Method and apparatus for changing the orientation of an absorbent article

The methods and apparatuses disclosed herein operate to change the orientation of an absorbent article. The apparatus includes a transfer apparatus having a frame that is rotatable about a first axis of rotation and a transfer member that is rotatable about a second axis of rotation. The method includes advancing an absorbent article in a machine direction. The absorbent article is defined by a longitudinal centerline intersected by a lateral centerline at a center. The method includes rotating the absorbent article from a first orientation where the longitudinal centerline extends in a cross direction to a second orientation where the longitudinal centerline extends in the machine direction. The method includes shifting the absorbent article such that the center of the absorbent article shifts from a first cross-directional position to a second cross-directional position. The steps of rotating the absorbent article and shifting the absorbent article may occur concurrently.

FIELD OF THE INVENTION

The present disclosure relates to methods and apparatuses for manufacturing absorbent articles, and more particularly, to methods and apparatuses for changing the orientation of an absorbent article.

BACKGROUND OF THE INVENTION

Along an assembly line, various types of articles, such as diapers and other absorbent articles, may be assembled by adding components to and/or otherwise modifying an advancing, continuous web of material. In some processes, advancing webs of material are combined with other advancing webs of material. In other processes, individual components created from advancing webs of material are combined with advancing webs of material, which in turn, are then combined with other advancing webs of material. In some cases, individual components created from advancing web or webs are combined with other individual components created from other advancing web or webs. Webs of material and component parts used to manufacture diapers may include: backsheets, topsheets, leg cuffs, waist bands, absorbent core components, front and/or back ears, fastening components, and various types of elastic webs and components such as leg elastics, barrier leg cuff elastics, stretch side panels, and waist elastics. Once the desired component parts are assembled, the advancing webs and component parts are subjected to a final knife cut to separate the webs into discrete diapers or other absorbent articles.

With reference toFIG. 1A, in some converting processes, discrete chassis14spaced apart from each other are advanced in a machine direction MD and are arranged with a longitudinal centerline16parallel with the cross direction CD. The discrete chassis14may be positioned such that a lateral centerline18of the chassis14is aligned with a machine direction centerline MDC. Opposing waist regions of the discrete chassis14may be joined with continuous lengths of elastically extendable front and back waistband webs advancing in the machine direction. While connected with the chassis14, the front and back waistband webs may be maintained in a fully stretched condition along the machine direction MD, forming a continuous length of absorbent articles. The continuous length of absorbent articles may then be folded in a cross direction CD. During the folding process in some converting configurations, one of the front and back waistband webs is folded 180° into a facing relationship with the opposing waistband. The continuous length of absorbent articles may be cut into discrete absorbent articles10, such as shown inFIG. 1A, and advanced to a packaging operation.

As a result of folding the absorbent articles10180° in the cross direction CD, in some converting configurations, a center12of the folded, discrete absorbent article10is offset from the machine direction centerline MDC as shown inFIG. 1B. In some processes, it may be necessary to rotate the folded, discrete absorbent article10in order to change the orientation of the discrete absorbent article10for downstream processing, such as packaging. However, some processes for rotating a discrete absorbent article10are configured to rotate the discrete absorbent article10about the center12of the discrete absorbent article10as shown inFIGS. 1B-1D. As a result, the center12of the folded discrete absorbent article10may be offset from the machine direction centerline MDC as shown inFIG. 1D. Consequently, it may be necessary to position downstream equipment off center from the machine direction centerline MDC in order to advance the folded discrete absorbent articles10along a centerline of the downstream equipment. However, due to size and space constraints in some converting operations, it may not be feasible to position equipment away from the machine direction centerline MDC.

Therefore, it would be beneficial to provide a process and apparatus for rotating and shifting a discrete absorbent article such that the discrete absorbent article is aligned with a machine direction centerline.

SUMMARY OF THE INVENTION

In some aspects, the present disclosure includes a method for changing the orientation of an absorbent article. The absorbent article defines a longitudinal centerline that intersects a lateral centerline at a center of the absorbent article. The method comprises the steps of: advancing the absorbent article in a first direction, wherein the absorbent article is oriented such that the longitudinal centerline extends in a second direction that is different from the first direction; rotating the absorbent article about an axis of rotation such that the longitudinal centerline extends in the first direction, wherein the axis of rotation is offset from the center of the absorbent article; and shifting the absorbent article such that the center of the absorbent article shifts in the second direction.

In some aspects, the present disclosure includes an apparatus for changing the orientation of an absorbent article. The apparatus comprises a frame defining a first axis of rotation, wherein the frame is configured to rotate about the first axis of rotation. The apparatus comprises a transfer member rotatably connected with the frame, wherein the transfer member defines a second axis of rotation. The transfer member is configured to rotate about the second axis of rotation. The first axis of rotation is orthogonal to the second axis of rotation. The transfer member comprises a receiving surface located on an end of the transfer member most distal from the first axis of rotation. The receiving surface is defined by a first centerline and a second centerline that intersect at a center, wherein the center of the receiving surface is offset from the second axis of rotation. The transfer member is selectively rotatable from a first position to a second position. In the first position, the first centerline extends in a first direction and the second centerline extends in a second direction that is orthogonal to the first direction. In the second position, the first centerline extends in the second direction and the second centerline extends in the first direction.

DETAILED DESCRIPTION OF THE INVENTION

The following definitions may be useful in understanding the present disclosure:

“Absorbent article” is used herein to refer to consumer products whose primary function is to absorb and retain soils and wastes. “Diaper” is used herein to refer to an absorbent article generally worn by infants and incontinent persons about the lower torso. The term “disposable” is used herein to describe absorbent articles which generally are not intended to be laundered or otherwise restored or reused as an absorbent article (for example, 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).

“Joined” is used herein to encompass configurations whereby an element is directly secured to another element by affixing the element directly to the other element, and configurations whereby an element is indirectly secured to another element by affixing the element to intermediate member(s) which in turn are affixed to the other element.

“Longitudinal” means a direction running substantially perpendicular from a waist edge to a longitudinally opposing waist edge of an absorbent article when the article is in a flat out, uncontracted state, or from a waist edge to the bottom of the crotch, i.e. the fold line, in a bi-folded article. Directions within 45 degrees of the longitudinal direction are considered to be “longitudinal.” “Lateral” refers to a direction running from a longitudinally extending side edge to a laterally opposing longitudinally extending side edge of an article and generally at a right angle to the longitudinal direction. Directions within 45 degrees of the lateral direction are considered to be “lateral.”

“Substrate” is used herein to describe a material which is primarily two-dimensional (i.e. in an XY plane) and whose thickness (in a Z direction) is relatively small (i.e. 1/10 or less) in comparison to the substrate's length (in an X direction) and width (in a Y direction). Non-limiting examples of substrates include a web, layer or layers or fibrous materials, nonwovens, films and foils such as polymeric films or metallic foils. These materials may be used alone or may comprise two or more layers joined together. As such, a web is a substrate.

“Nonwoven” refers herein to a material made from continuous (long) filaments (fibers) and/or discontinuous (short) filaments (fibers) by processes such as spunbonding, meltblowing, carding, and the like. Nonwovens do not have a woven or knitted filament pattern.

“Machine direction” (MD) is used herein to refer to the direction of material flow through a process. In addition, relative placement and movement of material can be described as flowing in the machine direction through a process from upstream in the process to downstream in the process.

“Cross direction” (CD) is used herein to refer to a direction that is not parallel with, and usually perpendicular to, the machine direction.

“Pant” (also referred to as “training pant”, “pre-closed diaper”, “diaper pant”, “pant diaper”, and “pull-on diaper”) refers herein to disposable absorbent articles having a continuous perimeter waist opening and continuous perimeter leg openings designed for infant or adult wearers. A pant can 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 can be preformed by various techniques including, but not limited to, joining together portions of the article using any refastenable and/or permanent closure member (for example, seams, heat bonds, pressure welds, adhesives, cohesive bonds, mechanical fasteners, etc.). A pant can be preformed anywhere along the circumference of the article in the waist region (for example, side fastened or seamed, front waist fastened or seamed, rear waist fastened or seamed).

“Pre-fastened” refers herein to pant diapers manufactured and provided to consumers in a configuration wherein the front waist region and the back waist region are fastened or connected to each other as packaged, prior to being applied to the wearer. As such pant diapers may have a continuous perimeter waist opening and continuous perimeter leg openings designed for infant or adult wearers. As discussed in more detail below, a diaper pant can be preformed by various techniques including, but not limited to, joining together portions of the diaper using refastenable and/or permanent closure members (for example, seams, heat bonds, pressure welds, adhesives, cohesive bonds, mechanical fasteners, etc.). In addition, pant diapers can be preformed anywhere along the circumference of the waist region (for example, side fastened or connected, front waist fastened or connected, rear waist fastened or connected).

The present disclosure relates to methods and apparatuses for changing the orientation of discrete absorbent articles advancing in a machine direction. The methods and apparatuses discussed herein operate to transfer the folded discrete article from a first carrier apparatus to a second carrier apparatus. The folded discrete article may advance in a first orientation on the first carrier apparatus and may be rotated and shifted to a second orientation and advanced onto the second carrier apparatus using the transfer methods and apparatuses disclosed herein. The folded discrete articles may be defined by a longitudinal centerline and a folded, lateral centerline that intersect at a center of the folded discrete article. In the first orientation, the longitudinal centerline of the folded discrete article may extend in a cross direction and the center may be located at a first cross-directional position. The transfer apparatus operates to rotate and shift the discrete article to the second orientation where the longitudinal centerline of the discrete article extends in the machine direction and the center of the folded discrete article shifts to a second cross-directional position that is different from the first cross-directional position.

The transfer apparatus may include a frame and a plurality of transfer members rotatably connected with the frame. The frame may be configured to rotate about a first axis of rotation and each transfer member may be configured to rotate about a second axis of rotation. The first axis of rotation may extend in a first direction and the second axis of rotation may extend in a second direction that is different from the first direction. A discrete article may advance in the machine direction onto a transfer member of the transfer apparatus. Concurrently, the frame may rotate about the first axis of rotation. As the discrete article advances onto the transfer member, the transfer member may be arranged in a first position and the discrete article may be arranged in a first orientation. The second axis of rotation may be offset from the center of the discrete article. The transfer member rotates the discrete article about the second axis of rotation while the frame continues rotating about the first axis of rotation. As the transfer member rotates about the second axis of rotation, the center of the discrete article shifts in the cross direction. As a result, the transfer member rotates to a second position and the discrete absorbent article shifts to a second orientation. At the second orientation, the longitudinal centerline of the discrete article may extend in the machine direction and the center of the discrete article shifts from a first cross-directional position to a second cross-directional position. However, it is to be appreciated that the discrete absorbent article may be arranged in various configurations at the second orientation depending upon the desired orientation for downstream processing.

While the present disclosure relates to discrete absorbent articles that have been folded about a fold axis that is aligned with a machine direction centerline, it is to be appreciated that the methods and apparatuses described herein may be used to change the orientation of various discrete articles arranged in various configurations. For example, the discrete article may include a fully assembled absorbent article, or the discrete article may include one or more components of an absorbent article. In some exemplary configurations, the discrete article may include a discrete chassis having a topsheet, backsheet, and an absorbent core. The discrete article may be folded, or may be configured in a flat, contracted or uncontracted state. The transfer apparatus may be used to rotate and shift a discrete article in various configurations and orientations.

The processes and apparatuses discussed herein may be used to rotate and shift various types of discrete articles, some of which may be used in the manufacture of different types of absorbent articles. To help provide additional context to the subsequent discussion, the following provides a general description of absorbent articles in the form of diaper pants that may be rotated and shifted in accordance with the methods and apparatuses disclosed herein. While the present disclosure relates to diaper pants, it is to be appreciated that the methods and apparatuses disclosed herein may be used in the manufacture of various types of absorbent articles.

FIGS. 2 and 3Ashow examples of an absorbent article100in the form of a diaper pant101that may be assembled and folded in accordance with the apparatuses and methods disclosed herein. In particular,FIG. 2shows a perspective view of a diaper pant101in a pre-fastened configuration andFIG. 3Ashows a plan view of the diaper pant101with the portion of the diaper that faces away from a wearer oriented toward the viewer. The diaper pant101shown inFIGS. 2 and 3Aincludes a chassis102and a ring-like elastic belt104. As discussed below in more detail, a first elastic belt106and a second elastic belt108are connected together to form the ring-like elastic belt104.

With continued reference toFIG. 3A, the chassis102includes a first waist region116, a second waist region118, and a crotch region120disposed intermediate the first and second waist regions. The first waist region116may be configured as a front waist region, and the second waist region118may be configured as back waist region. In some embodiments, the length of each of the front waist region116, back waist region118, and crotch region120may be one-third of the length of the absorbent article100. The diaper pant101may also include a laterally extending front waist edge121in the front waist region116and a longitudinally opposing and laterally extending back waist edge122in the back waist region118. To provide a frame of reference for the present discussion, the diaper pant101ofFIG. 3Ais shown with a longitudinal centerline124and a lateral centerline126that intersect at a center166of the extended diaper pant101. The longitudinal centerline124longitudinally bisects the diaper pant101such that the longitudinal centerline124is equidistant from the chassis side edges128and130. The lateral centerline126laterally bisects the diaper pant101such that the lateral centerline126is equidistant from the front and back waist edges121and122. The center166of the extended diaper pant101defines a machine direction centerline MDC.

As shown inFIGS. 2 and 3A, the diaper pant101may include an inner, wearer facing surface132, and an outer, garment facing surface134. The chassis102may include a backsheet136and a topsheet138. The chassis102may also include an absorbent assembly140, including an absorbent core142, disposed between a portion of the topsheet138and the backsheet136. As discussed in more detail below, the absorbent article100may also include other features, such as leg elastics and/or leg cuffs to enhance the fit around the legs of the wearer.

As shown inFIG. 3A, the periphery of the chassis102may be defined by the first longitudinal side edge128, a second longitudinal side edge130, a first laterally extending end edge144disposed in the first waist region116, and a second laterally extending end edge146disposed in the second waist region118. Both side edges128and130extend longitudinally between the first end edge144and the second end edge146. As shown inFIG. 3A, the laterally extending end edges144and146are located longitudinally inward from the laterally extending front waist edge121in the front waist region116and the laterally extending back waist edge122in the back waist region118. When the diaper pant101is worn on the lower torso of a wearer, the front waist edge121and the back waist edge122of the chassis102may encircle a portion of the waist of the wearer. At the same time, the chassis side edges128and130may encircle at least a portion of the legs of the wearer. And the crotch region120may be generally positioned between the legs of the wearer with the absorbent core142extending from the front waist region116through the crotch region120to the back waist region118.

Referring toFIG. 3A, the diaper pant101may also include elasticized leg cuffs156. It is to be appreciated that the leg cuffs156can be and are sometimes also referred to as leg bands, side flaps, barrier cuffs, elastic cuffs or gasketing cuffs. The elasticized leg cuffs156may be configured in various ways to help reduce the leakage of body exudates in the leg regions. Example leg cuffs156may include those described in U.S. Pat. Nos. 3,860,003; 4,909,803; 4,695,278; 4,795,454; 4,704,115; 4,909,803; and U.S. Patent Publication No. 2009/0312730, published on Dec. 17, 2009.

As mentioned above, diaper pants may be manufactured with a ring-like elastic belt104and provided to consumers in a configuration wherein the front waist region116and the back waist region118are connected to each other as packaged, prior to being applied to the wearer. As such, diaper pants101may have a continuous perimeter waist opening110and continuous perimeter leg openings112such as shown inFIG. 2.

As previously mentioned, the ring-like elastic belt104is defined by a first elastic belt106connected with a second elastic belt108. As shown inFIG. 3A, the first elastic belt106defines first and second opposing end regions106a,106band a central region106c, and the second elastic108belt defines first and second opposing end regions108a,108band a central region108c.

The central region106cof the first elastic belt106is connected with the first waist region116of the chassis102, and the central region108cof the second elastic belt108is connected with the second waist region118of the chassis102. As shown inFIGS. 2 and 3A, the first end region106aof the first elastic belt106is connected with the first end region108aof the second elastic belt108at first side seam178, and the second end region106bof the first elastic belt106is connected with the second end region108bof the second elastic belt108at second side seam180to define the ring-like elastic belt104as well as the waist opening110and leg openings112.

Referring toFIGS. 3A,3C, and3D, the first elastic belt106also defines an outer lateral edge107aand an inner lateral edge107b, and the second elastic belt108defines an outer lateral edge109aand an inner lateral edge109b. The outer lateral edges107a,109amay also define the front waist edge121and the laterally extending back waist edge122. The first elastic belt106and the second elastic belt108may also each include an outer, garment facing layer176and an inner, wearer facing layer174. It is to be appreciated that the first elastic belt106and the second elastic belt108may comprise the same materials and/or may have the same structure. In some embodiments, the first elastic belt106and the second elastic belt may comprise different materials and/or may have different structures. It should also be appreciated that the first elastic belt106and the second elastic belt108may be constructed from various materials. For example, the first and second belts may be manufactured from materials such as plastic films; apertured plastic films; woven or nonwoven webs of natural materials (for example, wood or cotton fibers), synthetic fibers (for example, polyolefins, polyamides, polyester, polyethylene, or polypropylene fibers) or a combination of natural and/or synthetic fibers; or coated woven or nonwoven webs. In some embodiments, the first and second elastic belts include a nonwoven web of synthetic fibers, and may include a stretchable nonwoven. In other embodiments, the first and second elastic belts include an inner hydrophobic, non-stretchable nonwoven material and an outer hydrophobic, non-stretchable nonwoven material.

The first and second elastic belts106,108may also each include belt elastic material interposed between the outer layer176and the inner layer174. The belt elastic material may include one or more elastic elements such as strands, ribbons, or panels extending along the lengths of the elastic belts. As shown inFIGS. 3A,3C, and3D, the belt elastic material may include a plurality of elastic strands168which may be referred to herein as outer, waist elastics170and inner, waist elastics172. As shown inFIG. 3A, the elastic strands168continuously extend laterally between the first and second opposing end regions106a,106bof the first elastic belt106and between the first and second opposing end regions108a,108bof the second elastic belt108. In some embodiments, some elastic strands168may be configured with discontinuities in areas, such as for example, where the first and second elastic belts106,108overlap the absorbent assembly140. In some embodiments, the elastic strands168may be disposed at a constant interval in the longitudinal direction. In other embodiments, the elastic strands168may be disposed at different intervals in the longitudinal direction. The belt elastic material in a stretched condition may be interposed and joined between the uncontracted outer layer and the uncontracted inner layer. When the belt elastic material is relaxed, the belt elastic material returns to an unstretched condition and contracts the outer layer and the inner layer. The belt elastic material may provide a desired variation of contraction force in the area of the ring-like elastic belt.

It is to be appreciated that the chassis102and elastic belts106,108may be configured in different ways other than as depicted inFIG. 3A. For example,FIG. 3Bshows a plan view of a diaper pant101having the same components as described above with reference toFIG. 3A, except the first laterally extending end edge144of the chassis102is aligned along and coincides with the outer lateral edge107aof the first elastic belt106, and the second laterally extending end edge146is aligned along and coincides with the outer lateral edge109aof the second belt108.

Components of the disposable absorbent article (i.e., diaper, disposable pant, adult incontinence article, sanitary napkin, pantiliner, etc.) described in this specification can at least partially be comprised of bio-sourced content as described in US 2007/0219521A1 Hird et al published on Sep. 20, 2007, US 2011/0139658A1 Hird et al published on Jun. 16, 2011, US 2011/0139657A1 Hird et al published on Jun. 16, 2011, US 2011/0152812A1 Hird et al published on Jun. 23, 2011, US 2011/0139662A1 Hird et al published on Jun. 16, 2011, and US 2011/0139659A1 Hird et al published on Jun. 16, 2011. These components include, but are not limited to, topsheet nonwovens, backsheet films, backsheet nonwovens, side panel nonwovens, barrier leg cuff nonwovens, super absorbent, nonwoven acquisition layers, core wrap nonwovens, adhesives, fastener hooks, and fastener landing zone nonwovens and film bases.

In at least one exemplary configuration, a disposable absorbent article component comprises a bio-based content value from about 10% to about 100% using ASTM D6866-10, method B, in another embodiment, from about 25% to about 75%, and in yet another embodiment, from about 50% to about 60% using ASTM D6866-10, method B.

In order to apply the methodology of ASTM D6866-10 to determine the bio-based content of any disposable absorbent article component, a representative sample of the disposable absorbent article component must be obtained for testing. In at least one embodiment, the disposable absorbent article component can be ground into particulates less than about 20 mesh using known grinding methods (for example, Wiley® mill), and a representative sample of suitable mass taken from the randomly mixed particles.

The apparatuses and methods of the present disclosure may be utilized to assemble various components of pre-fastened, refastenable diaper pants101. For example,FIG. 4Ashows a schematic view of a converting apparatus200adapted to manufacture diaper pants101. The method of operation of the converting apparatus200may be described with reference to the various components of the diaper pant101described above and shown inFIGS. 2 and 3A. Although the following methods are provided in the context of the diaper pants101shown inFIGS. 2 and 3A, it is to be appreciated that various embodiments of diaper pants can be manufactured according the methods disclosed herein, such as for example, the absorbent articles disclosed in U.S. Pat. No. 7,569,039, filed on Nov. 10, 2004; U.S. Pat. No. 7,569,039; U.S. Patent Publication No. 2012/0061016, published on Mar. 15, 2011; and U.S. Patent Publication No. 2012/0061015, published on Mar. 15, 2011.

The converting apparatus200advances a continuous length of absorbent articles202in a first direction, shown as the machine direction MD inFIG. 4A. With reference toFIG. 4B, a continuous length of absorbent articles202may be defined by multiple discrete chassis102spaced from each other along the machine direction MD and connected with each other by the first and second continuous waistband substrates206,208. The continuous length of absorbent articles202may be folded in a second direction, shown as the cross direction CD inFIG. 4C, such that the continuous first waistband substrate206and the continuous second waistband substrate208are in a facing relationship. Next, portions of the first and second continuous waistband substrates206,208may be bonded together. Subsequently, the continuous length of absorbent articles202may be cut between the bonded portions of the first and second waistbands206,208to form discrete diaper pants101. Then, the folded diaper pants101may advance to a transfer apparatus220where the diaper pants101may be rotated and shifted from a first orientation to a second orientation. From the transfer apparatus220, the folded diaper pant101may continue advancing in the machine direction MD to downstream processing.

As shown inFIGS. 4A and 4C, the continuous length of absorbent articles202advances to a folding apparatus212. At the folding apparatus212, each chassis102may be folded in the cross direction CD along a lateral fold line158to place the first waist region116, and specifically, the inner, wearer facing surface132into a facing, surface to surface orientation with the inner, wearer facing surface132of the second waist region118. As shown inFIG. 4C, the first and second continuous waistbands206,208may define an outer, garment facing surface135and an inner, wearer facing surface133. Folding the chassis102also positions the inner, wearer facing surface133of the second waistband substrate extending between each chassis102into a facing relationship with the inner, wearer facing surface133of the first waistband substrate206extending between each chassis102.

Referring toFIGS. 4A and 4D, the folded, continuous length of absorbent articles202may advance to the bonder apparatus214. At the bonder apparatus214, a portion of the first and second continuous waistband substrates206,208extending between discrete chassis102may be bonded together to form bonded portions210. It is to be appreciated that various types of bonder apparatuses and methods can be used to bond the second waistband substrate material208with the first waistband substrate material206, such as the methods and apparatuses disclosed in U.S. Pat. Nos. 6,248,195; 6,546,987; and 7,383,865, as well as U.S. Patent Publication No. 2012/0021186, published Jan. 26, 2012.

As shown inFIG. 4A, a continuous length of absorbent articles202may advance from the bonding apparatus214to a cutter216, shown in the form of a knife roll218for purposes of illustration. The cutter216cuts the bonded portions210along the cross direction CD to create a first side seam204aon a folded, discrete diaper pant101and a second side seam204bon a subsequently advancing folded diaper pant101as shown inFIG. 4E. The folded diaper pant101may define a folded, lateral centerline160that intersects the longitudinal centerline124of the diaper pant101at a center114of the folded diaper pant101. The folded, lateral centerline160laterally bisects the folded diaper pant101such that the folded, lateral centerline160is equidistant from the front waist edge121and the lateral fold line158. Subsequently, the folded diaper pant101is advanced to the transfer apparatus220where the folded diaper pant101may be rotated and shifted before advancing to downstream converting operations as shown inFIG. 4A.

The transfer apparatus220operates to change the orientation of the folded diaper pant101as the folded diaper pant101advances in the machine direction MD. With reference toFIGS. 4A,4F, and4G, the transfer apparatus220operates to change the orientation of the folded diaper pant101from a first orientation222to a second orientation224. As shown inFIG. 4F, in the first orientation222, the longitudinal centerline124of folded diaper pant101may extend in the cross direction CD and the center114of the folded diaper pant101may be located at a first cross-directional position226. The first cross-directional position226may be located a first cross-directional length LCD1from the machine direction centerline MDC. As shown inFIG. 4G, in the second orientation224, the longitudinal centerline124of the folded diaper pant101may extend in the machine direction MD and the center114of the folded diaper pant101may be located at a second cross direction position256. The second cross direction position256may be different from the first cross direction position226. As shown inFIG. 4G, the center114may be located at a second cross-directional length LCD2from the machine direction centerline MDC. It is to be appreciated that in some exemplary configurations, the center114of the folded diaper pant101may align with the machine direction centerline MDC. In such an exemplary configuration, the second cross-directional length LCD2may be zero.

As shown inFIGS. 5A and 5B, the transfer apparatus220may include a frame228and a plurality of transfer members230connected with the frame228. The frame228is adapted to rotate about a first axis of rotation232that extends in a first direction. The transfer members230are adapted to rotate about a second axis of rotation234. The second axis of rotation234extends in a second direction that is different from the first direction of the first axis of rotation232. The second axis of rotation234may be orthogonal to the first axis of rotation232. Each transfer member230is configured to advance a folded diaper pant101from the first carrier apparatus236to the second carrier apparatus238.

Referring toFIGS. 4A,5A and5B, in operation, the frame228rotates about the first axis of rotation232and the transfer member230rotates about the second axis of rotation234. A folded diaper pant101advances on a first carrier apparatus236adjacent to the transfer apparatus220. The folded diaper pant101is transferred from the first carrier apparatus236and onto the transfer member230as the transfer member230rotates adjacent to the first carrier apparatus236. When the folded diaper pant101advances onto the transfer member230, the folded diaper pant101is oriented in the first orientation222and the transfer member230is in the first position240, such as shown inFIG. 6. The frame228continues rotating about the first axis of rotation232and the transfer member230rotates the folded diaper pant101about the second axis of rotation234. The folded diaper pant101advances on the transfer member230until the transfer member230is positioned in a second position242and the folded diaper pant101is at the second orientation224, such as shown inFIG. 7. The folded diaper pant101is then transferred from the transfer member230and advanced onto the second carrier apparatus238that is located adjacent to the transfer apparatus220as shown inFIG. 5A.

Referring toFIGS. 5A and 8, each transfer member230may include a receiving member244having a receiving surface246located on an end of the transfer member230most distal from the first axis of rotation232. The receiving surface246may be defined by a first centerline248and a second centerline250that intersect at a center252of the receiving surface246. In some exemplary configurations, the center252of the receiving surface246may be offset from the second axis of rotation234, such as shown inFIG. 8. The receiving surface246may be curved, or partially curved in one or more directions. However, in some exemplary configurations, the receiving surface may be flat, or substantially flat in one or more directions. As shown inFIG. 8, the receiving surface246may be substantially rectangular in shape; however, it is to be appreciated that the receiving surface may form various other shapes, such as squares, circles, or ovals for example. The receiving surface246may be configured to receive one or more folded diaper pant101.

The transfer member230may also include a rotation assembly260that comprises a rotation member262as shown inFIG. 8. The rotation member262may be defined by a center264. The rotation member262may be operatively connected with the receiving member244. The receiving member244and the rotation member262may be separate elements, or in some exemplary configurations, the receiving member244and the rotation member262may be a single, continuous element. The second axis of rotation234may align with the center264of the rotation member262, such as shown inFIG. 8. In such an exemplary configuration, the folded diaper pant may be positioned on the receiving surface246of the receiving member244such that the center of the folded diaper pant is substantially aligned with the center252of the receiving member244. It is to be appreciated that in some exemplary configurations the center264of the rotation member262may be offset from the second axis of rotation234. While it is shown inFIG. 8that the rotation member262is substantially circular, it is to appreciated that the rotation member may have various shapes and configurations.

With continuing reference toFIG. 8, the receiving surface246of the receiving member244may be configured to hold the discrete article in various ways. For example, the receiving surface246of the receiving member244may be configured to hold the discrete article thereto using fluid pressure, magnets, or an adhesive, for example. In some exemplary configurations, the receiving surface246may include a plurality of apertures254located in the receiving surface246of the receiving member244. The apertures254may be in gaseous communication with a vacuum source for retaining the discrete articles on the receiving surface246of the receiving member244as the frame228and/or the transfer member230rotate about the first and second axis of rotation232,234, respectively. As shown inFIG. 8, the apertures254may be arranged into the shape of a folded diaper pant. However, it is to be appreciated that the apertures254may be arranged in various other configurations. The apertures254may also be used to apply a positive pressure to the discrete articles on the receiving surface246. The positive pressure may be used, for example, to assist in the removal of the folded diaper pant from the receiving surface246.

The transfer apparatus220may include eight transfer members230as shown inFIG. 9. However, it is to be appreciated that the transfer apparatus220may include various numbers of transfer members230that are each configured to rotate and shift a folded diaper pant from a first orientation to a second orientation.

With reference toFIGS. 5B,6,7, and9, in some exemplary configurations, the transfer member230may rotate from a first position240to a second position242while advancing the folded diaper pant101from the first carrier apparatus236to the second carrier apparatus238. As a result, the folded diaper pant101may rotate from the first orientation222to the second orientation224. In some exemplary configurations, the transfer member230may continuously rotate from about 80° to about 100° from the first position240to the second position242. In some exemplary configurations, the transfer member230may rotate 360° from the first position240, through the second position242, and back to the first position240. As shown inFIG. 9, in some exemplary configurations, the transfer member230may rotate 90° in a first direction A about the second axis of rotation234and may be configured to subsequently rotate 90° in a second direction B about the second axis of rotation234. Thus, the folded diaper pant101may be rotated at various rotation angles from the first orientation222shown inFIG. 4Fto the second orientation224shown inFIG. 4G. For example, the folded diaper pant101may be rotated about 90° (for example, +/−5°), or between about 80° and 100° from the first orientation222to the second orientation224. The rotation assembly260may be configured to rotate the receiving surface246of the receiving member244in various ways. For example, the rotation assembly260may be rotated using an electric servo motor, hydraulic or pneumatic actuators, or mechanical cams, for example.

Referring toFIG. 9, the frame228of the transfer apparatus220may be configured to continuously rotate about the first axis of rotation232. The frame228may rotate at a constant angular velocity such that the speed at the receiving surface246is constant. In some exemplary configurations, the frame228may rotate at a variable angular velocity such that the speed at the receiving surface246is variable. In some exemplary configurations, the frame228may rotate about 180° to transfer a folded diaper pant from a first carrier apparatus236to the second carrier apparatus238. The frame228may rotate at various rotation angles to transfer the folded diaper pant from a first carrier apparatus236to the second carrier apparatus238. In such an exemplary configuration, the frame228may rotate a transfer member230about 180° about the first axis of rotation232in the same direction to pick up a subsequent folded diaper pant from the first carrier apparatus236.

The first and second carrier apparatuses236,238from and to which the folded diaper pants101are transferred may be rolls, drums, curved conveyors, linear conveyors, and/or discrete heads following a curvilinear path, for example. The first and second carrier apparatuses236,238may be moving at a different surface velocity or at the same surface velocity. The transfer assembly apparatus220may pick up the folded diaper pant101from the first carrier apparatus236at the same velocity as is applied to the folded diaper pant101at the second carrier apparatus238. The first and second carrier members236,238may be configured to apply negative, vacuum pressure and/or positive, blow-off pressure to the folded diaper pants101. In some exemplary configurations, the first and second carrier apparatuses236,238may be configured to apply vacuum pressure to hold the discrete diapers pants101as the diaper pants advance on the first and second carrier apparatuses236,238. In some exemplary configurations, the first carrier apparatus236may be configured to apply positive, blow-off pressure to the discrete diaper pant101in order to assist the discrete diaper pant101in transferring from the first carrier apparatus236to the transfer apparatus220.

In operation, the folded diaper pant101advances in the machine direction MD on the first carrier apparatus236, such as shown inFIGS. 5B and 9. The folded diaper pant101is transferred from the first carrier apparatus236to the receiving surface246of the receiving member244as the frame228rotates about the first axis of rotation232. The transfer member230is arranged at the first position240as the folded diaper pant101is transferred onto the receiving surface246of the receiving member244, such as shown inFIG. 6. The folded diaper pant101advances onto the receiving surface246in a first orientation222where the longitudinal centerline124extends in the cross direction CD and the center114of the folded diaper pant101is located at a first cross-directional position226, such as shown inFIG. 4F. With reference toFIGS. 5A,5B,7, and9, the transfer member230concurrently rotates about the second axis of rotation234as the frame228rotates about the first axis of rotation232. As a result, the folded diaper pant101rotates and the center of the folded diaper pant101shifts in the cross direction CD. The frame228continues to rotate about the first axis of rotation232and the transfer member230continues to rotate about the second axis of rotation234until the transfer member230is arranged in the second position242. In the second position242, the folded diaper pant101is oriented in a second orientation224where the longitudinal centerline124extends in the machine direction MD and the center114of the folded diaper pant101is located at a second cross-directional position256such as shown inFIG. 4G. The second cross-directional position may align with the machine direction centerline MDC.

As shown inFIGS. 5A and 5B, the transfer member230rotates about 90° about the second axis of rotation234in a first direction, A. Concurrently, the frame228of the transfer apparatus220rotates about 180° about the first axis of rotation232in a machine direction MD. Subsequently, the folded diaper pant101may be transferred from the transfer apparatus220to the second carrier apparatus238. Vacuum may be intermittently interrupted in order to remove the folded diaper pant101from the receiving surface246of the receiving member244. In some exemplary configurations, positive, blow-off pressure may be applied to the folded diaper pant101to assist the folded diaper pant101in transferring from the transfer apparatus220to the second carrier apparatus238. The positive, blow-off pressure may be applied by a compressed air source or another fluid movement device through the apertures254.

As shown inFIGS. 4A,9, and10, once the folded diaper pant101is transferred to the second carrier apparatus238, the frame228of the transfer apparatus220continues to rotate and the transfer member230rotates from the second position back to the first position in order to advance a subsequent folded diaper pant. The frame228may rotate about 180° about the first axis of rotation232to rotate the transfer member230from the second position back to the first position. In some exemplary configurations, the transfer members230rotate in a second direction B around the second axis of rotation234to move from the second position to the first position as shown inFIG. 9. In other exemplary configurations, the transfer members230may continue rotating in the first direction A around the second axis of rotation234from the second position back to the first position.

As shown inFIG. 11A, in a first orientation222, the folded diaper pant101may be arranged such that the lateral fold line158is aligned with and extends along the machine direction centerline MDC and the center114of the folded diaper pant101is located in a first cross-directional position226, away from the machine direction centerline MDC. The transfer member shown inFIG. 11Ais in a first position240. As shown inFIGS. 11B and 11C, the transfer member230rotates about the second axis of rotation234and the center114of the folded diaper pant101shifts in the cross direction CD. As shown inFIG. 11D, the folded diaper pant101is located in a second orientation224and the transfer member230is located in a second position242. As a result of rotating the folded diaper pant101about the second axis of rotation234, the folded diaper pant101may shift from the first orientation222to the second orientation224where the center114of the folded diaper pant101is aligned with the machine direction centerline MDC. In the second orientation224shown inFIG. 11D, the folded diaper pant101is also rotated such that the longitudinal centerline124extends in the machine direction MD.

In some exemplary configurations, the transfer member may rotate the folded diaper pant and then subsequently shift the cross-directional position of the center of the folded diaper pant. For example, the transfer member may be driven by two separate actuators; one actuator may rotate the rotation assembly of the transfer member, and the second actuator may shift the receiving member such that the cross-directional position of center of the folded diaper pant shifts.

The folded diaper pant may be positioned in various configurations with respect to the second axis of rotation. For example, as shown inFIGS. 11A-11D, the second axis of rotation234may align with the intersection of the longitudinal centerline124and the lateral fold line158of the folded diaper pant101. In such an exemplary configuration, the longitudinal centerline124of the folded diaper pant101may align with the machine direction centerline MDC when the folded diaper pant101is rotated to the second orientation224. It is to be appreciated that the folded diaper pant101may be arranged in various configurations at the second orientation224depending upon the desired orientation of the folded diaper pant101when the folded diaper pant101is transferred to the second carrier apparatus.

FIGS. 12A-12Dshow another exemplary configuration for a transfer member230. As shown inFIG. 12A, the second axis of rotation234may be located a first distance DFAfrom the lateral fold line158and a second distance DLCfrom the longitudinal centerline124, where the first distance DFAand the second distance DLCare equal. As shown inFIG. 12D, in such an exemplary configuration, the longitudinal centerline124of the folded diaper pant101may align with the machine direction centerline MDC when the folded diaper pant101is rotated to the second orientation224. It is to be appreciated that in a configuration where the lateral fold line158is aligned with the machine direction centerline MDC at the first orientation222, the second axis of rotation234may be aligned with various points on the folded diaper pant101where the first distance DFAand the second distance DLCare equal. In such configurations, the longitudinal centerline124may be positioned along the machine direction centerline MDC when the folded diaper pant101is rotated to the second orientation224.

Referring toFIGS. 11A and 12A, the transfer methods and apparatuses disclosed herein may be configured to provide a relatively low rotational inertia IRto the transfer member230as the transfer member230rotates about the second axis of rotation234. The transfer member230may be defined by a mass distribution that corresponds with a center of mass of the transfer member230. If L is the distance from the second axis of rotation234and dm is the sum of the mass distribution of the transfer member230, the rotational inertia IRof the transfer member230is:
IR=∫L2dm

It is to be appreciated that the rotational inertia IRof the transfer member230is a function of the mass distribution of the transfer member230and also the center of mass of the transfer member. The closer the center of mass of the transfer member230is from the second axis of rotation234, the lower the rotational inertia IRof the transfer member230may be. If Icmis the rotational inertia at the center of mass of the transfer member230, M is the total mass of the transfer member230, and D is the distance from the second axis of rotation234to the center of mass of the transfer member230, the rotational inertia IRof the transfer member is:
IR=Icm+MD2

In order to provide a relatively low rotational inertia IRto the transfer member230as the transfer member rotates about the second axis of rotation234, the transfer member230may be configured in various ways. In some exemplary configurations, additional mass or counterweight may be added to the transfer member230to change the center of mass of the transfer member230. In other exemplary configurations, the rotation member262may be configured such that center of the rotation member262is be positioned relatively nearer to the second axis of rotation. In yet other exemplary configurations, the receiving member244may be configured to be located relatively nearer to the second axis of rotation234.

In some exemplary configurations, the center252of the receiving surface246may align with the second axis of rotation234as shown inFIGS. 13A and 13B. In such an exemplary configuration, the folded diaper pant101may cover only a portion of the receiving surface246. The folded diaper pant101may be positioned on the receiving surface246such that the lateral fold line158and the longitudinal centerline124of the folded diaper pant101intersect at the second axis of rotation234. It is to be appreciated that in the exemplary configurations shown inFIGS. 13A and 13B, the rotational inertia IRof the transfer member230may be relatively low as the center of mass of the transfer member230may be relatively near to the second axis of rotation234.

In some exemplary configurations, one transfer member230may rotate in a first direction A and a subsequent transfer member230may rotate in a second direction B, such as shown inFIG. 14. As such, it is to be appreciated that a transfer apparatus220may be used to rotate one folded diaper pant in the first direction A and to rotate the next folded diaper pant in the second direction B.

While the methods and apparatuses disclosed herein operate to rotate and shift a folded diaper pant, it is to be appreciated that the methods and apparatuses disclosed herein may also be used in various other processes in the manufacture of absorbent articles. In one exemplary configuration, the methods and apparatuses disclosed herein may be used to rotate and shift discrete diaper chassis. The diaper chassis may comprise various components, such as a topsheet, backsheet, and an absorbent core. The transfer apparatus may be used to rotate and shift discrete chassis that are subsequently combined with continuous lengths of first and second waistband substrates. The methods and apparatuses disclosed herein may be used with the methods and apparatuses for rotating and repitching a discrete chassis disclosed in U.S. patent application Ser. No. 13/447,531, filed on Apr. 16, 2012; U.S. patent application Ser. No. 13/447,544, filed on Apr. 16, 2012; U.S. patent application Ser. No. 13/447,568, filed on Apr. 16, 2012; and U.S. patent application Ser. No. 13/447,585, filed on Apr. 16, 2012.