APPARATUS AND METHODS FOR TRANSPORTING WEBS OF MATERIAL

Abstract

Provided are methods and apparatus for transporting either an entire web or discrete components of disposable products. The invention is a means of conveying the web or diaper components down the machine using mechanical forces to grip the nonwoven web and transfer it from one belt or roll to another without or reducing added vacuum. There is a carrier nonwoven web that goes down the length of the machine and other substrates are added on top of this. Methods and apparatus are disclosed to provide sufficient gripping to allow transport of diaper components through the fabrication process. Securing and releasing forces are supplied so that the components can be retained at some points and released at others.

Claims

1-7. (canceled)

8. A system for conveying a web material, the system comprising: a transfer apparatus comprising a material surface for moving the web material along a transfer path; wherein the transfer apparatus comprises a plurality of spikes that extend or selectively extend through or outwardly from the material surface to engage the web material.

9. The system of claim 8 wherein the transfer apparatus comprises a conveyor belt from which the plurality of spikes extend outwardly from the material surface to engage the web material.

10. The system of claim 9 wherein the plurality of spikes comprise unidirectional spikes slanted in a machine direction in which the conveyor belt moves the web material.

11. The system of claim 9 wherein the plurality of spikes comprise bidirectional spikes including first spikes slanted in a machine direction in which the conveyor belt moves the web material and second spikes slanted in a direction opposite the machine direction.

12. The system of claim 8 wherein the transfer apparatus comprises: a first conveyor belt comprising the material surface moving the web material along the transfer path; and a second conveyor belt positioned on a side of the first conveyor belt opposite the material surface, wherein the second conveyor belt includes the plurality of spikes, with the plurality of spikes extending up towards the first conveyor belt.

13. The system of claim 12 wherein a first portion of the first conveyor belt and a first portion of the second conveyor belt are positioned adjacent each other, such that the plurality of spikes on the second conveyor belt extend through the first conveyor belt, and wherein a second portion of the second conveyor belt moves away from a second portion of the first conveyor belt so as to be is spaced apart therefrom, such that the plurality of spikes on the second conveyor belt are removed from the first conveyor belt and do not extend therethrough.

14. The system of claim 13 wherein the second conveyor belt decelerates as compared to the first conveyor belt, so as to cause the plurality of spikes to be removed from the first conveyor belt.

15. The system of claim 8 wherein the transfer apparatus comprises a cylindrical drum from which the plurality of spikes extend outwardly to engage the web material.

16. The system of claim 15 wherein the plurality of spikes comprise unidirectional spikes slanted in a machine direction in which the cylindrical drum moves the web material.

17. The system of claim 15 wherein the plurality of spikes comprise bidirectional spikes including first spikes slanted in a machine direction in which the cylindrical drum moves the web material and second spikes slanted in a direction opposite the machine direction.

18. The system of claim 8 wherein the transfer apparatus comprises: an outer cylindrical drum comprising the material surface moving the web material along the transfer path, the outer cylindrical drum comprising a plurality of openings formed therein; and an inner cylindrical drum positioned within the outer cylindrical drum, wherein the inner cylindrical drum includes the plurality of spikes, with the plurality of spikes extending out through the plurality of openings in the outer cylindrical drum.

19. The system of claim 18 wherein a speed of the inner cylindrical drum is adjustable so as to change an angle of the plurality of spikes that extend out through the plurality of openings in the outer cylindrical drum, with the plurality of spikes selectively engaging and releasing the web material based on the angle thereof.

20. The system of claim 8 wherein the web material comprises a nonwoven web material that is either a continuous web or discrete items.

21. The system of claim 8 wherein the spikes engage the web material to convey the material along the transfer path without using a vacuum drawn through the material surface.

22. A method for conveying a web material, the method comprising: supplying a web material; transporting the web material in a machine direction along a transfer path via a transfer apparatus, the web material contacting a material surface of the transfer apparatus; and selectively securing the web material to the material surface of the transfer apparatus via a plurality of spikes that extend or selectively extend through or outwardly from the material surface to engage the web material.

23. The method of claim 22 wherein transporting the web material via the transfer apparatus comprises transporting the web material on a first conveyor belt comprising the material surface; and wherein selectively securing the web material to the material surface comprises positioning a second conveyor belt including the plurality of spikes relative to the first conveyor belt such that the plurality of spikes selectively protrude through the first conveyor belt.

24. The method of claim 23 wherein positioning the second conveyor belt comprises: positioning the second conveyor belt in a first position relative to the first conveyor belt along a first portion of the first and second conveyor belts, with the plurality of spikes protruding through the first conveyor belt when the second conveyor belt is in the first position; and positioning the second conveyor belt in a second position relative to the first conveyor belt along a second portion of the first and second conveyor belts, with the plurality of spikes being removed from the first conveyor belt when the second conveyor belt is in the second position.

25. The method of claim 23 further comprising decelerating the second conveyor belt as compared to the first conveyor belt, so as to cause the plurality of spikes to be removed from the first conveyor belt.

26. The method of claim 22 wherein transporting the web material via the transfer apparatus comprises transporting the web material on an outer cylindrical drum comprising the material surface, the outer cylindrical drum comprising a plurality of openings formed therein; and wherein selectively securing the web material to the material surface comprises positioning an inner cylindrical drum including the plurality of spikes within the outer cylindrical drum such that the plurality of spikes protrude through the outer cylindrical drum.

27. The method of claim 26 wherein selectively securing the web material to the material surface comprises adjusting a speed of the inner cylindrical drum relative to a speed of the outer cylindrical drum so as to change an angle of the plurality of spikes that extend out through the plurality of openings in the outer cylindrical drum, with the plurality of spikes selectively engaging and releasing the web material based on the angle thereof.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] FIGS. 1-6 generally represent a prior art apparatus and method of conveying and handing off articles by providing high speed vacuum porting to selected vacuum pattern areas on a rotating cylindrical roll.

[0030] FIG. 1 is a diagrammatic side view of a prior art process.

[0031] FIG. 2 is a top view of a prior art ear forming web including an individual ear detached from the web.

[0032] FIG. 3 is a front view of a prior art anvil roll.

[0033] FIG. 4 is a perspective view of a prior art anvil roll.

[0034] FIG. 5 is a cross sectional view of the prior art anvil roll.

[0035] FIG. 6 is a side view of the prior art anvil roll, showing an endface of the anvil, and a vacuum manifold pattern applied to vacuum holes disposed on the endface of the anvil.

[0036] FIG. 7 is a side view of a conveyor belt with forward and rearward facing retractable spikes.

[0037] FIG. 8 is a side view of a conveyor belt with forward facing retractable spikes.

[0038] FIG. 9 is a side view of a Venturi effect enabled belt, with downward blades carried by a conveyor.

[0039] FIG. 10 is a cross-sectional side view of a drum with vanes.

[0040] FIG. 11 is a perspective view of an embodiment of a conveyor drum capable of a passive Venturi draw.

[0041] FIG. 12 is a perspective view of an embodiment of a fan plate according to the present invention.

[0042] FIG. 13 is an elevation view of the plate of FIG. 12.

[0043] FIG. 14 is a cross-sectional view taken along line 14-14 of FIG. 11.

[0044] FIG. 15 is a side elevation view of a non-woven web material.

[0045] FIG. 15A is a close-up view of the nonwoven material of FIG. 15.

[0046] FIG. 16 is a side elevation view of a material conveyor belt.

[0047] FIGS. 16A-16D are close-up side elevation views of optional coatings applied to the belt of FIG. 16.

DETAILED DESCRIPTION

[0048] Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention.

[0049] FIGS. 1-6 generally describe a rotating anvil using vacuum to hold discrete pieces on a moving web, in the prior art. High speed vacuum is also used in a similar manner to transport discrete pieces and entire webs on flat conveyors through the manufacturing process. The present invention relates to transporting discrete pieces and entire webs through both rotation and flat conveyance by minimizing the vacuum usage shown in FIGS. 1-6 and on prior art flat vacuum conveyors (not shown).

[0050] Referring to the drawings there is seen in FIG. 1 a diagrammatic illustration of a prior art process for applying tabs to webs in a diaper making process. This prior art method of affixing the segments 12 to the web 10, with a different anvil, the new anvil 114 described below. Web 10 is a composite material used in formation of diapers which is generally formed of various layers of material such as plastic back sheets, absorbent pads and nonwoven topsheets. A series of ears 12 are applied to web 10. In the illustrated process a rotatable vacuum anvil 14 is used to supply the ears 12 to web 10. Anvil 14 has internally reduced air pressure or vacuum (not shown), and a plurality of openings 24 are provided through its surface to enable suction of the Lab segments 12 against the anvil surface 14. A web of the ear tab forming material 16 is fed by rollers 20 and 22 against the anvil surface 14 where it is cut into segments by a rotary knife 18.

[0051] In the prior art, the surface of the anvil roll 14 has vacuum holes 24 on its smooth surface. In a typical configuration of a slip-and-cut applicator, there is a pattern of vacuum holes 24 distributed to evenly draw the entering web onto the surface of anvil 14 and thence into the cut point where the knife edge 18 engages the anvil 14.

[0052] IL can be seen from FIG. 1 that in the prior art, the infeed of the ear tab forming material 16 can be at a first speed (with individual ears 12 spaced together), after which the individual ears gain speed to the speed of the anvil 14. Typical infeed speeds could be 120 mm/product for the infeed, while anvil speeds could be 450 mm/product on the anvil. This transition from the slower first speed to the quicker second speed takes place at the cut point, the ear tab forming material 16 slipping on the anvil 14 until cut. However, immediately at the transition cut point 18 from the slower speed to the faster speed, it is desired to place vacuum on the ears because centrifugal force would try to throw the ears off of the vacuum anvil 14.

[0053] A continuous ear forming web 16 is provided to the system. The web 16 is comprised of two portions, 12a and 12b, as shown in FIG. 2. Segment 12a is more specifically referred to as the tab section of the ear 12, segment 12b is the ribbon section of the ear 12. The ear forming material 16 is cut into individual ears 12 by the rotary knife 18 as shown in FIG. 1, along lines such as the dashed lines shown in FIG. 2.

[0054] Referring now to FIG. 3, a front view of an anvil roll 114 of the prior art is shown carrying ear forming material 16 (and later, an ear 12) in phantom. The anvil roll 114 is preferably formed with two vacuum portions 116 separated by a center groove portion 118. The vacuum portions 116 are preferably mirror images of each other. The anvil roll 114 is symmetrical about a center plane through its circumference. Each vacuum portion 116 contains several circumferential rows of circular vacuum holes 24. Each vacuum portion 116 may also contain a circumferential groove 120 with an additional circumferential row of vacuum holes 24 located in the circumferential groove 120.

[0055] The preferred embodiment of the anvil roll 114 of the prior art is also formed with two diametrically opposed anvil pockets 122 and two diametrically opposed pairs of ear retaining portions 124. The ear retaining portions can be created as inserts, with different vacuum patterns applied as the user deems necessary. Each anvil pocket 122 is a groove which extends across the face of the entire anvil roll 114. One ear retaining portion 124 is located on each of the vacuum portions 116. Each ear retaining portion 124 has an ear vacuum hole pattern 126 made of a plurality of vacuum holes 24 located at or near the surface of the anvil roll 144. The preferred embodiment, as shown in FIG. 3 is a plurality of rows of vacuum holes 24, each row having a plurality of vacuum holes 24, although more or less than those configurations or patterns shown can be used.

[0056] In operation, two webs of ear material 16 are carried by the anvil 114. One web of ear material 16 is located on each vacuum portion 116. A single ear 12 is cut from the ear web 16 when the rotary knife 18 engages the anvil roll 114 at the anvil pocket 122. Immediately after a single ear 12 is cut from the ear web 16, the single ear 12 is located on the ear retaining portion 124, particularly the tab portion 12a of the ear 12 as shown in FIG. 2. At this point the vacuum in the ear retaining portion 124 has been engaged to secure the single ear 12 to the anvil roll 114. As the anvil roll 114 rotates the vacuum is released at a predetermined location so that the single ear 12 can be applied to the diaper web 10. Because this configuration has two vacuum portions 116, a pair of two ears 12 is cut each time the rotary knife 18 engages the anvil roll 114. This allows for two pair of ears 12 to be cut with each revolution of the anvil roll 114. Shown in dotted line in FIG. 3 is a vacuum slot 128, described below.

[0057] Referring now to FIG. 4, a perspective view of the anvil 114 is shown. The anvil 114 will be described in relation to its endface and its outer surface, the outer surface that surface shown on FIG. 3 and the endface the two ends of the anvil 114.

[0058] The vacuum slot 128 contains a plurality of vacuum holes 24 that allow commutation of the vacuum to the entire ear vacuum hole pattern 126, allowing the pattern 126 to be activated simultaneously, as opposed to each of the rows that comprise the vacuum of vacuum holes 24 being enabled one at a time. The vacuum pattern 126 is activated utilizing drilled ports 28 that communicate the vacuum from the slot 128 to the individual holes 24 of the pattern 126. It should be noted that the pattern 126 can also be provided with a depressed slot configuration so that it too is all simultaneously enabled with vacuum.

[0059] The remaining vacuum holes 24 provided on the anvil roll 114 are enabled sequentially, by known vacuum commutation method utilizing cross drilled ports 28.

[0060] The vacuum slot 128 is provided at a first radius R1 on the anvil roll 114, the remaining vacuum holes provided at a different R2. The differing radii R1 and R2 allow two vacuum manifolds (not shown) to communicate each at a different radius, R1 or R2, thus selectively applying vacuum to the anvil.

[0061] Referring now to FIG. 5, a cross sectional view of the anvil roll 114 of the prior art is shown. In this embodiment, the slot 128 has been placed at R2. It is appreciated that the slot 128 communicating with the pattern 126 can be placed at either R1 or R2, and the remaining vacuum holes 24 communicating with drilled ports 28 can be interchanged at either R1 or R2. For machining purposes, it is likely preferable to place the slot 128 communicating with the pattern at R2 for simplicity in machining.

[0062] Referring now to FIG. 6, a side view of the anvil roll 114 is shown, showing the endface of the anvil, or the circular portion of the cylindrical body 114. The ear web 16 is shown infeeding to the anvil 114, where it is then cut with the rotary knife 18. It is desired to apply the vacuum to the pattern 126 simultaneously with the knife cut.

[0063] The range of vacuum application may be provided for with a manifold (not shown) that continuously applies vacuum to vacuum patterns V1 and V2. Vacuum pattern V1 is at R1, Vacuum pattern V2 is at R2. Vacuum pattern V1 applies vacuum to the slot 128 each time the slot 128 rotates through the vacuum pattern V1 provided on the manifold. When the slot 128 is in communication with V1, vacuum is applied to vacuum holes 24 associated in the slot 128 on the endface of the anvil for commutation to the pattern 126 on the outer surface of the anvil 114. When the slot 128 is not in communication with V1, the vacuum to the pattern 126 is turned off.

[0064] Vacuum pattern V2 is applied to the vacuum holes 24 disposed on the endface of the anvil 114 and the associated circumferential ribbon vacuum hole pattern on the outer surface of the anvil 114 throughout V2. As each successive vacuum hole 24 rotates through V2, the vacuum is on. As each successive vacuum hole 24 leaves V2, its vacuum is turned off.

[0065] From the center of the endface, a radius extending to the contact point of the knife 18 with the anvil roll 114 can be extended, and as the anvil roll rotates through angle B as shown, the rotation of the ear 12 will be from the knife point to the transfer point TP. It is throughout this angle B that vacuum is desired across the pattern 126 and onto the ear 12. To accomplish this, a smaller angle C has vacuum applied to it. The angle C can be expressed mathematically as the angle B minus twice the width 128 of the slot 128. This is because pattern 126 is placed in communication with the slot 128, the slot 128 communicates vacuum simultaneously to the pattern 126. Therefore, the leading edge of the ear 12 and the trailing edge of the ear 12 will receive vacuum at the same time. Therefore, the user must allow the leading edge of the ear 12 to pass by the knife 18 the desired length of the ear 12 prior to engaging the vacuum onto the ear 12. Similarly, prior to arriving at the transfer point TP, the vacuum will have to be released on both the leading and trailing edges of the ear 12 simultaneously, allowing the ear 12 to continue on its downstream path.

[0066] An angle A, larger than angle B, is provided to define V2, as it is desired to draw the web 16 into contact with the anvil both prior to and during cutting by the knife 18.

[0067] Many of the same transport functions are accomplished by the present invention using conveyance techniques accomplished without vacuum or with minimal assisted vacuum. Both flat and rotational conveyance are contemplated in the description below.

[0068] Referring now to FIG. 7, retractable spikes 202 and 204 above a belt can grip in both directions (202 slanted to the right, machine direction, forward; and 204 slanted to the left, reverse) and retract when needed, through a belt 200 or cylinder wall.

[0069] Referring now to FIG. 8, an alternate embodiment is shown with unidirectional spikes 202, slanted to the right, machine direction, forward.

[0070] In lieu or in addition to spikes, a mechanical grip can be accomplished by using either a hook fastener (such as the hook component of a hook and loop fastening system) (see FIG. 16B) or rough sandpaper (see FIG. 16A), which both can grip well and release provided the nonwoven is pulled upward when leaving these surfaces. Additionally, other surfaces such as thermal spray applied texture, shot peening texture, knurling, and Electric discharge machining (EDM) surface features can also provide a mechanical grip of sufficient strength. As can be seen in FIG. 15, a nonwoven material generally has a fuzzy finish, which may be frictionally engaged with such exemplary surfaces as metallic-fiber impregnated material (see FIG. 16C) or elastomeric resin coating (see FIG. 16D).

[0071] The spikes 202 and 204 of FIGS. 7 and 8 could be retracted in a number of ways. When it is desired to transfer the web or film to another belt or roller, the next processing step can be placed above the plane of transport. Considering the forward spike 202 example of FIG. 8, the nonwoven would simply lift off the spike if the nonwoven is lifted in an upward direction or takes place at a faster speed than the current step. Alternatively, the bottom end of the spikes 202 and 204 can be attached to another belt (not shown) travelling below the pictured belt. That lower belt can be made to drop down at the point in the process where it is desired to pull the spikes out of the web. The spikes 202 and 204 can be made to decelerate with respect to the upper belt and that forces the forward facing spikes 202 to drop down or out of the nonwoven. Still alternatively, the spiked surface could be mounted on individual segments like tractor treads. This would allow modular replacements if the material becomes worn or damaged. It would also allow fixture of a rough surface (such as hook material as in a hook and loop material) to a belt and avoid delamination from the upper material having a different curvature than the lower belt when it goes up or down in the described process.

[0072] The same principles described above can be applied to cylinders, such as the cylinder of FIG. 1. In such an arrangement, an inner cylinder carries the spikes 202 or 204 protruding from it and through an outer shell with holes or slots in it. The angle of the spikes 202 or 204 can be adjusted by changing the relative speed of the inner and outer cylinders. The cylinder could be used for hold and transfer operations by having the inner cylinder comprising several portions of cylinders (i.e. arcs) that can each move independently and allow one portion of the outer cylinder to be gripping the nonwoven while another portion of that cylinder is releasing the nonwoven.

[0073] As applied to a configured belt, holes in the surface for vacuum and the forward flow would take with downward facing blades that drag the air forward. For example, downward facing blades 202 could be applied to a belt 200 as shown in FIG. 9. Alternatively, these blades could be made into a chevron shape so that they face downward (not shown), but also have the edges extending ahead of the chevrons apex. The chevron sides can block air from entering laterally, while the space below the belt can be open. The only place to draw replenishing air would be through the vacuum holes in the belt. At sections where it is desired to release the nonwoven, air can be blown vertically from below the belt at those fixed positions to erase any Venturi effect. The same concept can be applied to cylinders with and open center so that the air flow generated by those blades driving the air downward, can be channeled out the sides of the rotating cylinder. To use this technique in a cut and space execution, two outer cylinders within which this bladed cylinder turns can be employed (not shown). The cylinder adjacent to the bladed cylinders can be fixed with holes drilled at locations where holding is needed, and no holes in sections where transfer is needed. An exterior cylinder is drilled with holes provided, and turning at the speed needed to convey the web,

[0074] \Referring now to FIG. 11, a cross-sectional side view of a drum 240 with vanes 202 is show. This cylindrical drum 240 is a bladed cylinder revolving in the direction shown at a speed desired to convey the nonwoven. The vanes 202 have the effect of creating a vacuum by allowing air outside the drum 240 to be drawn into the drum 240 through vanes 202 in vane 202 voids not covered by non-woven and thereby create negative pressure within the drum 240 to voids covered by non-woven. Fixed blowers within the cylinder (not shown) direct air outward through the revolving cylinder at the locations where a blow-off is desired. These chevron blades or vanes 240 can also comprise partial blades with segments missing where it is desired to direct the outward air flow so that blower tubes can be positioned very near the revolving inner surface of the cylinder 240. The concept of providing through vanes 202 would also work in a belt, flat or curved.

[0075] An alternate embodiment 300 is shown in FIGS. 11-14. In this embodiment, a conveying drum 302 has a plurality of holes 303 formed through its outer surface, which lead to an internal drum cavity 305. In conventional systems, a powered vacuum was coupled to such drum cavity 305 to draw air through the holes 303 at predetermined locations about the rotational path of the drum 302. In this embodiment 300, however, the air pressure within the cavity 305 is reduced not by an external powered vacuum, but by a fan plate 304 coupled to the non-drive end of the drum 302. The plate 304 has a plurality of vanes 307 extending outwardly from its axis of rotation 309, the vanes 307 terminating at open airflow ports 311 about the circumference of the plate 304. As the drum 302 is rotated, the vanes 307 draw ambient air from within the drum cavity 305 and force it out of the ports 311. In this fashion, the increased velocity of the moving air inside of the cavity 305 causes the pressure of such air to drop, thereby drawing air into the cavity 305 through the holes 303 from outside of the drum 302, thereby causing a passive Venturi draw to hold materials to the surface of the drum 302. While the drum may be driven by a drive shaft 310, an optional air passage 312, in communication with the drum cavity 305, may be provided through at least a portion of the drive shaft 312.

[0076] The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention.