Abstract:
An apparatus for transferring articles such as absorbent cores or disposable diaper chassis components from a rotary mechanism, such as a pad turner, to a linear mechanism, such as a conveyor, for further processing. A puck on the apparatus is capable of stretching and rotating the article during this transfer procedure. The puck includes a pair of end segments each of which is arranged to move from a first position where each end segment is at a first distance and a first angle relative to the puck and a second position where each end segment is at a second distance and a second angle relative to the puck during the transfer process.

Description:
RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part of co-pending U.S. application Ser. No. 12/806,283 filed 9 Aug. 2010, which is a continuation of patent application Ser. No. 11/357,546 filed 17 Feb. 2006 (now U.S. Pat. No. 7,770,712) and is a continuation of U.S. application Ser. No. 13/178,104 filed 7 Jul. 2011, which is a divisional application of U.S. application Ser. No. 12/070,879 filed 21 Feb. 2008 (now U.S. Pat. No. 7,975,584) which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/902,477, filed 21 Feb. 2007. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    This invention related to an apparatus for transferring articles such as absorbent pads in the manufacture of disposable absorbent articles such as diapers, incontinence control garments or female sanitary pads as they advance along a production line. 
         [0003]    In the production and manufacture of disposable products such as sanitary napkins or pants-type diapers, it frequently becomes necessary to manufacture a component of the product in one orientation, and then to rotate that component part 90° so that it is suitably oriented for use in another step in the production process. Various devices have been developed for this purpose and are known to those experienced in the industry. Examples of such apparatus are those described in U.S. Pat. Nos. 4,726,876, 4,880,102, and 5,025,910, the disclosures of which are incorporated herein by reference. 
         [0004]    As discussed above, a typical article to be reoriented by the apparatus of this invention is an absorbent pad. Because absorbent pads are typically comprised of several webs, an absorbent core and several elastic members, there is a tendency of these assemblies to contract and become distorted during transfer operations which greatly complicates handling of the pad during further processing. Control of the pad is important. 
       SUMMARY OF THE INVENTION 
       [0005]    The apparatus of the present invention is an active puck that is capable of rotating and stretching an article between a pick-up and a lay-down point. 
         [0006]    An active puck is disclosed that picks up an article from a first conveying means, the article traveling in a first orientation, carries, stretches and rotates the article, so the article is traveling in a second orientation, and deposits the article onto another conveying means. A cam plate comprising a guiding structure of increasing radius cooperates with a vacuum slide to urge stretching of the article is provided. A vacuum puck carries the article while the slide rotatably operates through the increasing (or decreasing) radius. 
         [0007]    The puck includes a puck body having a first end and a second end with a first end segment at the first end and a second end segment at the second end. Each of the first and second end segments are slidably engaged with a pair of generally curved rails. As the puck in rotated, the first and second end segments slide along the rails, moving the first and second end segments relative to the puck body and tilting the first and second end segments relative to the puck body. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a fragmentary side elevation view, shown in diagrammatic form, of a pad transferring assembly; 
           [0009]      FIG. 2  is a perspective fragmentary, diagrammatic view, showing related apparatus by means of phantom lines and illustrating the path of movement of pads moving in accordance with the invention; 
           [0010]      FIG. 3  is a top view of an embodiment of an active pad turning puck of the present invention; 
           [0011]      FIG. 4  is a top view of an embodiment of an active pad turning puck of the present invention; 
           [0012]      FIG. 5  is a top view of an embodiment of an active pad turning puck of the present invention; 
           [0013]      FIG. 6  is an exploded view of an active pad turning puck of the present invention; 
           [0014]      FIG. 7  is a top view of an alternate embodiment of an active pad turning puck of the present invention; 
           [0015]      FIG. 8  is a top view of an alternate embodiment of an active pad turning puck of the present invention; 
           [0016]      FIG. 9  is a top view of an additional alternate embodiment of an active pad turning puck of the present invention; 
           [0017]      FIG. 10  is a top view of an additional alternate embodiment of an active pad turning puck of the present invention. 
           [0018]      FIG. 11  is a top view of an additional alternate embodiment of an active pad turning puck of the present invention. 
           [0019]      FIG. 12  is a perspective view of a puck support according to the present invention. 
           [0020]      FIG. 13  is a perspective view of an additional alternative embodiment of an active pad turning puck according to the present invention. 
           [0021]      FIG. 14  is a side elevation view of the puck of  FIG. 13 . 
           [0022]      FIG. 15  is a cross-section view taken along line  14 - 14  of  FIG. 14 . 
           [0023]      FIG. 16  is a top plan view of the puck of  FIG. 13 . 
           [0024]      FIGS. 17A ,  17 B and  17 C are simplifies side elevation views of the puck of  FIG. 13  as it rotates from a first web receiving position ( FIG. 17A ) to a second web placement position ( FIG. 17C ). 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0025]    Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims. 
         [0026]    Referring more particularly to the drawings, there is seen in  FIG. 1  an apparatus  10  carrying pucks, or transfer heads  16 , of the present invention. The apparatus  10  is adapted to receive a series of articles  14  from an upstream conveyor or vacuum drum (not shown) onto a pad turning device  12  which includes a plurality of radially extending transfer heads  16 . 
         [0027]    The location where articles  14  are received from the upstream point onto the pucks  16  is known as the pick up point. The location where articles  14  are deposited from the pucks  16  to a downstream drum or conveyor  20  is known as the lay down point. 
         [0028]    The pad turning device  12  may be, for example, a rotary pad turner of the type more fully described in U.S. Pat. No. 5,025,910 which is incorporated herein by reference. The articles  14 , such as absorbent pads, may be any elongated articles which need to be rotated approximately 90° during the course of a manufacturing operation. In the present invention, the elongated articles are also stretched away from their center point in a direction, such as a radial direction, away from the axis of the puck  16  as will be described later. 
         [0029]    Such pad turning devices  12  are especially needed and are suited for use in connection with the manufacture and packaging of sanitary napkins as well as absorbent pads which are used in the assembly of disposable garments such as adult incontinence garments or children&#39;s training pants. 
         [0030]    Also seen in  FIG. 1 , articles  14  are successively and individually picked-up by the transfer heads  16  of the pad transfer device  12 . In the illustrated embodiment, the articles  14  are picked up from a vacuum drum (not shown). Various conventional conveying and direction changing devices such as rollers may be employed in the feeding of the web and do not form a part of this invention. 
         [0031]    After the articles  14  have been rotated 90 degrees, they are deposited at the lay down point onto drum  20 . The pucks  16  of the present invention can stretch the articles  14 , as will be described below, and deposit them in the stretched condition onto drum  20 . A conveyor  28  or the like transport the articles  14  for further processing or to a packaging device, as required by a particular application. 
         [0032]    Referring to  FIG. 2 , there is seen a diagrammatic depiction of the travel path of the web  22  and the resultant pads  14  which are formed therefrom. In this depiction the various apparatus have been eliminated but are partially illustrated by means of phantom lines. 
         [0033]    As can be seen, the article is rotated 90° from the pick up point to the lay down point, and is also stretched during this time it spends on the puck  16 . The active puck  16  of this invention is more fully described in the remaining Figures. 
         [0034]    As shown in  FIG. 3 , a top view of an embodiment of an active pad turning puck  16  of the present invention is shown. A plurality of vacuum slides  34  are positioned about a puck assembly  38 . The vacuum slides  34  are intended to engage a portion of articles  14  (not shown) by vacuum ports  42 , and manipulate by stretching or otherwise the articles  14 . As is well known in the art, each of the segments can be connected internally to a source of vacuum. A pattern of holes is provided on the surface of each segment through which the internal vacuum acts to draw the pads  14  towards the surface. It is clear that this technology can be applied to the transfer and placement of many different types of articles in the disposable goods industry and other industries as well. 
         [0035]    In use, rotation of the puck assembly  38  relative to a cam plate  40  causes cam followers  32  to track through channels  36 . Channels  36  are of an increasing radius from the center of the cam plate  40 . Because cam followers  32  are coupled with vacuum slides  34 , rotation of the puck assembly  38  relative to the cam plate  40  causes sliding of the vacuum slides inwardly and outwardly as shown in  FIG. 4 . The cam followers  32  are urged inwardly and outwardly due to the increasing radius of the channels  36  in a first direction of travel, and the decreasing radius of channels  36  in the second rotational direction of travel, preferably in a washing machine-like back and forth style. 
         [0036]    Referring now to  FIG. 5 , a top view the active pad turning puck  16  of the present invention is shown. In this embodiment, vacuum ports  42  are shown, and may be applied to the vacuum slides  34 , the puck assembly  38 , or both. The vacuum ports are coupled to a manifold  44  and ultimately a source of vacuum (not shown). 
         [0037]    Referring now to  FIG. 6 , an exploded view of the active pad turning puck  16  of the present invention is shown. In this embodiment, a shaft adaptor plate  46  is shown to receive shaft  48 , through a void provided proximal to the center of cam plate  40 . The support subassembly  50  is provided for coupling of the puck  16  to the pad turning device  12 . 
         [0038]    Referring now to  FIG. 7 , a top view of an alternate embodiment of an active pad turning puck  16  of the present invention is shown. In this embodiment, ends  39  of the puck assembly  38  are slidably enabled, as the vacuum slides  34  described previously. Rotation is again a driving force of sliding movement caused by the cam follower  32  coupled to the ends  39 , as shown in  FIG. 8 . 
         [0039]    Referring now to  FIGS. 9 and 10 , a top view of an additional alternate embodiment of an active pad turning puck  16  of the present invention is shown. In this embodiment, a plurality of channels  36  are provided, each channel  36  receiving a cam follower  32  coupled to a slidable element, either ends  39  or slides  34 . Of course, a single circuitous channel  36  could be provided for receiving multiple cam followers  32 . Again, cam followers  32 , upon rotation, urge the slidable elements outward and inward. 
         [0040]    Referring now to  FIG. 11 , an additional alternative embodiment of a puck  16  of the present invention is shown. In this embodiment, it can be seen that a slidable elements  46  are provided at corners of the puck assembly  38 . These slidable elements  46  will move somewhat radially away from the center of the puck  16 , although the direction of movement can be controlled through different arrangements of the channel or channels  36 . 
         [0041]    In use, the transfer apparatus  10  rotates from the pick up point, stretches the article  14  while the article is upon a puck  16  by slidable elements, and deposits the article  14  on a conveyor  28  or the like for downstream processing. As the puck  16  rotates between the pick up and deposition points, the cam followers are urged into an increasing radius of the channel  36 . Between the deposition point and the next subsequent pick up point, the puck  16  will rotate back to its initial position, and the cam followers are urged into an its decreasing radius of the channel  36 , causing the slidable elements  34  or  39  to return to their initial, retracted position, ready to receive another article  14 . 
         [0042]      FIGS. 12 ,  13 ,  14 ,  15 ,  16 ,  17 A,  17 B and  17 C show an additional embodiment of a puck according to the present invention. Referring to  FIG. 13 , the puck  116  has a puck body  138  having a first web surface  150 , a support surface  152  preferably oppositely disposed from the web surface  150 , and a bearing shaft  148  depending from the support surface  152 . The bearing shaft  148  is adapted to be rotatably supported by a puck support  154  (see  FIG. 12 ), such as being rotatably held in the bearing aperture  180  in the puck support head  156 . The puck body  138  includes a vacuum chamber (not shown) within the body  138 . Communicating fluidly with the vacuum chamber are preferably a plurality of web vacuum holes  158  extending through the web surface  150  and a plurality of support vacuum holes  160  extending through the support surface  152 . The web vacuum holes  158  are provided about the first web surface  150 , and may be evenly spaced and provided near at least a portion of the perimeter of the web surface  138 . The support vacuum holes  160  provide a means for drawing a vacuum through the web vacuum holes  158  and the vacuum chamber in the puck body  138 . Preferably, the support vacuum holes  160  are mateable and adapted to cooperate with the vacuum apertures  162  extending into the puck support  154 . By imparting a force to the bearing shaft  148  or other portion of the puck  116 , the puck  116  may be spun from a web-receiving orientation  164  to a web-placement orientation  166 . Such force may be applied to the bearing shaft  148  using any means known in the art including, but not limited to, by way of a spin linkage (not shown) coupled to both the bearing shaft  148  and a spin cam follower (not shown), which is disposed at least partially in a spin cam race (not shown) as is shown and described in detail in U.S. Pat. No. 7,975,584, which is incorporated herein by reference. Though any web placement position  166  angle may be desirable, the depicted angle  168  is ninety degrees from the web receiving position  164 . 
         [0043]    The puck body  138  preferably includes a first end and a second end. The puck  116  preferably includes a pair of end segments  139 , with a first end segment  139  at the first end of the puck body  138  and a second end segment  139  at the second end of the puck body  138 . Each end segment  139  has an end web surface  151 . 
         [0044]    Each end segment  139  is preferably slidably disposed upon a pair of rails  170 . In the illustrated embodiment four rail segments  170  are mounted on a pair of rail plates  184 . Each end segment  139  has a block  186  sized and configured for slidable engagement with an associated rail  170  disposed on each lateral side thereof. Preferably, the rails  170  are configured to allow the associated end segment  139  to slide away from the puck body  138  while the end segment  139  tilts as shown in  FIGS. 17A through 17C . Specifically, each of the rails  170  preferably has a first end adjacent the puck body  138  and an opposed second end. Each of the rails  170  preferably includes a generally horizontal portion at the first end thereof. Each rail  170  is preferably generally curved toward the web surface  150  as shown in  FIGS. 17A through 17C . In this manner, as the end segments  139  slide away from the puck body  138  along the rails  170 , the angle of the end web surface  151  relative to the web surface  150  is changed. When the end segments  139  are at the position furthest from the puck body  138  the end web surface  151  of each end segment  139  is generally parallel to the web surface  150 . 
         [0045]    A cam plate  172  is preferably provided between a desired puck support  154  and the puck  116 . The cam plate  172  preferably includes at least one cam groove  174  having a changing radius. Thus, when the puck  116  is in the web receiving position  164 , the end segments  139  are in a first position, preferably nearer the puck body  138  (see  FIG. 17A ). When the puck  116  is in the web placement position  166 , the end segments are in a second position, preferably further from the puck body  138  (see  FIG. 17C ). 
         [0046]    It should be understood that the foregoing arrangement serves to effect the slide of the end segments  139 , in a generally up-and-out manner. As the rotation of the bearing shaft  148  causes the puck  116  to spins from the web receiving position  165  to the web placement position  166 , an end web cam follower  176  that is placed in the cam groove  174  causes the end segment  139  to slide along the rails  170  from a first position (see  FIG. 17A ) to a second position, preferably further from the puck body  138  (see  FIG. 17C ). The engagement of the block  186  with the rails  170  causes the each end segment  139  to rotate as it slides away from the puck body  138  along the rails. 
         [0047]    The end web surfaces  139  are also preferably provided with a plurality of web vacuum holes  158  in fluid communication with an end web vacuum chamber  178 . The end web vacuum chamber  178  is preferably in fluid communication with the vacuum chamber (not shown) in the puck body  138 . Such fluid communication between the end web vacuum chamber  274  and puck body  138  vacuum chamber may be provided by one or more vacuum bellows  180 . 
         [0048]    The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.