Source: http://www.google.com/patents/US5556504?dq=3984803
Timestamp: 2014-07-10 20:13:28
Document Index: 402588694

Matched Legal Cases: ['arts 32', 'arts 32', 'arts 32', 'arts 32', 'arts 32', 'arts 32', 'arts 132', 'art 132']

Patent US5556504 - Apparatus for placing discrete parts transversely onto a moving web - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign in<nobr>Advanced Patent Search</nobr>PatentsThis invention pertains to processing continuous webs such as paper, film, composites, and the like, in dynamic continuous processing operations. More particularly, it relates to transferring discrete parts to a continuous web, whether paper, film, composite, or the like. Specifically, the invention...http://www.google.com/patents/US5556504?utm_source=gb-gplus-sharePatent US5556504 - Apparatus for placing discrete parts transversely onto a moving webAdvanced Patent SearchPublication numberUS5556504 APublication typeGrantApplication numberUS 08/459,606Publication dateSep 17, 1996Filing dateJun 2, 1995Priority dateJan 25, 1994Fee statusPaidAlso published asCA2155137A1, CA2155137C, DE69616280D1, DE69616280T2, EP0806926A1, EP0806926B1, US6319347, US6899780, US20020036051, WO1996023470A1Publication number08459606, 459606, US 5556504 A, US 5556504A, US-A-5556504, US5556504 A, US5556504AInventorsGregory J. Rajala, Paul M. Niemi, Daniel J. OshefskyOriginal AssigneeKimberly-Clark CorporationExport CitationBiBTeX, EndNote, RefManPatent Citations (24), Referenced by (49), Classifications (24), Legal Events (4) External Links: USPTO, USPTO Assignment, EspacenetApparatus for placing discrete parts transversely onto a moving webUS 5556504 AAbstract This invention pertains to processing continuous webs such as paper, film, composites, and the like, in dynamic continuous processing operations. More particularly, it relates to transferring discrete parts to a continuous web, whether paper, film, composite, or the like. Specifically, the invention relates to methods and apparatus for taking discrete parts from a source in a taking zone, optionally taking the discrete parts as components of a continuous web, onto a transport head on a transfer assembly, severing the discrete parts from the continuous web if received as part of a continuous web, rotating the transfer assembly about a first axis and correspondingly rotating the transport head about a second axis radial to the first axis, to thereby present the discrete parts to a receiver in a transfer zone, and transferring the discrete parts to the receiver in the transfer zone. The invention includes using a roughened taking section on the transport head, interacting with textured surface on the discrete parts, to hold the discrete parts to the transport head, with optional use of suction through the transport head to assist in holding the discrete parts to the transport head. Novel apparatus is included for delivering suction to and through rotating slip rings.
What is claimed is: 1. Apparatus for taking discrete parts traveling at a first speed in a first direction in a taking zone and transferring the discrete parts to a receiver traveling at a second speed in a second direction in a transfer zone, said apparatus comprising:a transfer assembly mounted on a shaft for rotation about a first axis oriented in a third direction transverse to and disposed in a plane parallel with the first direction, said transfer assembly including a shell segment supported by said shaft and at least one transport head rotatably mounted on said shell segment for taking the discrete parts in the taking zone, wherein a leading edge of the discrete parts are oriented at a first angle with respect to the first direction of travel, and for transferring the discrete parts to the receiver in the transfer zone; first driver means for rotating said transfer assembly about said first axis at a variable velocity so that said transport head travels substantially at the first speed as the discrete parts are taken onto the transport head in the taking zone, and travels at the second speed as the discrete parts are applied to the receiver in the transfer zone; and means for transferring drive from said first driver means to said transport head comprising a cam drive means, input shaft and output means, said cam drive means having a cam circumferentially secured to a drum affixed to a gear box and a cam follower movably affixed to said cam, said output means having an actuating arm movably connected to said transport head through a crank clevis wherein said transferring drive means rotates said transport head about a second axis transverse to said first axis to thereby orient the leading edge of the discrete part at a second angle different from the first angle as measured with respect to the second direction of travel of the receiver in the transfer zone. 2. The apparatus of claim 1 further comprising means for retaining said discrete parts engaged against said transport head from the taking zone until said discrete parts are transferred at the transfer zone.
3. The apparatus of claim 2 wherein said retaining means includes vacuum means for providing vacuum to said transport head.
4. The apparatus of claim 3 wherein said transport head comprises an arcuate top wall transversely oriented relative to said first direction, said arcuate wall including a taking portion having a roughened surface and at least one suction port for communicating vacuum from said vacuum means to said discrete parts while said discrete parts are engaged against said transport head from the taking zone until said discrete parts are transferred at the transfer zone.
5. The apparatus of claim 4 wherein said roughened surface includes a base surface component and an array of protrusions extending at least about 0.006 millimeters from said base surface component.
6. The apparatus of claim 2 wherein said first driver means includes the gear box comprising a second driver means and a driven means which in combination rotate said transfer assembly, said second driver means and said driven means includes a pair of complementary noncircular gears.
7. The apparatus of claim 1 wherein said second axis of rotation is substantially perpendicular to said first axis of rotation.
8. The apparatus of claim 4 wherein said vacuum means includes control means for applying and removing said vacuum to and from said taking portion of said transport head.
9. The apparatus of claim 8 wherein said control means includes:(a) a slip ring fixedly secured to said shell segment and movably mounted for rotation about an outer circumferential wall of a tubular conduit; (b) a first array of suction ports in said outer circumferential wall along a portion of a path of rotation of said slip ring; and (c) a second array of suction ports circumferentially disposed about a portion of said slip ring so that said second array suction ports become aligned with said first array suction ports as said slip ring rotates about said tubular conduit, thereby supplying suction to said taking portion of said transport head. 10. The apparatus of claim 9 wherein said vacuum means applies suction to said taking portion of said transport head through an arc of rotation of at least about 30 degrees to about 330 degrees.
11. The apparatus of claim 10 wherein said vacuum means applies suction to said taking portion of said transport head through an arc of rotation that substantially coincides with the rotation of said transport head from the taking zone to the transfer zone.
12. Apparatus for taking discrete parts traveling at a first speed in a first direction in a taking zone and transferring the discrete parts to a receiver traveling at a second speed in a second direction in a transfer zone, said apparatus comprising:a transfer assembly mounted on a shaft for rotation about a first axis oriented in a third direction transverse to, and disposed in a plane parallel with, the first direction, said transfer assembly including a shell segment supported by said shaft and at least one transport head rotatably mounted on said shell segment for taking the discrete parts in the taking zone and for transferring the discrete parts to the receiver in the transfer zone, wherein a leading edge of the discrete parts are oriented at a first angle with respect to the first direction of travel; first driver means for rotating said transfer assembly about said first axis at a variable velocity so that said transport head travels substantially at the first speed as the discrete parts are taken onto the transport head in the taking zone, and travels at the second speed as the discrete parts ere applied to the receiver in the transfer zone, said first driver means includes a gear box comprising a second driver means and a driven means which in combination rotate said transfer assembly, said second driver means and said driven means including a pair of complementary noncircular gears; means for transferring drive from said first driver means to said transport head to rotate said transport head about a second axis transverse to said first axis to thereby orient the leading edge of the discrete part at a second angle different from the first angle as measured with respect to the second direction of travel of the receiver in the transfer zone; and vacuum means for providing vacuum to said transport head having control means for applying and removing vacuum to and from said taking portion of said transport head, said control means includes:slip ring fixedly secured to said shell segment and movably mounted for rotation about an outer circumferential wall of a tubular conduit; first array of suction ports in said outer circumferential wall along a portion of a path of rotation of said slid ring; and second array of suction ports circumferentially disposed about a portion of said slip ring so that said second array suction ports become aligned with said first array suction ports as said slid ring rotates about said tubular conduit, thereby supplying suction to said taking portion of said transport head. 13. The apparatus of claim 12 wherein said transport head comprises an arcuate top wall transversely oriented relative to said first direction, said arcuate wall including a taking portion including a base surface component and an array of protrusions extending at least about 0.006 millimeters from said base surface component, said taking portion further including at least one suction port for communicating vacuum from said vacuum means to said discrete parts while said discrete parts are engaged against said transport head from the taking zone until said discrete parts are transferred at the transfer zone.
14. The apparatus of claim 12 wherein said transferring drive means includes:(a) a drum affixed to said gear box; (b) a cam circumferentially secured to said drum; (c) a cam follower movably affixed to said cam; and (d) an actuating arm movably connected to said transport head and said cam follower. Description
This is a divisional application of application U.S. Ser. No. 08/381,364, filed on Jan. 31, 1995, which is a CIP of Ser. No. 08/186,352 filed on Jan. 25, 1994.
Priority is claimed under 35 U.S.C. 120 with respect to application Ser. No. 08/186,352, filed Jan. 25, 1994, herein incorporated by reference.
FIELD OF THE INVENTION The present invention relates to a method and apparatus, for receiving discrete parts travelling at a speed and applying the parts to a web travelling at a different speed. The invention more particularly concerns a method and apparatus for receiving discrete parts of a continuously moving web of material travelling at a certain speed and applying the parts to a second continuously moving web travelling at a different speed.
It is a further object to provide methods and apparatus for holding the discrete parts on the transport head by providing a toughened surface on the transport head, and a cooperating textured surface on the discrete parts.
In a first family of embodiments, the invention contemplates a method for taking discrete parts travelling at a first speed in a first direction, and transferring the discrete parts to a receiver travelling at a second speed in a second direction, the method comprising the steps of providing a rotatable transfer assembly, and at least one transport head mounted on the transfer assembly, for taking the discrete parts onto the at least one transport head in a taking zone, and for transferring the discrete parts to the receiver in a transfer zone; taking a discrete part onto the at least one transport head in the taking zone wherein a leading edge of the discrete part is oriented at a first angle "A" with respect to the first direction of travel; after taking the discrete part onto the at least one transport head, (i) rotating the rotatable transfer assembly about a first axis oriented in a third direction transverse to, and disposed in a plane parallel with, the first direction, at a variable angular velocity such that the at least one transport head travels at a first surface speed which substantially equals the first speed of the discrete part as the discrete part is taken onto the at least one transport head in the taking zone, and travels at a second surface speed which substantially equals the second speed of the receiver as the discrete part is transferred to the receiver in the transfer zone, the rotating of the rotatable transfer assembly defining an orbital path, and (ii) rotating the transport head about a second radial axis intersecting the first axis and extending outwardly therefrom, to thereby orient the leading edge of the discrete part at an angle "B" measured with respect to the second direction of travel of the receiver in the transfer zone, different from angle "A"; and transferring the so rotated discrete part to the receiver in the transfer zone.
Preferably, the method also includes providing, on the transport head, an area having a roughened surface, and providing, on the discrete part, a textured surface, that interacts with the area of toughened surface on the transport head to thereby secure the holding of the discrete part to the transport head.
Preferably, the method of this second family of embodiments also includes providing, on the transport head, an area having a toughened surface, and providing, on the discrete part, a textured surface, the textured surface of the discrete part interacting with the area of toughened surface on the transport head to thereby secure the holding of the discrete part to the transport head.
In a third family of embodiments, the invention contemplates apparatus for taking discrete parts travelling at a first speed in a first direction, and transferring the discrete parts to a receiver travelling at a second speed in a second direction, the apparatus comprising a transfer assembly mounted for rotation about a first axis oriented in a third direction transverse to, and disposed in a plane parallel with, the first direction; at least one transport head mounted on the transfer assembly, for taking the discrete parts onto the at least one transport head in a taking zone, wherein a leading edge of the discrete part is oriented at a first angle "A" with respect to the first direction of travel, and for transferring the discrete parts to the receiver in a transfer zone; a first driver, for driving the transfer assembly about the first axis, at a variable angular velocity such that the at least one transport head travels at a first surface speed which substantially equals the first speed of the discrete part as the discrete part is taken onto the at least one transport head in the taking zone, and travels at a second surface speed which substantially equals the second speed of the receiver as the discrete part is applied to the receiver in the transfer zone, the rotating of the transfer assembly thereby defining an orbital path; and a second driver for rotating the transport head about a second radial axis of rotation intersecting the first axis, and extending outwardly from the first axis, to thereby orient the leading edge of the discrete part at an angle "B" measured with respect to the second direction of travel of the receiver in the transfer zone, different in magnitude from angle "A".
Preferably, the transport head has a receiving area for taking the discrete parts, the receiving area having a toughened surface comprising a first base surface component, and a second component comprising a first array of protrusions extending outwardly at least about 0.006 millimeter, preferably up to about 3 millimeters, more preferably between about 0.01 millimeter and about 0.03 millimeter, from the base surface component for receiving the discrete parts thereunto, such that the protrusions on the receiving area can interact with a textured surface on the discrete part to thereby secure the discrete part to the transport head.
FIG. 11 is a sectional view taken at 11--11 of FIG. 8.
FIG. 13 is a cross section of the taking section of the outer wall of the transport head, with a discrete part thereon, taken at 13--13 in FIG. 10.
FIG. 16 is an elevation view generally taken at 16--16 of FIG. 8.
Alternatively, the illustrated driven means 60 may include a noncircular driven gear 62 which is connected to a jackshaft instead of being connected to the output shaft 64. The term "jackshaft" connotes a rotatable shaft supported in two locations that is capable of receiving the rotational energy from the driving means 50 and transferring the energy to the output shaft 64. The jackshaft is parallel to but offset from the input shaft 52 such that the noncircular drive gear 54 is configured to engage and rotate the noncircular driven gear 62. The driven means 60 may further include a transmitting means, such as a pair of complementary gears connected to the jackshaft and output shaft 64 respectively, for conducting the rotational energy from the jackshaft to the output shaft 64 to rotate the output shaft 64 and the transfer assembly 40. Alternatively, the transmitting means may include any mechanism known to those skilled in the art by which rotational energy can be conducted from one shaft to another such as, for example, circular gears, v-belts, timing belts, continuous chains and the like or combinations thereof. Further, the transmitting means may include a second pair of complementary noncircular gears to provide additional speed variations.
As illustrated in FIGS. 3A, 3B, 4 and 5, the example of the driving means 50 includes the rotatable noncircular drive gear 54 connected to an input shaft 52. The illustrated example of each of the driven means 60 includes the corresponding rotatable noncircular driven gear 62 connected to a corresponding jackshaft 66, represented by 66A, 66B and 66C. Each jackshaft 66 is parallel to but offset from the input shaft 52 such that the noncircular drive gears 54 are configured to engage and rotate the respective noncircular driven gears 62 thereby rotating, the respective jackshafts 66. Thus, as illustrated, the single noncircular drive gear 54 is configured to engage and rotate the three noncircular driven gears represented by 62A, 62B and 62C which are respectively connected to the three jackshafts represented by 66A, 66B and 66C. Each driven means 60 may further include a transmitting means 70, as representatively illustrated in FIG. 3B, such as a pair of complementary gears connected to each jackshaft 66 and each concentric shaft 68 respectively, for conducting the rotational energy from each jackshaft 66A, 66B and 66C to the respective concentric shaft 68A, 68B and 68C thereby rotating the respective concentric shaft 68 and transfer assembly 40. Alternatively, the transmitting means 70 may include any mechanism known to those skilled in the art by which rotational energy can be conducted from one shaft to another such as, for example, circular gears, v-belts, timing belts, continuous chains and the like or combinations thereof.
Area=L1 +0.5(b1 +b2) (L2 -L1)     (1)
R=Area/2&#928;                                               (2)
L1 =low speed of the transfer assembly (mm/repeat)
L2 =high speed of the transfer assembly (mm/repeat)
b1 =total time during the trapezoidal portion of the curve (repeats)
b2 =total time to dwell at high speed (repeats)
b3 =total time to dwell at low speed (repeats)
&#952;inslow=2&#928;b3                                 (3)
&#952;infast=2&#928;b2                                 (4)
&#952;inaccel=2&#928;(b1 -b2)                     (5)
&#952;outslow=(L1 b3)/R                         (6)
&#952;outfast=(L2 b2)/R                         (7)
&#952;outaccel=[2(b1 -b2)(L1 /2+(L2 -L1)/4))]/R (8)
Slow speed ratio=Y1 =&#952;outslow/&#952;inslow=L1 /(2&#928;(R)) (9)
High speed ratio=Y2 =&#952;outfast/&#952;infast=L2 /(2&#928;(R)) (10)
&#951;accel =A-B cos (C&#952;)                        (11)
where ηaccel =ratio as a function of angular position during transition and
A=(Y1 +Y2)/2                                     (12)
B=(Y2 -Y1)/2                                     (13)
C=2&#928;/&#952;inaccel                                     (14)
Rdriven gear =Dcenter /(1+&#951;accel)       (15)
Rdrive gear =Dcenter -Rdriven gear          (16)
Rdriven gear =The radius of the noncircular driven gear
Rdrive gear =The radius of the noncircular drive gear
Dcenter =The desired gear center to center distance
Thus, the design of the profile of the complementary noncircular gears can be analytically determined to obtain the desired output function which can include variable angular velocities with fixed speed dwells. One must note that when two sets of complementary noncircular gears are used the output angles of the first set become the input angles of the second set. In addition, all of the angles on the gears must add up to 2Π radians or 360 degrees.
As compared to conventional methods, such as the slip gap method described above, for changing the speed of a discrete part such that it can be applied to a continuously moving web, the use of noncircular gears provides the ability to obtain greater changes in speed and to maintain constant speeds for a fixed duration. The fixed speed dwell achieved by using noncircular gears can be accurately and inexpensively designed to precisely control the length and placement of the discrete parts 32.
For example, in the various aspects of the invention, the profile of the noncircular gears 54 and 62 is analytically designed such that the rotatable transfer assembly 40 receives discrete the parts 32 in the taking zone 42 while maintaining a constant surface speed substantially equal to the incoming speed of the parts 32. Moreover, the profile of the noncircular gears 54 and 62 is designed such that the surface speed of the rotatable transfer assembly 40 changes to a second constant surface speed as the rotatable transfer assembly 40 moves from the taking zone 42 to the transfer zone 44. The term "surface speed," as used herein, refers to the speed of the circumferential, outer peripheral surface of the transfer assembly 40 as defined by arcuate outer surfaces 74 of the respective transport heads 46. The profile of the noncircular gears can be designed such that the speed of the discrete parts 32 being transferred is substantially equal to the speed of the substrate web 34 as the discrete parts are applied to the substrate web in the transfer zone 44. The surface speed of the transfer assembly 40 is maintained substantially constant in the taking zone 42 and the transfer zone 44 for from at least about 0 to about 300 degrees of rotation, desirably from about 10 to about 300 degrees of rotation, and more desirably from about 120 to about 240 degrees of rotation of the transfer assembly 40. In addition, the surface speed increase or decrease of the transfer assembly 40 as it moves from the taking zone 42 to the transfer zone 44 defines a speed ratio of from at least about 0.9:1 to about 20:1, desirably from about 0.9:1 to about 10:1, and more desirably from about 0.9:1 to about 4:1. The term "speed ratio", as used herein, defines the ratio of the surface speed of the transfer assembly 40 as the parts 32 are applied to the substrate web 34 to the surface speed of the transfer assembly 40 as the parts 32 are taken.
The method and apparatus of the present invention may be used in the manufacture of articles such as diapers, training pants, and adult incontinence products, among other uses. The method and apparatus may be used to apply discrete parts or components, such as, for example, waist elastic, leg elastic, tapes, snaps and hook and loop materials to the diaper or incontinence product. Articles such as diapers and incontinence products are described, for example, in U.S. Pat. No. 4,704,116 issued Nov. 3, 1987, to Enloe; U.S. Pat. No. 4,798,603 issued Jan. 17, 1989, to Meyer et al.; U.S. Pat. No. 4,710,187 issued Dec. 1, 1987, to Boland et al.; U.S. Pat. No. 4,770,656 issued Sep. 13, 1988, to Proxmire et al.; and No. 4,762,521 issued Aug. 9, 1988 to Roessler et al.; the disclosures of which are incorporated herein by reference.
In the example illustrated in FIGS. 8 and 11, the rotatable transfer assembly 140 includes three shell segments 148A, 148B, and 148C, supported by concentric shaft 168 and tubular suction conduit 158.
Accordingly, as shown in FIGS. 10, 11 and 16, starting from the taking zone 142, the arcuate top wall 174 of the transport head is disposed transverse to the direction of travel of the incoming web 136 of elastic material as the respective transport head picks up the incoming elastic material. The cam mechanism 172 then rotates the transport head 90 degrees about radial axis 176 by the time it reaches the transfer zone 144, and rotates it back the same 90 degrees by the time it returns to the taking zone.
Slip ring 119A is bolted to shell segment 148A by bolts 121, and extends about, and is mounted for rotation about tubular suction conduit 158 at a fixed longitudinal location along the length of the conduit. A first array of suction ports 122A is disposed circumferentially about the outer wall of the conduit 158 along a portion of the path of rotation of slip ring 118A. FIGS. 10 and 11. A second array of suction ports 123A is disposed about a portion of the circumference of slip ring 119A adjacent shell segment 148A, and in alignment with the first array of suction ports in the conduit 158. Conventional suction seals (not shown) are used between the slip ring and the outer circumferential wall of the conduit 158. Accordingly, as the slip ring 119A rotates about conduit 158 with shell segment 148A, the second array of suction ports on the slip ring comes into alignment with the first array of suction ports on the conduit. Upon such alignment, suction is effected between conduit 158 and the interior chamber 124A of the shell segment 148A, as shown in FIG. 11. Correspondingly, the suction in the interior chamber 124A is transferred to transport head 146A through a third array of suction ports 126A in the top cover 128A of shell segment 148A.
Crank clevis 114 (FIG. 12) is mounted to shell segment 148A by upper and lower bearings 198, 199. A pair of arms 200 extend outwardly from the main body 201 of the crank clevis, for receiving the actuating arm 110A. A pair of upper and lower generally circular bearing posts 202, 204 extend upwardly and downwardly, respectively, from the upper and lower surfaces of arms 200 and engage the upper and lower bearings 198, 199. Male slot key 206 extends upwardly from the upper bearing post 202.
The arcuate top wall 212 of the transport head 146 includes a taking section 218. Referring to FIGS. 10 and 13-15, each taking section 218 has a length "L" and a width "W", with the length being disposed in a direction transverse to the arc of the arcuate top wall 212, whereby each taking section 218 lies within generally a constant portion of the corresponding arcuate outer surface 174 along its entire length.
As seen in FIG. 13, each taking section 218 includes a substrate portion 220 extending above the main level 221 of the arcuate outer surface 174 of top wall 212 of transport head 146, and a toughened coating 222.
"Textured surface" and "texture" of the surface of the parts 132 refers to any irregularities in the respective surface of the part that gives effective third dimension to the surface. Thus, for example, the fibers in nonwoven or woven fabrics comprise irregularities. Similarly, an emboss pattern in an otherwise smooth surface layer of film or nonwoven fabric would comprise a texture. Irregularities may be uniformly spaced as in a repeat emboss pattern or woven fabric, or spaced randomly as with nonwoven fibers.
As seen in FIGS. 8-16, the arcuate outer surface 174 of the transport head is oriented transverse to the direction of travel of the incoming webs 136 at the respective transport head. Suction is activated on the taking sections of the transport head 146C as transport head 146C rotates into position to take the incoming webs onto its taking sections. As the transfer assembly continues to rotate about its horizontal axis 178, the taking sections of the transport head 146C take and hold corresponding portions of the webs 136, thus continuing the drawing of the webs 136 into the transfer assembly. Accordingly, the leading edge of each part 132 is oriented at an angle "A" transverse to the direction in which the part is travelling when the part is taken onto the transport head in taking zone 142.
Without plasma coating 222, and using 45 inches of water, suction, the above web material 136, including layers 230A, 230B of 0.7 ounce per square yard spunbonded polypropylene and four threads of 940 decitex lycra, after being severed by heated cutter 184, exhibits greater than 10% snap-back. Using the plasma coating 222, and using only one inch water of suction, snap-back is less than 10% retracts to length shorter than 90% of the length, L1, as shown in FIG. 6. Both the amount of suctions and the characteristics of the coating material 222 can be adjusted to affect the amount of snap-back tolerated by the specifications of the material being processed and the product being made. The amount of snap-back increases as the amount of suction is decreased. Snap-back also increases as the character of the coating material 222 changes to reduce the amount of entanglement between the fibers or other texturing of the surface of layers 230 and the protrusions 225.
As used herein, "transverse" direction, when referring to rotation of the discrete parts means anything not aligned with the first direction of travel of the receiving web 36 or 136, and not 180� from the first direction.
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