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WO1999032385A1 - Systeme de reperage pour echelonner des bandes de materiau avançant simultanement et a longueurs de pas variables - Google Patents

Systeme de reperage pour echelonner des bandes de materiau avançant simultanement et a longueurs de pas variables Download PDF

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Publication number
WO1999032385A1
WO1999032385A1 PCT/US1998/027135 US9827135W WO9932385A1 WO 1999032385 A1 WO1999032385 A1 WO 1999032385A1 US 9827135 W US9827135 W US 9827135W WO 9932385 A1 WO9932385 A1 WO 9932385A1
Authority
WO
WIPO (PCT)
Prior art keywords
web
target
controlled
pitch length
preprinted
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US1998/027135
Other languages
English (en)
Inventor
Douglass Scott Henry
Toshiyuki Matsuda
Charles Phillip Miller
Alton Henry Stephens
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Procter and Gamble Co
Original Assignee
Procter and Gamble Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to AU20884/99A priority Critical patent/AU2088499A/en
Priority to KR1020007006770A priority patent/KR20010024771A/ko
Priority to JP2000525328A priority patent/JP2003522084A/ja
Priority to CA002318999A priority patent/CA2318999A1/fr
Priority to EP98965416A priority patent/EP1040063A1/fr
Application filed by Procter and Gamble Co filed Critical Procter and Gamble Co
Publication of WO1999032385A1 publication Critical patent/WO1999032385A1/fr
Priority to US09/495,651 priority patent/US6444064B1/en
Anticipated expiration legal-status Critical
Priority to US10/158,669 priority patent/US6743314B2/en
Priority to US10/161,360 priority patent/US6764563B2/en
Priority to US10/324,368 priority patent/US6955733B2/en
Ceased legal-status Critical Current

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Classifications

    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/15577—Apparatus or processes for manufacturing
    • A61F13/15772—Control
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H23/00—Registering, tensioning, smoothing or guiding webs
    • B65H23/04—Registering, tensioning, smoothing or guiding webs longitudinally
    • B65H23/18—Registering, tensioning, smoothing or guiding webs longitudinally by controlling or regulating the web-advancing mechanism, e.g. mechanism acting on the running web
    • B65H23/188—Registering, tensioning, smoothing or guiding webs longitudinally by controlling or regulating the web-advancing mechanism, e.g. mechanism acting on the running web in connection with running-web
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H23/00—Registering, tensioning, smoothing or guiding webs
    • B65H23/04—Registering, tensioning, smoothing or guiding webs longitudinally
    • B65H23/18—Registering, tensioning, smoothing or guiding webs longitudinally by controlling or regulating the web-advancing mechanism, e.g. mechanism acting on the running web
    • B65H23/188—Registering, tensioning, smoothing or guiding webs longitudinally by controlling or regulating the web-advancing mechanism, e.g. mechanism acting on the running web in connection with running-web
    • B65H23/1882—Registering, tensioning, smoothing or guiding webs longitudinally by controlling or regulating the web-advancing mechanism, e.g. mechanism acting on the running web in connection with running-web and controlling longitudinal register of web
    • B65H23/1886—Synchronising two or more webs

Definitions

  • the present invention relates to a registration system for phasing simultaneously advancing webs of material having variable pitch lengths. More specifically, the present invention relates to a registration system useful for controlling and correcting the phase and position of simultaneously advancing continuous webs of a pre-printed polymer backsheet material characterized by significant pitch variation, and a partially fabricated consumer product, such as a catamenial or diaper product.
  • Registered graphic designs or characters are desirably used in connection with disposable articles such as diapers to enhance their outward appearance for greater consumer acceptance.
  • the positioning of a web preprinted with registered graphics such that the graphics are properly placed in relation to the rest of the diaper product is desirable, e.g., in order to provide a large-sized graphic without cutting it at an incorrect location, but has typically been problematic. This is important not only for desirable aesthetic appearance, but also for example, because young children may become disturbed at seeing graphic representations of animals cut up into pieces (e.g., a head cut off).
  • breathable polymer films that are particularly useful as backsheet materials for disposable absorbent articles typically have good surface characteristics that make them suitable for the application of multicolored, high resolution graphics, which are consumer-preferred, but such films tend to be mechanically unstable with a particular tendency toward thermal shrinkage in the machine direction. Such instabilities contribute to the difficulty in correctly positioning the pre-printed polymer web on the product web such that the graphic is correctly positioned, or phased, to the product web.
  • the graphic-printed web is discretized, or cut, into segments. Each segment is then placed on the target web or product in the desired position. This does not, however, ensure the centering of the graphic on the target web; furthermore, it limits the overall product design.
  • the length of the discretized segments must be less than the length of the product, which may allow leakage in the areas where the product is longer than the discretized segment, for example, in the waist region of a diaper.
  • the present invention is directed to a registration system for phasing simultaneously advancing webs of material having variable pitch lengths comprising: (a) means for feeding a continuous target web containing consecutively spaced target objects along a path at a first velocity, the target web having a target web pitch length between consecutive target objects; (b) means for feeding a continuous controlled web of material preprinted with consecutively spaced preprinted objects along a path at a second velocity, the preprinted web having a controlled web pitch length between consecutive preprinted objects; (c) means for adjusting the controlled web pitch length such that the controlled web pitch length is approximately equal to the target web pitch length; (d) detection means for detecting a preselected feature of the controlled web; (e) means for generating an error signal based upon the detection of the preselected feature of the controlled web; and (f) means for adjusting the second velocity such that the preprinted objects are shifted toward the target objects on the target web.
  • Figure 1 is a plan view of a preferred embodiment of a disposable diaper of the present invention in a flat, uncontracted position showing a desired location for a preprinted graphic object;
  • Figure 2A is a schematic diagram showing simplified representations of a portion of a continuous diaper backsheet web having consecutively spaced graphics printed thereon and a portion of a diaper product web;
  • Figure 2B is a top view of a diaper product web including a representation of the diaper core area
  • Figure 3 is a graphical representation of the pitch length variation typically experienced by preprinted microporous materials that have been subjected to typical conditions of winding and warehouse storage;
  • Figures 4A and 4B are perspective views of portions of preferred embodiments of laminates of microporous material and nonwoven material, illustrating the impact of running the microporous material at a pitch length different from that of the nonwoven material;
  • Figure 5 is a schematic diagram showing the process of combining two simultaneously advancing webs
  • Figure 6 is a schematic diagram showing a preferred registration control system of the present invention.
  • Figure 7 is a front view of a preferred embodiment of a disposable absorbent article having registered graphics.
  • Figure 8 is a simplified plan view of another preferred embodiment of a disposable absorbent article having registered graphics.
  • Machine direction or "MD” means the direction of movement of the product along a manufacturing line.
  • the machine direction is shown in Figures 1 and 5 as an arrow labeled MD.
  • Phase refers to the machine direction position of an object expressed as a degree of rotation. For example, the phase representation from 0° to 360° for a flat, uncontracted diaper 20 is shown in Figure 1.
  • the phase position of an object can be described as any identifiable feature of the object.
  • X° is representative of an exemplary desired phase position of the graphic object 22.
  • Product pitch length means the length of material, on a relaxed basis, that runs the full length of the product under production.
  • a product pitch for typical diaper products is illustrated as "PP" in Figure 2B.
  • Regular process means that two or more continuous webs having phased features are combined in a correct phase relationship to one another.
  • Registered graphics refers to single or multiple color graphic objects that are printed on a web close to a specified pitch length on a relaxed web basis.
  • the registration system of the present invention permits small but significant variation from the intended product pitch length of the product delivered.
  • Target web or “independent web” is the main web which represents the product under production.
  • This target web may be a diaper chassis with the leading edge of the absorbent core being a reference for the target object. It is to be expected that this reference target object may also have a spacing with small but significant variations.
  • strobe an arbitrary once per product "strobe” is used as the reference. Small but significant variation in strobe locus relative to the passing of the reference target object is to be expected.
  • Target object means the location on the target web to which the preprinted object on the controlled web is intended to align. Note that alignment may take place at some standard offset from a easily recognizable feature or "target object.”
  • Target web pitch length means the nominal repeat length between consecutively spaced target objects on the target web.
  • the target web pitch length may contain small but significant variation during the use of the registration system of the present invention, e.g., ⁇ 2% between consecutive target objects.
  • Controlled web or "manipulated web” means the preprinted web which is manipulated (extended or contracted) as needed to align the preprinted object with the target object.
  • the controlled web is comprised of a microporous polymer film suitable for use as, or as part of, a diaper backsheet.
  • Preprinted object means the preprinted feature located on the controlled web at consecutively spaced, but typically not statistically controllable, locations on the controlled web.
  • the preprinted object is preferably high resolution, multicolored graphics that are appealing to consumers.
  • Preprinted object as used herein may also refer to a collection of objects, see e.g., graphics 122 in Figure 8, and includes pre-bonded, pre-applied, pre-cut, and pre-glued objects.
  • Preprinted refers to printing or combining on a separate independent process not control linked to the registration process.
  • Controlled web pitch length means the repeat length between consecutively spaced preprinted objects on the controlled web. Like the target web pitch length, the controlled web pitch length may contain small but significant variation during the use of the registration system of the present invention.
  • a preferred embodiment of the present invention is directed to a registered process for phasing simultaneously advancing continuous target and controlled webs, the target web containing target objects and the controlled web containing preprinted objects, while permitting all in-running continuous webs to sustain small but significant variations in the spacing of key objects (such as preprinted graphics). Such variations result for example, from climatic conditions, machine conditions and variations, printing errors, and creep.
  • the present invention accounts for the variation in the spacing of key objects that is inherent in the mechanically unstable microporous polymer films that are particularly useful as controlled webs herein, while providing gentle handling conditions for these delicate webs.
  • a diaper converting line i.e., registration of preprinted graphic objects (preprinted objects) phased to diaper cores (target objects) on a diaper converting line
  • preprinted objects preprinted graphic objects
  • target objects target objects
  • phase position of the target web usually the product under production, e.g., the diaper chassis assembly
  • position of the phased objects e.g., a preprinted object, such as a preprinted graphic on a polymer backsheet web
  • target web pitch length and the controlled web pitch length are rarely identical. It will be understood by those of skill in the art that any incoming fed web may be designated as a target web or a controlled web, and processed accordingly.
  • the continuous registration system of the present invention performs two functions simultaneously in order to correctly combine two or more incoming webs having different phase positions, as described above. First, it continuously corrects the preprinted pitch length, or spacing of the graphics consecutively preprinted on the controlled web, to match the pitch length of the target web. Second, it continuously synchronizes the phase positions of the two webs such that they are combined in the proper position, e.g., such that the graphic 22 is correctly located as desired on the diaper 20, for example, in substantially the positions shown in Figures 1 , 7 or 8.
  • the target web preferably comprises that part of the diaper chassis itself that is generally continuously comprised of the core and topsheet assembly, prior to the attachment of the backsheet web.
  • the target web is represented in Figures 2A and 2B as target web 40.
  • the target web 40 contains target objects 42 consecutively but not equidistantly spaced thereupon at a target web pitch length, "Ltp".
  • Target objects 42 are preferably the absorbent cores of the disposable diaper chassis.
  • Ltp need not be identical to the product pitch length PP of the diaper product; in fact, the target web 40 will likely have small but significant variation in consecutive product pitch lengths PP due to climatic conditions during storage and transport, thermally induced creep, and the like.
  • the pitch length Lpp of the controlled web 30 may be either longer or shorter than Ltp.
  • the target object position may be directly sensed or inferred from the use of an electronic strobe.
  • a preferred embodiment of the present invention uses an electronic strobe. This signal happens once per machine cycle at the same place in the machine cycle. For example, if the machine cycle is represented by 1000 counts, then the strobe may be arbitrarily set at 500 to 600 "on” and balance of cycle "off. The leading edge transition between "off to "on” marks a machine time fixed position to which a graphic is registered.
  • the operator inputs an offset value using an "advance/retard" button while examining the position of the controlled web graphic using an actual strobe light. Once the offset value is set, the registration system will target the controlled web graphic to the same point in the machine cycle.
  • the controlled web 30 preferably comprises a continuous film material, preferably a breathable microporous polymer film, that is used as part of the diaper backsheet.
  • the controlled web 30 has preprinted objects 22, consecutively but not equidistantly printed thereupon at a particular controlled web pitch length, "Lpp".
  • Lpp is invariably something other (either longer or shorter) than both the product pitch length PP and the pitch length of the target web Ltp due to climatic conditions, thermally induced creep, and the like.
  • An exemplary Lpp is shown in Figure 2A.
  • preprinted objects 22 are registered graphics that are colorful, high resolution designs that are appealing to the consumer, who is typically a care-giver to the wearer of the diaper, or who in other cases may actually be the wearer.
  • corrections of pitch delta C, C2, etc. associated with the registration system of the present invention may not actually be necessary for product functionality; however, they are critically important for consumer acceptance of the diaper products produced. And, in some cases, children wearing a disposable article herein that has an improperly phased graphic, e.g., an animal with its head cut off, may be upset.
  • Figure 3 illustrates the instabilities in controlled web pitch length Lpp that typically arise due to the inherent thermal instability of the preferred microporous polymer films of the present invention. Such thermal instability leads to differential shrinkage of the microporous film, and significant variations in Lpp frequently result.
  • the position along a wound roll (i.e., a continuous, controlled web 30) of microporous polymer film that has been preprinted with registered graphics is represented on the X axis.
  • the start of the roll is indicated at the origin of the axes, while moving to the right along the X axis indicates moving toward the core of the roll, corresponding to unwinding the roll.
  • preprinted pitch length Lpp is represented in millimeters. As can be seen, differences in preprinted pitch lengths Lpp of up to about 10 mm may be seen between various locations on the same web of material.
  • the registration system of the present invention is thus designed to overcome the phasing problems associated with combining the target web 40 and the controlled web 30 where Ltp is not equal to Lpp, where Lpp is inherently variable, and where both webs are simultaneously and continuously fed to a combining operation.
  • the process has the ability to on-goingly adjust the pitch length of the controlled web 30 as delivered to match or to more closely approximate that of the target web 40.
  • the system of the present invention makes such correction in a gentle, non-abrupt and gradual fashion so as to account for the delicate nature of the web, which is preferably a microporous polymer film, without damaging it.
  • the system is capable of making more rapid and abrupt adjustments that would not be acceptable with the preferred microporous polymer films.
  • Changing the tension in a web causes a change in the pitch length of the web.
  • more tension stretches the material of controlled web 30, causing the pitch length Lpp to increase, while less tension relaxes the controlled web 30, causing the pitch length Lpp to decrease.
  • the absolute tension in the controlled web 30 should not approach zero tension, as control of the controlled web 30 would be lost. Conversely, more or less web may be metered to the process, which also changes the level of tension in the web.
  • the system of the present invention thus introduces small tension transients, which provides on-going correction.
  • This serves to maintain the integrity of the delicate, mechanically unstable polymer films that are useful for disposable absorbent articles herein. It also serves to correct the phase relationships of objects on the each incoming web in increments that are too small to be detected by the web handling process, which means that there is little possibility for the amount of error to become large enough to trigger the shutdown functions of the web handling process.
  • it allows for manufacture of consecutive products that may have insignificant differences in the locations of the graphic objects on each product.
  • control system prepares small transient corrections in a timely fashion that intervene in the control of incoming web handling drives to prevent mismatches between the positions of the target object and the preprinted object from drifting out of the zone that the consumer would find acceptable.
  • Exemplary control algorithms herein include manual control, a control algorithm based on statistical process control, or a PID control system.
  • a preferred embodiment herein is a PID control algorithm which controls the feed rate of the controlled web 30 only as necessary to minimize the strobed distance between a fixed position of converter machine time with user-set offset and the sensed mark. If the space between the sensed marks of the controlled web 30 ( Lpp), is longer than the target pitch length Ltp, more web 30 is fed to the process, reducing the web tension and allowing the space between graphics to contract.
  • a preferred embodiment herein uses a direct sensing approach to determine the position of the graphic on the incoming controlled web 30.
  • a sensor is selected which detects differences between light passing through the web via different printed colors. The color of the target web object, the position of the target web object relative to other objects of the same color, and the size of the target object combine to create the means for generating a clean signal whose position is strobed once per machine cycle.
  • Alternative means of establishing position of graphics include: 1 ) sensing a visible timing mark on a part of the web that is later removed by the process; 2) sensing a fluorescently-printed or other invisible-to-the-human eye mark; or 3) using a grid of sensors to look for a recognized pattern of light diffusion.
  • the PID control system shown in Figure 6 seeks to minimize the error distance which is observed once per product.
  • the proportional gain (Kp) 71 sends a correction signal to the controlled web feed drive that is proportional to the size of the error.
  • the integral gain factor (Ki) 74 is set to eliminate the steady state offset typical of purely proportional control. While a differential gain factor may also be used, it is believed that best results are obtained by setting this equal to zero. It is observed in Figure 6 that the error signal trims the operation of the feed drive which is typically running at "gear ratio" relative to rate of product production. Although speed and position may vary, on average one preprinted object must be processed per target product.
  • the registration system of the present invention preferably adjusts the pitch Lpp of the controlled web 30 by on-goingly adjusting the tension in the controlled web 30.
  • the Lpp is adjusted to "Lc", which is used herein to mean "length at combining.”
  • Lc is equal or approximately equal to Ltp, i.e., the pitch length of the controlled web 30 is made approximately equal to that of the target web 40 so that the preprinted object, preferably graphic 22, can be positioned in the correct phase relationship to the product.
  • This tension acts through the web modulus, Ew, of the controlled web 30, according to the following equation:
  • T controlled web tension
  • Ew web modulus of controlled web.
  • Ltp is equal to Lc.
  • Lc1/Lc2 (1 + T2/Ew2)/(1 + T1/Ew1).
  • the tension variables T as well as the modulus variables Ew each have a range of variation, so the ratio of the Lc values will always vary somewhat from unity.
  • the difference between the Lc ratio and unity is referred to herein as "puckering": .
  • Puckering% (Lc1/Lc2 - 1) x 100.
  • the puckering value can assume positive or negative values depending which web has the least relaxed length. After the finished product is cut apart, the combined web is pulled to the length of the incoming web with the least relaxed length. This causes the other web to "pucker.” Above a certain tolerance level, puckering has a noticeable impact on the appearance of the product. For a diaper backsheet formed from a nonwoven material and a polymer film preprinted with graphic designs, puckering levels up to about ⁇ 2%, while noticeable, are generally not perceived as distorting the appearance of the product.
  • puckering levels can intentionally be created, or puckering may otherwise be controlled to create materials with different tactile feels as desired. Note that even below ⁇ 2% that puckering can be controlled and located on the product according to the present invention to minimize its impact on product appearance. To do this, the laminated material furthest away from the consumer is overfed and pulled back, thus hiding the puckering from the consumer.
  • the present invention has the capability of registering controlled webs having pitch lengths that are not uniform, and which can be either longer or shorter than the machine product pitch length.
  • the ability to register materials with pitch lengths longer than the product under production allows the designer of such a product to tailor the surface texture of the product. This is demonstrated in Figures 4A and 4B, where two materials are laminated together by passing through a nip point. The material which is longer than the finished product pitch is pulled back by the other material. By making the layer of the laminate that is furthest away from the eye of the consumer the material that is pulled back, the impact of the registration process on the texture of the finished product is mitigated.
  • the pitch length of the nonwoven web 32 (Ltp) which may form a portion of the diaper backsheet is longer than the pitch length (Lpp) of the polymer film (controlled web) 30.
  • Ltp the pitch length of the nonwoven web 32
  • Lpp the pitch length of the polymer film
  • Figure 4B shows the surface texture impact of the pitch lengths (Lpp) of the polymer film (controlled web) 30 longer than the pitch length (Ltp) of the nonwoven material web 32.
  • the nonwoven material pulls back the polymer film material after the final cut.
  • the impact of the unequal combining is manifested on the inside of the product and is hidden from the eye of the consumer.
  • the nonwoven material 32 may be fed into the system as an independent web having phased objects with variable pitch length.
  • the nonwoven web and preferably the controlled web are phased as described herein, and combined; then the combination laminate material is phased and combined to the target web (diaper product web) as described herein.
  • the available adjustment rate for registered graphics is limited. It is important to design the registered printing such that a reasonable tolerance of graphic position is accommodated.
  • the graphic position tolerance should be greater than or equal to the web to web position shift typically seen at the time of web splicing; that is, at the time that a subsequent roll of preprinted web is supplied to the web combining process at the time that the previous roll is used up by the process.
  • the roll to roll error is different and generally greater that the normal variation within a single roll.
  • the splice tolerances of the present invention are controlled in concert with the tolerances of preprinted object position to reduce splice time rejected product to ideally zero (other than rejection of the splice tape itself).
  • the selection of the raw material to be used for the backsheet, i.e., the controlled web 30, is somewhat constrained by both the product design and the registration system of the present invention.
  • the key parameters that are unique to registered graphics are impacted by the needs of product functionality.
  • a preferred material is a breathable microporous polymer film.
  • a preferred microporous polymer film is formed from a mixture of polyethylene and calcium carbonate, and titanium dioxide if needed to increase the white appearance of the film, since whiteness is a film characteristic that is necessary for widespread consumer acceptance.
  • the microporous polymer film has high thermal stability characteristics in order to support the printing of high resolution color graphics thereon.
  • the film meets a maximum of ⁇ 1% repeat pitch variation, i.e., mismatch, but more typically ⁇ 2% is likely to be seen. It is believed that puckering ratios ranging from about 0.97 to about 1.015 may successfully be provided using this system, making it possible to handle films with an even wider range of pre-printed pitch length variation.
  • the process of combining the two webs 30 and 40 is schematically represented in Figure 5.
  • the controlled web 30 is initially fed at a velocity Vo.
  • the target web 40 is fed to the combining stage 50 at a velocity Vt.
  • Detection of the position of a preprinted object (e.g., graphic 22) moving in the machine direction MD occurs at preprinted object detection stage 34.
  • detection of a target object (e.g., diaper core 42) moving in the machine direction MD occurs at the product detection stage 44 or alternatively via an optic/resolver 50a (automatically) or an operator (manually).
  • pitch mismatch must be corrected.
  • this pitch delta C accumulates as the number of products accumulates.
  • the pitch delta is about C
  • the pitch delta is about C2
  • the pitch delta is about C3 and so on.
  • Phase error may be caused when a transient change occurs in the controlled web 30 via a control web splice or some phase upset in the position of the preprinted object 22 in relationship to the target object 42.
  • error signal 70 is generated based upon recording of position of incoming timing mark by resolver strobe.
  • This error signal is transformed into a correction signal via a PID algorithm.
  • integral gain is used to attenuate steady state error, and differential gain is preferably set at zero.
  • This correction signal forces a programmable drive or differential correction shaft to speed up or slow down the axis driving the controlled web 30 at a metering point 30b.
  • Vo is adjusted to Vc (see Figure 5) by gain factors 71 and 74, see Figure 6, to maintain the position of the preprinted object graphic 22 and the target object core 42, by changing flow rate of the controlled web 30.
  • the main reference signal is provided by the resolver 50a and is referred to as the converter position reference signal 62.
  • the converter position reference signal 62 is the resolver change in position over time, i.e., a velocity reference signal (preferably one revolution of the resolver per target object 42). This signal 62 is equal to the pitch length of the product times the converter rate.
  • the registration control system 60 provides a trim correction factor, which is typically a small percentage of the servo velocity reference signal 76, to the converter position reference signal 62, based on the pitch mismatch and phase correction described above, by automatically calculating an error signal 70 and adjusting the servo system velocity via the velocity loop 78, to change the flow rate of the control web 30.
  • phase correction aspect of the control dilemma i.e., the process control issue
  • initial setup of the registration system 60 online requires phase correction.
  • the position of the preprinted object 22 assumes an arbitrary but controlled position relative to that of the target object 42. This arbitrary position may be out of phase, requiring the operator to change the fixed target position constant 44 to initially set the preprinted object 22 to the target object 42 (from this time on no additional manual intervention is needed).
  • Proportional gain 71 is needed to drive the system 60 to new setpoint, target constant 44.
  • the error signal 70 is multiplied by a proportional gain factor 71 and then added to a converter position reference 50a to generate a base reference signal 75.
  • Proportional gain 71 is needed to drive the system to the setpoint target constant 44.
  • Disposable diaper products typically include a topsheet material, an absorbent core, and a backsheet material.
  • the topsheet material is located to be placed facing the body or nearest the body when the diaper is worn and is generally provided with a liquid permeable region so that body exudates can flow through the topsheet to the absorbent core, where they are contained.
  • the backsheet material which is placed away from the body during wear, is typically liquid impermeable so that outer clothing or other articles such as bedsheets are not wetted by the body exudates.
  • Such an exemplary diaper is disclosed in, for example, Buell U.S. patent 5,569,234, directed to a "Disposable Pull-on Pant".
  • topsheet In addition to the basic topsheet, core, and backsheet components, it will be understood by those of skill in the art that many other features for disposable absorbent articles are within the scope of the present invention.
  • barrier cuffs as described in Lawson and Dragoo U.S. patents 4,695,278 and 4,795,454 are a desirable feature for disposable absorbent articles.
  • skin care-type topsheets that are provided with lotion thereon for the purpose of reducing skin irritation and chafing are a desirable feature herein.
  • pull-on diaper 150 which is generally pulled onto the body of the wearer by inserting the legs into the leg openings 162 and pulling the article up over the waist.
  • pull-on diaper refers to pull-on garments worn by small children and other incontinent individuals to absorb and contain body exudates. It should be understood that other pull-on garments such as training pants, incontinent briefs, feminine briefs, feminine hygiene garments or panties, and like, are included herein.
  • the diaper 150 is generally comprised of a backsheet 152, a topsheet 154 and an absorbent layer 156 (shown in dashed lines in Figure 8) located between the backsheet 152 and the topsheet 154.
  • the backsheet 154 is the surface which faces away from the wearer's body, while the topsheet 152 is the surface which faces toward the wearer's body.
  • the backsheet 152 is comprised of at least a microporous polymer film printed with registered graphics, e.g., 120, 122, as described herein.
  • the backsheet 152 may further comprise a layer of nonwoven material (see reference numeral 32, Figs.
  • the nonwoven web may be fed to the web handling process as a continuous incoming web and may be combined in a desired relationship with the controlled web 30 and the the target web 40.
  • a laminated nonwoven backsheet it is desirable that the surface texture of the non-woven not be impacted by a laminated sublayer, e.g. a microporous polymer film sublayer, which pulls it back and causes it to "pucker.” It is more desirable that any puckering that is required for the operation of a registration system be limited to the underlying polymer material, which is neither seen nor felt by the user of the product, see Figure 4B.
  • the system of the present invention can be used in cases where the pitch length Lpp of the microporous film web (controlled web 30) may be longer or shorter than that of the product, Ltp. Overfeeding the target web may lead to superior surface tenure.
  • Lpp is less than Ltp
  • the film material pulls back the nonwoven material that forms part of the product. This creates a roughened texture of the exposed surface of the laminates where the consumer can see and feel.
  • Lpp is greater than Ltp
  • Lc should be greater than both Lpp and Ltp, to avoid the possibility of a zero-tension situation.
  • Elastically extensible side panels 156 are provided to ensure more comfortable and contouring fit by initially conformably fitting the pull-on diaper 150 to the wearer and sustaining this fit throughout the time of wear well past when it has been loaded with exudates.
  • Leg elastics 158 and waist elastic region 160 are also provided to enhance the fit around the legs and waist, respectively.
  • Figure 7 shows the front view of the diaper 150 with an exemplary graphic 120 positioned in about the upper region of the backsheet, on the front side of the diaper 150.
  • Figure 8 there is shown a simplified plan view of an embodiment of a disposable absorbent article in its flat, uncontracted state prior to formation.
  • graphic 120 is shown in the back region of the diaper with graphics 122 additionally shown in the front region of the diaper.

Landscapes

  • Health & Medical Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Vascular Medicine (AREA)
  • Epidemiology (AREA)
  • Biomedical Technology (AREA)
  • Heart & Thoracic Surgery (AREA)
  • Manufacturing & Machinery (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Animal Behavior & Ethology (AREA)
  • General Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Veterinary Medicine (AREA)
  • Absorbent Articles And Supports Therefor (AREA)
  • Orthopedics, Nursing, And Contraception (AREA)
  • Controlling Rewinding, Feeding, Winding, Or Abnormalities Of Webs (AREA)

Abstract

L'invention porte sur un système de repérage pour échelonner des bandes de matériau (30, 40) avançant simultanément et présentant des longueurs de pas variables. Ce système comprend un dispositif acheminant, à une première vitesse (V),une bande (40) cible continue contenant des objets (42) cibles espacés le long d'une voie, la bande cible ayant une longueur de pas (L+P) entre des objets cibles consécutifs; un dispositif acheminant le long d'une voie, à une seconde vitesse (Vc), une bande de matériau (30) réglée, continue, comportant des objets (22) préimprimés espacés, consécutifs, la bande préimprimée ayant une longueur (Lpp) de pas régulée entre des objets préimprimés consécutifs; un dispositif de réglage de la longueur du pas de la bande cible de sorte que cette longueur de pas soit approximativement égale à la longueur du pas de la bande cible; un détecteur (34) permettant de détecter une caractéristique présélectionnée de la bande régulée; un dispositif générant un signal d'erreur en fonction de la détection de la caractéristique présélectionnée de la bande régulée; et un dispositif de réglage de la seconde vitesse de sorte que les objets préimprimés soient décalés vers les objets cibles de la bande cible.
PCT/US1998/027135 1997-12-19 1998-12-19 Systeme de reperage pour echelonner des bandes de materiau avançant simultanement et a longueurs de pas variables Ceased WO1999032385A1 (fr)

Priority Applications (9)

Application Number Priority Date Filing Date Title
AU20884/99A AU2088499A (en) 1997-12-19 1998-12-19 Registration system for phasing simultaneously advancing webs of material havingvariable pitch lengths
KR1020007006770A KR20010024771A (ko) 1997-12-19 1998-12-19 레지스터 시스템 및 일회용 흡수성 제품
JP2000525328A JP2003522084A (ja) 1997-12-19 1998-12-19 可変のピッチ長を有する材料の同時に進行するウェッブの位相合わせのための位置合わせシステム
CA002318999A CA2318999A1 (fr) 1997-12-19 1998-12-19 Systeme de reperage pour echelonner des bandes de materiau avancant simultanement et a longueurs de pas variables
EP98965416A EP1040063A1 (fr) 1997-12-19 1998-12-19 Systeme de reperage pour echelonner des bandes de materiau avan ant simultanement et a longueurs de pas variables
US09/495,651 US6444064B1 (en) 1997-12-19 2000-02-01 Registration system for phasing simultaneously advancing webs of material having variable pitch lengths
US10/158,669 US6743314B2 (en) 1997-12-19 2002-05-30 Registration system for phasing simultaneously advancing webs of material having variable pitch lengths
US10/161,360 US6764563B2 (en) 1997-12-19 2002-06-03 Registration system for phasing simultaneously advancing webs of material having variable pitch lengths
US10/324,368 US6955733B2 (en) 1997-12-19 2002-12-20 Method and system for registering pre-produced webs with variable pitch length

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
USPCT/US97/23620 1997-12-19
PCT/US1997/023620 WO1999032384A1 (fr) 1997-12-19 1997-12-19 Systeme d'enregistrement pour l'avance simultanee, en phase, de feuilles de materiaux a longueurs de pas variables

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1997/023620 Continuation-In-Part WO1999032384A1 (fr) 1997-12-19 1997-12-19 Systeme d'enregistrement pour l'avance simultanee, en phase, de feuilles de materiaux a longueurs de pas variables

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US09/495,651 Continuation-In-Part US6444064B1 (en) 1997-12-19 2000-02-01 Registration system for phasing simultaneously advancing webs of material having variable pitch lengths

Publications (1)

Publication Number Publication Date
WO1999032385A1 true WO1999032385A1 (fr) 1999-07-01

Family

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Family Applications (2)

Application Number Title Priority Date Filing Date
PCT/US1997/023620 Ceased WO1999032384A1 (fr) 1997-12-19 1997-12-19 Systeme d'enregistrement pour l'avance simultanee, en phase, de feuilles de materiaux a longueurs de pas variables
PCT/US1998/027135 Ceased WO1999032385A1 (fr) 1997-12-19 1998-12-19 Systeme de reperage pour echelonner des bandes de materiau avançant simultanement et a longueurs de pas variables

Family Applications Before (1)

Application Number Title Priority Date Filing Date
PCT/US1997/023620 Ceased WO1999032384A1 (fr) 1997-12-19 1997-12-19 Systeme d'enregistrement pour l'avance simultanee, en phase, de feuilles de materiaux a longueurs de pas variables

Country Status (7)

Country Link
EP (1) EP1040063A1 (fr)
JP (1) JP2003522084A (fr)
KR (1) KR20010024771A (fr)
AU (2) AU5803898A (fr)
CA (1) CA2318999A1 (fr)
WO (2) WO1999032384A1 (fr)
ZA (1) ZA9811676B (fr)

Cited By (23)

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US7153561B2 (en) 2003-07-11 2006-12-26 Kimberly-Clark Wordwide, Inc. Absorbent article with graphic design thereon
EP2036522A1 (fr) * 2007-07-20 2009-03-18 Joa, Curt G., Inc. Appareil et procédé pour minimiser les déchets et améliorer la qualité et la production des opérations de traitement sur Internet
US7851666B2 (en) * 2002-06-07 2010-12-14 Kimberly-Clark Worldwide, Inc. Components of articles including contrasting printed blocks
US7919668B2 (en) 2002-06-07 2011-04-05 Kimberly-Clark Worldwide, Inc. Components of articles including continuous detector materials
US8168254B2 (en) 2006-04-27 2012-05-01 Sca Hygiene Products Ab Method and arrangement for synchronized positioning of at least one essentially continuous material web based on a virtual master function
EP1532499B2 (fr) † 2002-08-07 2015-01-07 Kimberly-Clark Worldwide, Inc. Procede pour le guidage de bande
US9089453B2 (en) 2009-12-30 2015-07-28 Curt G. Joa, Inc. Method for producing absorbent article with stretch film side panel and application of intermittent discrete components of an absorbent article
US9283683B2 (en) 2013-07-24 2016-03-15 Curt G. Joa, Inc. Ventilated vacuum commutation structures
US9289329B1 (en) 2013-12-05 2016-03-22 Curt G. Joa, Inc. Method for producing pant type diapers
US9387131B2 (en) 2007-07-20 2016-07-12 Curt G. Joa, Inc. Apparatus and method for minimizing waste and improving quality and production in web processing operations by automated threading and re-threading of web materials
US9433538B2 (en) 2006-05-18 2016-09-06 Curt G. Joa, Inc. Methods and apparatus for application of nested zero waste ear to traveling web and formation of articles using a dual cut slip unit
US9550306B2 (en) 2007-02-21 2017-01-24 Curt G. Joa, Inc. Single transfer insert placement and apparatus with cross-direction insert placement control
US9566193B2 (en) 2011-02-25 2017-02-14 Curt G. Joa, Inc. Methods and apparatus for forming disposable products at high speeds with small machine footprint
US9603752B2 (en) 2010-08-05 2017-03-28 Curt G. Joa, Inc. Apparatus and method for minimizing waste and improving quality and production in web processing operations by automatic cuff defect correction
US9622918B2 (en) 2006-05-18 2017-04-18 Curt G. Joe, Inc. Methods and apparatus for application of nested zero waste ear to traveling web
WO2017083455A1 (fr) * 2015-11-11 2017-05-18 The Procter & Gamble Company Procédés et appareils d'alignement de substrat dans des chaînes de transformation d'article absorbant
US9809414B2 (en) 2012-04-24 2017-11-07 Curt G. Joa, Inc. Elastic break brake apparatus and method for minimizing broken elastic rethreading
US9944487B2 (en) 2007-02-21 2018-04-17 Curt G. Joa, Inc. Single transfer insert placement method and apparatus
US10167156B2 (en) 2015-07-24 2019-01-01 Curt G. Joa, Inc. Vacuum commutation apparatus and methods
EP3437597A4 (fr) * 2016-03-28 2019-04-24 Unicharm Corporation Procédé de fabrication et dispositif de fabrication d'un emballage pour article absorbant
US10456302B2 (en) 2006-05-18 2019-10-29 Curt G. Joa, Inc. Methods and apparatus for application of nested zero waste ear to traveling web
US10751220B2 (en) 2012-02-20 2020-08-25 Curt G. Joa, Inc. Method of forming bonds between discrete components of disposable articles
US11737930B2 (en) 2020-02-27 2023-08-29 Curt G. Joa, Inc. Configurable single transfer insert placement method and apparatus

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* Cited by examiner, † Cited by third party
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US6352528B1 (en) 1999-11-22 2002-03-05 Kimberly-Clark Worldwide, Inc. Absorbent articles including hidden graphics
JP3351763B2 (ja) † 1999-07-19 2002-12-03 花王株式会社 吸収性物品の製造方法
JP3735586B2 (ja) 2002-05-30 2006-01-18 ユニ・チャーム株式会社 表示要素形成方法
JP3732459B2 (ja) 2002-05-30 2006-01-05 ユニ・チャーム株式会社 表示要素形成方法
US8157776B2 (en) 2006-04-27 2012-04-17 Sca Hygiene Products Ab Method and arrangement for detection of a synchronizing mark being used in synchronized positioning of at least one essentially continuous material web
RU2421390C2 (ru) * 2006-04-27 2011-06-20 Ска Хайджин Продактс Аб Способ и устройство для синхронизированного позиционирования, по меньшей мере, одного, по существу, непрерывного полотна материала
JP4841416B2 (ja) * 2006-12-13 2011-12-21 花王株式会社 搬送ウエブの位置制御方法

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WO1998021135A1 (fr) * 1996-11-13 1998-05-22 Kimberly-Clark Worldwide, Inc. Procede et appareil d'alignement pour couches elastifiees continuellement en mouvement, faites d'elements multiples

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WO1988003089A1 (fr) * 1986-10-27 1988-05-05 Adolph Coors Company Procede et dispositif de production de materiaux composites stratifies
WO1997024094A1 (fr) * 1995-12-29 1997-07-10 Kimberly-Clark Worldwide, Inc. Article absorbant a jeter presentant un dessin repere, et son procede de fabrication
WO1997024283A1 (fr) * 1995-12-29 1997-07-10 Kimberly-Clark Worldwide, Inc. Appareil reglant la mise en concordance de deux couches continuellement mobiles d'un materiau, et article fabrique avec
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WO1998021134A1 (fr) * 1996-11-13 1998-05-22 Kimberly-Clark Worldwide, Inc. Procede et appareil pour l'alignement de couches etirables continuellement en mouvement
WO1998021137A1 (fr) * 1996-11-13 1998-05-22 Kimberly-Clark Worldwide, Inc. Procede et dispositif de calage, par rapport a une autre couche, d'une couche apte au traitement et en mouvement continu
WO1998021135A1 (fr) * 1996-11-13 1998-05-22 Kimberly-Clark Worldwide, Inc. Procede et appareil d'alignement pour couches elastifiees continuellement en mouvement, faites d'elements multiples

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7851666B2 (en) * 2002-06-07 2010-12-14 Kimberly-Clark Worldwide, Inc. Components of articles including contrasting printed blocks
US7919668B2 (en) 2002-06-07 2011-04-05 Kimberly-Clark Worldwide, Inc. Components of articles including continuous detector materials
EP1532499B2 (fr) † 2002-08-07 2015-01-07 Kimberly-Clark Worldwide, Inc. Procede pour le guidage de bande
US7153561B2 (en) 2003-07-11 2006-12-26 Kimberly-Clark Wordwide, Inc. Absorbent article with graphic design thereon
US8168254B2 (en) 2006-04-27 2012-05-01 Sca Hygiene Products Ab Method and arrangement for synchronized positioning of at least one essentially continuous material web based on a virtual master function
US9433538B2 (en) 2006-05-18 2016-09-06 Curt G. Joa, Inc. Methods and apparatus for application of nested zero waste ear to traveling web and formation of articles using a dual cut slip unit
US9622918B2 (en) 2006-05-18 2017-04-18 Curt G. Joe, Inc. Methods and apparatus for application of nested zero waste ear to traveling web
US10456302B2 (en) 2006-05-18 2019-10-29 Curt G. Joa, Inc. Methods and apparatus for application of nested zero waste ear to traveling web
US9950439B2 (en) 2007-02-21 2018-04-24 Curt G. Joa, Inc. Single transfer insert placement method and apparatus with cross-direction insert placement control
US9944487B2 (en) 2007-02-21 2018-04-17 Curt G. Joa, Inc. Single transfer insert placement method and apparatus
US10266362B2 (en) 2007-02-21 2019-04-23 Curt G. Joa, Inc. Single transfer insert placement method and apparatus
US9550306B2 (en) 2007-02-21 2017-01-24 Curt G. Joa, Inc. Single transfer insert placement and apparatus with cross-direction insert placement control
US9387131B2 (en) 2007-07-20 2016-07-12 Curt G. Joa, Inc. Apparatus and method for minimizing waste and improving quality and production in web processing operations by automated threading and re-threading of web materials
EP2036522A1 (fr) * 2007-07-20 2009-03-18 Joa, Curt G., Inc. Appareil et procédé pour minimiser les déchets et améliorer la qualité et la production des opérations de traitement sur Internet
US10702428B2 (en) 2009-04-06 2020-07-07 Curt G. Joa, Inc. Methods and apparatus for application of nested zero waste ear to traveling web
US9089453B2 (en) 2009-12-30 2015-07-28 Curt G. Joa, Inc. Method for producing absorbent article with stretch film side panel and application of intermittent discrete components of an absorbent article
US9603752B2 (en) 2010-08-05 2017-03-28 Curt G. Joa, Inc. Apparatus and method for minimizing waste and improving quality and production in web processing operations by automatic cuff defect correction
USRE48182E1 (en) 2010-08-05 2020-09-01 Curt G. Joa, Inc. Apparatus and method for minimizing waste and improving quality and production in web processing operations by automatic cuff defect correction
US9907706B2 (en) 2011-02-25 2018-03-06 Curt G. Joa, Inc. Methods and apparatus for forming disposable products at high speeds with small machine footprint
US9566193B2 (en) 2011-02-25 2017-02-14 Curt G. Joa, Inc. Methods and apparatus for forming disposable products at high speeds with small machine footprint
US10751220B2 (en) 2012-02-20 2020-08-25 Curt G. Joa, Inc. Method of forming bonds between discrete components of disposable articles
US9809414B2 (en) 2012-04-24 2017-11-07 Curt G. Joa, Inc. Elastic break brake apparatus and method for minimizing broken elastic rethreading
US9908739B2 (en) 2012-04-24 2018-03-06 Curt G. Joa, Inc. Apparatus and method for applying parallel flared elastics to disposable products and disposable products containing parallel flared elastics
US11034543B2 (en) 2012-04-24 2021-06-15 Curt G. Joa, Inc. Apparatus and method for applying parallel flared elastics to disposable products and disposable products containing parallel flared elastics
US9283683B2 (en) 2013-07-24 2016-03-15 Curt G. Joa, Inc. Ventilated vacuum commutation structures
US9289329B1 (en) 2013-12-05 2016-03-22 Curt G. Joa, Inc. Method for producing pant type diapers
US10167156B2 (en) 2015-07-24 2019-01-01 Curt G. Joa, Inc. Vacuum commutation apparatus and methods
US10494216B2 (en) 2015-07-24 2019-12-03 Curt G. Joa, Inc. Vacuum communication apparatus and methods
US10633207B2 (en) 2015-07-24 2020-04-28 Curt G. Joa, Inc. Vacuum commutation apparatus and methods
WO2017083455A1 (fr) * 2015-11-11 2017-05-18 The Procter & Gamble Company Procédés et appareils d'alignement de substrat dans des chaînes de transformation d'article absorbant
EP3437597A4 (fr) * 2016-03-28 2019-04-24 Unicharm Corporation Procédé de fabrication et dispositif de fabrication d'un emballage pour article absorbant
US11737930B2 (en) 2020-02-27 2023-08-29 Curt G. Joa, Inc. Configurable single transfer insert placement method and apparatus

Also Published As

Publication number Publication date
EP1040063A1 (fr) 2000-10-04
AU5803898A (en) 1999-07-12
JP2003522084A (ja) 2003-07-22
KR20010024771A (ko) 2001-03-26
WO1999032384A1 (fr) 1999-07-01
AU2088499A (en) 1999-07-12
CA2318999A1 (fr) 1999-07-01
ZA9811676B (en) 2000-06-28

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