can be variably modified to an output
source such as, for example, cams, linkages, and the like or
combinations thereof as long as the changes in rotational speed are
substantially created by the motor 161. It will be further
appreciated that the apparatuses 101 and 101' of the present
disclosure may utilize one or, in the alternative, two, three, four
or more combinations of heads 105 or 105'.
[0128] The heads 105 and 105' may comprise one or more gripping
mechanism so that the surface of the heads 105 and 105' may engage
a discrete article 102. The gripping mechanism(s) may comprise a
fluid pressure (e.g., vacuum) that may be selectively imposed
through fluid ports the head 105 leading to the surface 153 of the
head 105. For instance, the fluid pressure may be activated when
picking up a discrete article 102 and deactivated when releasing
the discrete article 102. In other instances, a negative fluid
pressure (i.e., vacuum) may be activated when picking up the
discrete article 102 in a pick-up zone and a positive fluid
pressure may be activated to "blow off" the discrete article 102 in
a drop-off zone. In this manner, control may be maintained over the
discrete articles 102 at all times during the transfer process.
Alternatively, the gripping mechanism(s) may comprise any technique
known to those skilled in the art for gripping and releasing
discrete articles 102 such as, mechanical clamps, adhesives,
electrostatic charges, electrical clamps, magnetic clamps, and the
like or combinations thereof.
[0129] The motor 161 may comprise a programmable motor, such as a
programmable rotary motor or a programmable linear motor. The use
of a programmable motor may provide an inexpensive and adaptable
method for receiving the discrete articles 102 at a first
tangential and angular velocity and applying the articles at a
second, different tangential and angular velocity. The variable
angular velocity of the head 105 throughout one revolution of the
head 105 about the rotation axis 107 may be produced by varying the
current supplied to the motor 161. Since the transfer device 171 is
operably coupled to the output of the motor 161, changes in the
angular velocity and position of the motor 161 may directly
correlate to changes in the angular velocity and position of the
head 105. The current supplied to the motor 161 may be controlled
using any of a variety of methods for programming motors known to
those skilled in the art such as, standard cam curve functions, a
reference data table containing reference points, desired motor
encoder points, and the like or combinations thereof.
[0130] The programmable motors used to drive the heads 105 and 105'
may provide variable angular velocities to the heads 105 and 105',
including periods where the angular velocity remains constant for a
fixed duration. These constant angular velocity dwell times may be
advantageous when picking up and transferring a discrete article,
particularly when the pick-up and transfer occurs over substantial
arc lengths of contact. Alternatively, one or more of the constant
speed regions may be changed to a controlled variable speed region.
This may enable the discrete article 102 to be picked up at a
variable speed, which, when the discrete article 102 is elastic,
would allow tensions to be varied incrementally therein which may
be desirous in certain product features. In another example, the
constant speed of the motor 161 in a drop-off zone may be such that
the corresponding speed of the head 105 is different from, such as
less than, the speed of the second moving carrier member 106 at
transfer. Such speed variations may generate tension in the
discrete article 102 by incrementally transferring the discrete
article 102 in a controlled manner from the head 105' traveling at
a first tangential speed to the second moving carrier member 106
moving at a second tangential speed or linear speed when the second
moving carrier member is a linear conveyor.
[0131] It will be further appreciated that the tangential and
angular velocities of the head 105 outside of the pick-up and
drop-off zones may be tailored to aid the performance of secondary
processes including adhesive application, printing of
identification or registration marks, application of bonding aids,
moisture addition, and the like and combinations thereof. Such
changes in the tangential and angular velocities may be beneficial
by presenting specific velocity profiles or even additional periods
of constant velocity, which may allow for more precise interaction
with the secondary processes being performed.
[0132] Programmable motors may be purchased from any number of
suppliers of programmable motors such as Rockwell Automation,
located in Milwaukee, Wis. Further, the program inputs to the
motors can be generated by one of ordinary skill in the art if
provided with the analytical representation of the desired output
function. For instance, the creation of the electronic cam profile
for the motor may be developed by first determining the key input
variables. Some key input variables are based on desired product
features, the base design of the apparatus 101 and the desired
cycle speed of the apparatus 101. Secondly, the radius of the outer
surface of the head 105 is determined. Once the radius is
determined, the required cam inputs of rotational velocities,
distances traveled and time available for acceleration may be
calculated, which serve as the input to the cam profile generator.
Additional details regarding these calculations are disclosed, for
example, in U.S. Pat. No. 6,450,321 to Blumenthal et al.
[0133] Referring to FIGS. 23 and 24, another example form of an
apparatus 101 of the present disclosure is illustrated. The
apparatus 101 may comprise one or more heads 105 engaged with or
formed with a base 173, and a motor or programmable motor 161. The
base 173 may be directly engaged with a drive shaft 158 of the
motor or programmable motor 161. This is known as direct drive. The
base 173 and the drive shaft 158 may together be known as the
transfer device 171. The base 173 is directly driven by the drive
shaft 158 of the programmable motor 161. Stated another way, when
the drive shaft 158 is rotated, the base 173 is rotated about an
axis of rotation 107. The heads 105, owing their engagement with
the base 173, are then are orbited about the axis of rotation 107.
In some instances, another apparatus, similar to the apparatus 101
may be provided opposite to apparatus 101, such that they can work
on unison. In such an instance, the rotation axes of each apparatus
may be positioned coaxially with the heads extending between the
motors of the apparatuses.
[0134] FIG. 25 illustrates a portion of the apparatus 101
comprising a base 173 and two heads 105 extending from the base.
The rotation axis of the heads 105 is indicated as 107. The heads
105 may each have fluid ports 109 defined therein, such that one or
more fluid pressures may be provided at the surface 153 of the
heads 105.
[0135] Referring to FIGS. 26 and 27, the heads 105 may each define
one or more fluid cavities 111 therein. The surface 153 may define
one or more fluid ports 109 therein. The one or more fluid ports
109 may be in at least partial fluid communication with the one or
more fluid cavities 111 so that fluid pressure (positive and/or
negative) may be applied to discrete articles 102 positioned on the
surface 153 of the heads 105 in locations where the discrete
articles 102 overlap the one or more fluid ports 109. The one or
more fluid cavities 111 may be in fluid communication with one or
more fluid pumps (see e.g., fluid pump 115 in FIG. 21) configured
to provide a positive and/or negative fluid pressure to the fluid
cavities 111. In a form, one fluid pump may be configured to
provide a positive fluid pressure and another fluid pump may be
configured to provide a negative fluid pressure. One or more of the
fluid pumps may be in fluid communication with a manifold on the
apparatus which is in fluid communication with at least some of the
fluid cavities 111. In such an instance, positive and/or negative
fluid pressure may be provided by the manifold to the at least some
fluid cavities 111 as desired and as will be recognized by those of
skill in the art.
[0136] Referring to FIG. 27, an example cross-sectional view of the
head 105 taken about line 27-27 of FIG. 7 is illustrated. A fluid
cavity 111 is formed within the head 105 and is in fluid
communication with the fluid ports 109 (see FIG. 25). An optional
support material 113 may be positioned within the head 105 and at
least partially surround the fluid cavity 111. The support material
113 may comprise a low density material, a low density foam, a
plastic material, a non-foam material, or a foam material, for
example. The support material may have channels in it so that the
fluid cavity 111 may be in fluid communication with the fluid ports
109. The support material, in some instances, may also merely be
portions of the head and made of the same materials as the
head.
[0137] Each programmable motor may be in electrical communication
with a motor control system. The motor control system may comprise
an amplifier and/or a controller. Example motor control systems 270
are illustrated in FIGS. 21-24. The motor control system 270 may
regulate, control, and/or vary the speed at which the programmable
motor runs throughout an orbit, or partial orbit, of the head 105
causing the head 105 to increase or decrease in speed based on
where it is in its rotation.
[0138] A portion of the apparatus 101 (or 101') comprising the head
105 (or 105) is illustrated in FIGS. 28A-28C. The head 105 of the
apparatus 101 is shown in different positions of rotation about the
rotation axis 107 and engaged with a discrete article 102. During
one revolution of the head 105 about the rotation axis 107, the
head 105 may have a first angular velocity, AV1 (FIG. 28A), a
second angular velocity, AV2 (FIG. 28B), and a third angular
velocity, AV3 (FIG. 28C). The first, second, and third angular
velocities may all be different. Alternatively, at least one of the
first, second, and third angular velocities may be different than
the other two. In other instances, the head 105 may have more than
three different angular velocities within one revolution about the
rotation axis 107. By rotating the head 105 at a plurality of
angular velocities within one revolution about the rotation axis
107, the head 105 may be able to pick up the discrete article 102
while moving at the first angular velocity, AV1, accelerate or
decelerate to the second angular velocity, AV2, and then drop off
the discrete article 102 at the third angular velocity, AV3. The
first and third angular velocities may be same or different. In an
instance, the first and third angular velocities may be constant,
or substantially constant, throughout a pick-up zone or a drop-off
zone, while the second angular velocity, AV2, may be variable. The
second angular velocity, AV2, may be used when the head 105 is
outside of a pick-up zone or a drop-off zone for the discrete
article 102.
[0139] Again referring to FIGS. 28A-28C, a surface of the head 105
(or 105) may have a plurality of tangential velocities within one
revolution of the head 105 about the rotation axis 107. The
tangential velocities may be TV1 (FIG. 28A), TV2 (FIG. 28B), and
TV3 (FIG. 28C). All of the tangential velocities may be the same or
different. In an instance, at least one of the tangential
velocities may be different than the other two tangential
velocities. By rotating the surface of the head 105 at a plurality
of tangential velocities within one revolution about the rotation
axis 107, the surface of the head 105 may be able to pick up the
discrete article 102 while moving at the first tangential velocity,
TV1, accelerate or decelerate to the second tangential velocity,
TV2, and then drop off the discrete article 102 at the third
angular velocity, TV3. The first and third tangential velocities
may be same or different. In an instance, the first and third
tangential velocities may be constant or substantially constant
throughout a pick-up zone or a drop-off zone, while the second
tangential velocity may be variable. The second tangential
velocity, TV2, may be used when the head 105 is outside of a
pick-up zone or a drop-off zone for the discrete article 102.
[0140] FIGS. 29A-29C schematically illustrate the transfer of a
discrete article 102 progressing through a drop-off zone between a
transfer member 112 of the transfer assembly 100 and a head 105' of
the apparatus 101', as an example, although a similar concept would
apply at a discrete article pick-up zone when the head 101 is
transferring the discrete article 102 to the transfer member 112.
The transfer member 112 is rotating about the rotation axis 132 of
the transfer assembly 100 and the head 105' is rotating about the
rotation axis 107'. In FIGS. 29A-29C, the transfer member 112 may
have a constant, or substantially constant, angular velocity, AV1,
at the point or zone of discrete article transfer. The head 105'
may have an angular velocity, AV2, that may be constant, or
substantially constant, at the point or zone of discrete article
transfer. The angular velocity, AV1, may be equal to, or
substantially equal to, the angular velocity, AV2 at the point or
zone of discrete article transfer. In other instances, the angular
velocity, AV1, may be less than, greater than, or different than
the angular velocity, AV2, at the point or zone of discrete article
transfer. FIG. 29A illustrates the beginning of an example discrete
article transfer. FIG. 29B illustrates a middle portion of the
example discrete article transfer. FIG. 29C illustrates the end of
the example discrete article transfer. It is to be noted that the
constant, or substantially constant, minimum gap or distance may be
provided intermediate the surface 136 of the transfer member 112
and a surface of the head 105' to ensure smooth and reliable
transfer without fold-over of portions of the discrete article 102.
The constant, or substantially constant, minimum gap or distance is
described in further detail above.
[0141] FIGS. 30A-30C schematically illustrate the transfer of a
discrete article 102 progressing through a drop-off zone between
the transfer member 112 of the transfer assembly 100 and a head
105' of the apparatus 101', as an example, although a similar
concept would apply at a discrete article pick-up zone when the
head 105 transfers the discrete article 102 to the transfer member
112. The transfer member 112 is rotating about the rotation axis
132 of the transfer assembly 100 and the head 105' is rotating
about the rotation axis 107'. In FIGS. 30A-30C, the transfer
surface 136 of the transfer member 112 may have a constant, or
substantially constant, tangential velocity, TV1, at the point or
zone of discrete article transfer. The head 105' may have a
tangential velocity, TV2, that may be constant, or substantially
constant, at the point or zone of discrete article transfer. The
tangential velocity, TV1, may be equal to, or substantially equal
to, the tangential velocity, TV2, at the point or zone of discrete
article transfer. In other instances, the tangential velocity, TV1,
may be less than, greater than, or different than the tangential
velocity, TV2, at the point or zone of discrete article transfer.
FIG. 30A illustrates the beginning of an example discrete article
transfer. FIG. 30B illustrates a middle portion of the example
discrete article transfer. FIG. 30C illustrates the end of the
example discrete article transfer. It is to be noted that the
constant, or substantially constant, minimum gap or distance may be
provided intermediate the surface 136 of the transfer member 112
and a surface of the head 105' to ensure smooth and reliable
transfer without fold-over of portions of the discrete article 102.
The constant, or substantially constant, minimum gap or distance is
described in greater detail above.
[0142] FIGS. 31A-31C schematically illustrate the transfer of a
discrete article 102 progressing through a drop-off zone between
the transfer member 112 of the transfer assembly 100 and a head
105' of the apparatus 101', as an example, although a similar
concept would apply at a discrete article pick-up zone when the
head 105 transfers the discrete article 102 to the transfer member
112. The transfer member 112 is rotating about the rotation axis
132 of the transfer assembly 100 and the head 105' is rotating
about the rotation axis 107'. In FIGS. 31A-31C, the transfer
surface 136 of the transfer member 112 may have a constant, or
substantially constant, tangential velocity, TV1, at the point or
zone of discrete article transfer. The surface of the head 105' may
have a tangential velocity, TV2, that may be constant, or
substantially constant, at the point or zone of discrete article
transfer. Alternatively, the tangential velocity, TV2, of the
surface of the head 105' may be variable at the point or zone of
discrete article transfer. The tangential velocity, TV1, may be
less than, the tangential velocity, TV2, at the point or zone of
discrete article transfer to tension the discrete article being
transferred. The tangential velocity, TV2, of the surface of the
head 105' may be at least about 2% to about 35%, at least about 2%
to about 30%, at least about 5% to about 25%, at least about 3% to
about 25%, at least about 3%, at least about 5%, at least about
10%, or at least about 15%, specifically reciting all 0.1%
increments within the specified ranges and all ranges formed
therein or thereby, greater than the tangential velocity, TV1, of
the transfer surface 136 at the point or zone of discrete article
transfer to tension the discrete article 102 being transferred.
Tensioning of the discrete articles being transferred may allow for
multiple product sizes to be run using the same transfer assembly
100. The tensioning essentially may create a situation of
controlled slippage of the discrete articles from one component to
another component where a shorter discrete article can be
transferred to a larger head. Further, the tensioning may at least
partially remove wrinkles in the discrete articles being
transferred. Also, the tensioning may at least partially improve
control of the discrete articles during transfer, as the tensioning
may at least partially limit the discrete articles from being
disturbed by moving air or other factors that negatively impact the
transfer.
[0143] FIG. 31A illustrates the beginning of an example discrete
article transfer, including tensioning of the discrete article 102.
FIG. 31B illustrates a middle portion of the example discrete
article transfer, including tensioning of the discrete article 102.
FIG. 31C illustrates the end of the example discrete article
transfer, including tensioning of the discrete article 102. It is
to be noted that the constant, or substantially constant, minimum
gap or distance may be provided intermediate the surface 136 of the
transfer member 112 and a surface of the head 105' to ensure smooth
and reliable transfer without fold-over of portions of the discrete
article 102. The constant, or substantially constant, minimum gap
or distance is described in greater detail above.
[0144] FIGS. 32A-32C schematically illustrate transfer of a
discrete article 102 from the head 105' of the apparatus 101' to
the second moving carrier member 106 (or to webs moving over the
second moving carrier member). The head 105' rotates about the
rotation axis 107' of the apparatus 101', while the second moving
carrier member 106 rotates about rotation axis 117. A surface of
the head 105' has a first tangential velocity, TV1, at the point or
zone of discrete article transfer. The first tangential velocity,
TV1, may be constant, or substantially constant at the point or
zone of discrete article transfer. A surface of the moving carrier
member 106 may have a second tangential velocity, TV2, at the point
or zone of discrete article transfer. The second tangential
velocity, TV2, may be equal to, substantially equal to, greater
than, or less than, the first tangential velocity, TV1, at the
point or zone of discrete article transfer. If the second
tangential velocity, TV2, is greater than the first tangential
velocity, TV1, at the point or zone of discrete article transfer,
the discrete article 102 may be tensioned during the transfer. The
second tangential velocity, TV2, may be at least about 2% to about
35%, at least about 2% to about 30%, at least about 5% to about
25%, at least about 3% to about 25%, at least about 3%, at least
about 5%, at least about 10%, or at least about 15%, specifically
reciting all 0.1% increments within the specified ranges and all
ranges formed therein or thereby, greater than the first tangential
velocity, TV1, at the point or zone of discrete article transfer to
tension the discrete article 102 being transferred. On the input
side of the transfer assembly 100, a surface of the first moving
carrier member 104 may have a tangential velocity that is slower
than the tangential velocity of a surface of the head 105 to
tension the discrete article at the point or zone of discrete
article transfer.
[0145] FIGS. 33A-33C schematically illustrate transfer of a
discrete article 102 from the head 105' of the apparatus 101' to a
linear conveyor 106'. The head 105' rotates about the rotation axis
107' of the apparatus 101'. A surface of the head 105' has a first
tangential velocity, TV1 at the point or zone of discrete article
transfer. The first tangential velocity, TV1, may be constant, or
substantially constant at the point or zone of discrete article
transfer. A surface of the linear conveyor 106' may have a linear
velocity, LV2. The linear velocity, LV2, may be equal to,
substantially equal to, greater than, or less than the first
tangential velocity, TV1, at the point or zone of discrete article
transfer. The linear velocity, LV2, may be at least about 2% to
about 35%, at least about 2% to about 30%, at least about 5% to
about 25%, at least about 3% to about 25%, at least about 3%, at
least about 5%, at least about 10%, or at least about 15%,
specifically reciting all 0.1% increments within the specified
ranges and all ranges formed therein or thereby, greater than the
first tangential velocity, TV1, at the point or zone of discrete
article transfer to tension the discrete article 102 being
transferred. On the input side of the transfer assembly 100, a
surface of a linear conveyor may have a tangential velocity that is
slower than the tangential velocity of a surface of the head 105 to
tension the discrete article at the point or zone of discrete
article transfer.
[0146] In a form, a method of transferring discrete articles
between a transfer assembly comprising one or more transfer members
and an apparatus comprising one or more heads is provided. The
discrete articles may be transferred from a transfer surface of the
transfer member to a surface of the head of the apparatus (output
side of transfer assembly) and/or may be transferred from the
surface of the head of the apparatus to the transfer surface of the
transfer member (input side of transfer assembly). The transfer
assembly may comprise a frame defining a first rotation axis and at
least one transfer member each comprising a transfer surface
configured to receive one or more of the discrete articles. The
method may comprise rotating the transfer member of the transfer
assembly about the first rotation axis at a substantially constant
angular velocity, maintaining the transfer surface at a
substantially constant minimum distance away from a surface of the
head at a point or zone of discrete article transfer, and rotating
the head of the apparatus about a second rotation axis at a
plurality of angular velocities. A first angular velocity of the
head may be constant, or substantially constant, at the point or
zone of discrete article transfer. Alternatively, the first angular
velocity of the head may be variable at the point or zone of
discrete article transfer.
[0147] A tangential velocity of the transfer surface of the
transfer member may be constant, or substantially constant, at the
point or zone of discrete article transfer. A tangential velocity
of the surface of the head of the apparatus may be the same as, or
substantially the same as (e.g., +/-2%), the constant, or
substantially constant, tangential velocity of the transfer surface
at the point or zone of discrete article transfer. In some
instances, the tangential velocity of the surface of the head of
the apparatus may also be variable at the point or zone of discrete
article transfer and/or may be different than the constant, or
substantially constant, tangential velocity of the transfer surface
at the point or zone of discrete article transfer.
[0148] The method may comprise rotating the head of the apparatus
about the second rotation axis (e.g., rotation axis 107) at a
second angular velocity when the head is outside of a zone of
discrete article transfer. The second rotation axis may be parallel
to, substantially parallel to, or transverse to, the first rotation
axis of the transfer assembly. The second angular velocity of the
head may be different than or the same as the first angular
velocity of the head.
[0149] In an instance, the discrete articles may be transferred
from the transfer surface of the transfer member to the surface of
the head on an output side of the transfer assembly. The method may
comprise rotating the head about the second rotation axis at a
third, different angular velocity when the surface of the head is
transferring the discrete articles to a discrete article conveying
device, such as the second moving carrier member 106 or the linear
conveyor 106'. A tangential velocity of the surface of the head may
match, or substantially match, a tangential velocity or linear
speed of the discrete article conveying device at a second point of
discrete article transfer. The method may comprise rotating the
head about the second rotation axis between the first, second, and
third angular velocities in one revolution of the head.
[0150] The surface of the head may comprise an arcuate portion or
may be fully arcuate. The transfer surface may be flat,
substantially flat, or may comprise one or more flat portions. The
transfer surface may also be arcuate or comprise one or more
arcuate portions in some instances. The method may comprise moving
the flat or substantially flat transfer surface radially inwardly
and radially outwardly relative to the first rotation axis of the
transfer assembly at the point of discrete article transfer to
maintain the substantially constant minimum distance or gap between
the surface of the head and the transfer surface. The transfer
surface of the transfer member may also be rotated about a third
rotation axis (e.g., rotation axis 164) between a first position
and a second position. The first rotation axis (e.g., rotation axis
132) of the transfer assembly may extend in a first direction and
the third rotation axis of the transfer assembly may extend in a
second, different direction. The first rotation axis of the
transfer assembly may be parallel to, or substantially parallel to
(e.g., +/-5 degrees), the second rotation axis (e.g., rotation axis
107) of the apparatus, and the third rotation axis of the transfer
assembly may be perpendicular to, or substantially perpendicular to
(e.g., +/-5 degrees), the first and second rotation axes.
[0151] The transfer surface of the transfer assembly may be rotated
between about 80 degrees and about 100 degrees, about 90 degrees,
or 90 degrees, about the third rotation axis of the transfer
assembly between the first position and the second position. Other
degrees of rotation between the first position and the second
position are also specified herein, but not again set forth here
for brevity.
[0152] The method may further comprise using a radial displacement
mechanism operably engaged with a portion of the transfer member to
maintain the transfer surface at the substantially constant minimum
distance away from the surface of the head of the apparatus at the
point or zone of discrete article transfer. The method may also
comprise maintaining a substantially constant pressure between the
transfer surface and the surface of the head of the apparatus at
the point or zone of discrete article transfer.
[0153] In a form, a method of transferring discrete articles
between a transfer assembly and an apparatus comprising one or more
heads is provided. The transfer assembly may comprise a frame
defining a first rotation axis and at least one transfer member
each comprising a transfer surface configured to receive one or
more of the discrete articles. The method may comprise rotating the
transfer member of the transfer assembly about the first rotation
axis at a constant, or substantially constant, angular velocity and
maintaining the transfer surface at a constant, or substantially
constant, minimum distance away from a surface of the head at a
point or zone of discrete article transfer. A tangential velocity
of the transfer surface may be constant or substantially constant
at the point or zone of discrete article transfer. The method may
further comprise rotating the head of the apparatus about a second
rotation axis at a variable angular velocity. A first angular
velocity of the head may be constant, substantially constant, or
variable, at the point or zone of discrete article transfer. A
tangential velocity of the surface of the head may be the same as,
or substantially the same as (e.g., +/-2%), the constant, or
substantially constant, tangential velocity of the transfer surface
at the point or zone of discrete article transfer. The tangential
velocity of the surface of the head, in other instances, may be
different than the constant, or substantially constant, tangential
velocity of the transfer surface at the point or zone of discrete
article transfer.
[0154] The transfer surface may be flat, substantially flat, or may
comprise a flat portion. In other instances, the transfer surface
may be arcuate or comprise one or more arcuate portions. The
surface of the head may comprise one or more arcuate portions or
may be arcuate. The surface of the head may be configured to
receive one of the discrete articles. The first rotation axis of
the transfer assembly may be parallel to, or substantially parallel
to, the second rotation axis of the apparatus. The method may
comprise rotating the transfer member about a third rotation axis
of the transfer assembly between a first position and a second
position. The transfer member may be rotated between about 80
degrees and about 100 degrees, about 90 degrees, or 90 degrees,
about the third rotation axis between the first position and the
second position. Other degrees of rotation between the first and
second positions are specified herein, but are not again set forth
for brevity. The first rotation axis of the transfer assembly and
the second rotation axis of the apparatus may be perpendicular to,
or substantially perpendicular to, the third rotation axis of the
transfer assembly.
[0155] In a form, a method may comprise transferring discrete
articles between a transfer assembly and an apparatus comprising at
least one head. The transfer assembly may comprise a frame defining
a first rotation axis and at least one transfer member each
comprising a transfer surface configured to receive one or more of
the discrete articles. The transfer surface may be flat,
substantially flat, or may comprise one or more flat or
substantially flat portions. In other instances, the transfer
surface may be arcuate or may comprise one or more an arcuate
portions. The method may comprise rotating the transfer member of
the transfer assembly about the first rotation axis at a constant,
or substantially constant, angular velocity, maintaining the
transfer surface at a constant, or substantially constant, minimum
distance away from a surface of the head at a point or zone of
discrete article transfer, and rotating the head of the apparatus
about a second rotation axis at a variable angular velocity. A
first angular velocity of the head may be constant, substantially
constant, or variable at the point or zone of discrete article
transfer. The surface of the head may be arcuate or may comprise an
arcuate portion. The first rotation axis of the transfer assembly
may be parallel to, or substantially parallel to, the second
rotation axis of the apparatus. The method may comprise rotating
the transfer member about a third rotation axis of the transfer
assembly between a first position and a second position. The first
rotation of the transfer assembly axis may extend in a first
direction. The third rotation axis of the transfer assembly may
extend in a second, different direction. The transfer member may be
rotated about the third rotation axis between about 80 degrees and
about 100, about 90 degrees, or 90 degrees, between the first
position and the second position. Other degrees increments between
the first and second positions are specified herein, but not set
forth again for brevity.
[0156] A first tangential velocity of the transfer surface of the
transfer member may be constant, or substantially constant, at the
point or zone of discrete article transfer. A second tangentially
velocity of the surface of the head may be constant, substantially
constant, or variable at the point or zone of discrete article
transfer. The first and second tangentially velocities may be the
same, substantially the same, or different at the point or zone of
discrete article transfer.
[0157] In a form a method of transferring discrete articles from a
transfer assembly to an apparatus comprising one or more heads is
provided. The transfer assembly may comprise a frame defining a
first rotation axis and at least one transfer member each
comprising a transfer surface configured to receive one of the
discrete articles. The method may comprise rotating the transfer
member of the transfer assembly about the first rotation axis,
maintaining the transfer surface at a substantially constant
minimum distance away from a surface of the head at a point or zone
of discrete article transfer. The transfer surface of the transfer
member may be moved at a first constant, or substantially constant,
tangential velocity at the point or zone of discrete article
transfer. The method may further comprise rotating the head of the
apparatus about a second rotation axis. The surface of the head may
be moved at a second constant, or substantially constant,
tangential velocity at the point or zone of discrete article
transfer. The second constant, or substantially constant,
tangential velocity of the head may be greater than the first
constant, or substantially constant, tangential velocity of the
transfer surface at the point or zone of discrete article transfer
to tension the discrete articles being transferred. The second
constant, or substantially constant, tangential velocity may be at
least about 2% to about 35%, at least about 2% to about 30%, at
least about 5% to about 25%, at least about 3% to about 25%, at
least about 3%, at least about 5%, at least about 10%, or at least
about 15%, specifically reciting all 0.1% increments within the
specified ranges and all ranges formed therein or thereby, greater
than the first tangential velocity at the point or zone of discrete
article transfer to tension the discrete article being
transferred.
[0158] The transfer member may be rotated about the first rotation
axis of the transfer assembly at a constant, or substantially
constant, angular velocity. The head may be rotated about the
second rotation axis of the apparatus at a variable angular
velocity. The rotating the head about the second rotation axis step
may comprise rotating the head about the second rotation axis
between a first angular velocity, a second angular velocity, and at
least a third angular velocity, or between a plurality of angular
velocities, in one revolution of the head. The first, second, and
third angular velocities may all be different. In other instances,
at least one of the first, second, and third angular velocities may
be different than the other two angular velocities.
[0159] The transfer surface of the transfer member may be rotated
about a third rotation axis of the transfer assembly between a
first position and a second position. The third rotation axis may
not be parallel to the first rotation axis of the transfer assembly
and, instead, may be perpendicular, or substantially perpendicular,
to the first rotation axis. The transfer surface may be rotated
between about 80 degrees and about 100 degrees, about 90 degrees,
or 90 degrees, between the first position and the second position.
Other degree increments between the first position and second
position are described herein, but not set forth again for
brevity.
[0160] The transfer surface may be flat, substantially flat, or may
comprise one or more flat portions. The transfer surface may also
be arcuate, in other instances. The surface of the head may be
arcuate or may comprise one or more arcuate portions. The method
may comprise moving the flat or substantially flat transfer surface
radially inwardly and radially outwardly relative to the first
rotation axis of the transfer assembly at the point or zone of
discrete article transfer to maintain the substantially constant
minimum distance. The method may comprise using a radial
displacement mechanism operably engaged with a portion of the
transfer member to maintain the transfer surface at the constant,
or substantially constant, minimum distance away from the surface
of the head of the apparatus at the point or zone of discrete
article transfer. The method may also comprise maintaining a
constant, or substantially constant, pressure between the transfer
surface of the transfer member and the surface of the head of the
apparatus at the point or zone of discrete article transfer.
[0161] In a form, a method of transferring discrete articles from a
transfer assembly to an apparatus comprising one or more heads is
provided. The transfer assembly may comprise a frame defining a
first rotation axis and at least one transfer member each
comprising a transfer surface configured to receive one or more of
the discrete articles. The method may comprise rotating the
transfer member of the transfer assembly about the first rotation
axis of the transfer assembly at a constant, or substantially
constant, angular velocity and maintaining the transfer surface at
a constant, or substantially constant, minimum distance away from a
surface of the head at a point or zone of discrete article
transfer. The transfer surface may be moved at a first constant, or
substantially constant, tangential velocity at the point or zone of
discrete article transfer. The method may comprise rotating the
head of the apparatus about a second rotation axis at a variable
angular velocity or at a plurality of angular velocities. The
surface of the head may be moved at a second constant, or
substantially constant, tangential velocity at the point or zone of
discrete article transfer. The second constant, or substantially
constant, tangential velocity of the head may be greater than the
first constant, or substantially constant, tangential velocity of
the transfer surface at the point or zone of discrete article
transfer to tension the discrete article being transferred. The
second constant, or substantially constant, tangential velocity may
be at least about 2% to about 35%, at least about 2% to about 30%,
at least about 5% to about 25%, at least about 3% to about 25%, at
least about 3%, at least about 5%, at least about 10%, or at least
about 15%, specifically reciting all 0.1% increments within the
specified ranges and all ranges formed therein or thereby, greater
than the first constant, or substantially constant, tangential
velocity at the point or zone of discrete article transfer to
tension the discrete article being transferred.
[0162] The rotating of the head of the apparatus step may comprise
rotating the head about the rotation axis of the apparatus between
a first angular velocity, a second angular velocity, and a third
angular velocity, or between a plurality of angular velocities, in
one revolution of the head. The first, second, and third angular
velocities may all be different. In other instances, at least one
of the first, second, and third angular velocities may be different
than the other two.
[0163] The transfer surface may be flat, substantially flat, or may
comprise one or more flat portions. In other instances, the
transfer surface may be arcuate or comprise one or more arcuate
portions. The surface of the head may be arcuate or may comprise
one or more arcuate portions.
[0164] The method may further comprise moving the flat or
substantially flat transfer surface radially inwardly and radially
outwardly relative to the first rotation axis of the transfer
assembly at the point or zone of discrete article transfer to
maintain the constant, or substantially constant, minimum distance.
The method may also comprise using a radial displacement mechanism
operably engaged with a portion of the transfer member to maintain
the transfer surface at the constant, or substantially constant,
minimum distance away from the surface of the head of the apparatus
at the point or zone of discrete article transfer. The method may
additionally comprise maintaining a constant, or substantially
constant, pressure between the transfer surface and the surface of
the head of the apparatus at the point or zone of discrete article
transfer.
[0165] In a form, a method of transferring discrete articles from a
transfer assembly to an apparatus comprising one or more heads is
provided. The transfer assembly may comprise a frame defining a
first rotation axis and one or more transfer members each
comprising a transfer surface configured to receive one or more of
the discrete articles. The transfer surface may be flat,
substantially flat, or may comprise one or more flat portions. The
transfer surface may also be arcuate, or comprise arcuate portions,
in some instances. The method may comprise rotating the transfer
member of the transfer assembly about the first rotation axis and
maintaining the transfer surface at a constant, or substantially
constant, minimum distance away from a surface of the head at a
point or zone of discrete article transfer. The transfer surface
may be moved at a first constant, or substantially constant,
tangential velocity at the point or zone of discrete article
transfer. The method may comprise rotating the head of the
apparatus about a second rotation axis. The surface of the head may
be moved at a second constant, or substantially constant,
tangential velocity at the point or zone of discrete article
transfer. The surface of the head, in other instances, may also be
moved at a variable tangential velocity at the point or zone of
discrete article transfer. The second constant, or substantially
constant, tangential velocity of the head may be greater than the
first constant, or substantially constant, tangential velocity of
the transfer surface at the point or zone of discrete article
transfer to tension the discrete articles being transferred.
[0166] In all of the methods described herein, the methods may
comprise retaining one or more of the discrete articles to the
transfer surfaces or to the surfaces of the heads through fluid
pressures, static, magnetic, adhesives, and/or adhesive attraction,
for example.
[0167] The transfer members, apparatuses comprising the heads,
wheels, rotation assemblies, and/or any other part or component
that rotates about a rotation axis may comprise aluminum, steel,
plastic, titanium, carbon fiber composite, and/or other high
strength/light weight material. By using high strength/light weight
materials, the amount of mass rotating about a rotation axis may be
reduced compared to related art transfer assemblies or apparatuses.
This reduction in mass may allow the overall transfer apparatuses
of the present disclosure to operate at a higher throughput of
discrete articles per minute.
[0168] The overall transfer apparatuses of the present disclosure
may process or transfer over 800 discrete articles per minute,
alternatively, over 900 discrete articles per minute,
alternatively, over 1,000 discrete articles per minute,
alternatively, over 1,100 discrete articles per minute,
alternatively, over 1,200 discrete articles per minute, and
alternatively, over 1,300 discrete articles per minute. In other
instances, the overall transfer apparatuses of the present
disclosure may process or transfer between 600 and 1500 discrete
articles per minute, specifically including each whole number
within the specified range.
[0169] Any of the methods and apparatuses described herein may be
used in conjunction with the inventive concepts disclosed in
European Patent Application No. EP12162251.8, entitled METHOD AND
APPARATUS FOR MAKING PERSONAL HYGIENE ABSORBENT ARTICLES, and filed
on Mar. 29, 2012.
[0170] Any of the transfer surfaces (e.g., 136), carrier members
(e.g., 104, 106), and/or the heads (e.g., heads 105, 105') may
comprise one or more resilient materials thereon. The resilient
materials may comprise one or more foams, rubbers, silicon rubbers,
polymers, and/or polyurethane. The resilient materials may cover
the entire surfaces of the transfer surfaces, the carrier members,
and/or the heads, or may cover less than the entire surfaces of the
transfer surfaces, the carrier members, and/or the heads. The
resilient members may be provided to achieve better transfer of
discrete articles by allowing one component to apply a force to
another component during transfer. Stated another way, the
resilient members may be provided to allow for interference
transfer between at least some of the various components discussed
in this paragraph. In some forms, the resilient members may have a
Shore A hardness of between about 20 and about 80, specifically
reciting all 0.5 Shore A hardness increments within the specified
range.
[0171] 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."
[0172] Every document cited herein, including any cross referenced
or related patent or application, 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 embodiment disclosed or claimed
herein or that it alone, or in any combination with any other
reference or references, teaches, suggests or discloses any such
embodiment. 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.
[0173] While particular embodiments of the present disclosure have
been illustrated and described, it would be obvious to those
skilled in the art that various other changes and modifications may
be made without departing from the spirit and scope of the present
disclosure. It is therefore intended to cover in the appended
claims all such changes and modifications that are within the scope
of this disclosure.
* * * * *