MXPA00011121A - Process and apparatus for cutting of discrete components of a multi-component workpiece and depositing them with registration on a moving web of material - Google Patents

Abstract

This invention pertains to a machine and process forcutting discrete workpiece components from webs of material, precisely registering them with respect to one another, and depositing them with precise registration onto a constantly moving web of material, the webs of material optionally all moving at different speeds. In a particular embodiment of the invention, a process for manufacturing a multi-component absorbent personal hygiene article is described.

Description

PROCESS AND APPARATUS FOR CUTTING DISCRETE COMPONENTS OF A WORKPIECE OF MULTIPLE COMPONENTS AND DEPOSIT THEM WITH CORRESPONDENCE ON FABRIC OF MATERIAL IN MOTION FIELD OF THE INVENTION The present invention relates to a method and apparatus for receiving discrete parts of a work piece that move at different speeds relative to one another and apply the parts to a fabric of moving material. More particularly, the invention relates to a method and an apparatus for receiving discrete portions from at least two fabrics of the movable material that move at different speeds and deposit the discrete parts with a controllable correspondence on a third tissue of moving material. continually.

BACKGROUND OF THE INVENTION Items such as infant diapers, adult incontinence diapers, sanitary napkins and the like have generally been manufactured by processes wherein the discrete parts or components of the article are deposited on a continuously moving product fabric. Frequently, the speed at which they occur the parts or components and are supplied inside the process is not the same as the advance speed of the product fabric itself. In such cases, the speed of production and / or deposit of the component parts on the moving tissue must be varied to match the speed of the fabric of the product to properly match the parts with the moving tissue without affecting _adv, e > Quite the process or the finished item.

Various methods are known in the art to change the velocity of a part or component of material to deposit it on a continuously moving tissue. One method employs segmented rollers in sections which move in and out in a radial direction to their direction of rotation. As the roller is rotated, the segments are driven through gear or camming means to move them in and out by changing the linear surface speed of the roller segments as the roller rotates through each revolution.

Another method uses festoons to reduce the speed of moving tissue to which the parts or components are to be applied. The continuously moving tissue is temporarily retarded at the speed of the component parts to be deposited, with the excess part of the tissue continually moving, folding in festoons. Although the tissue continuously in motion is retarded to equalize the speed of the component parts, the parts are transferred to the fabric and the speed of the fabric is then accelerated to fold the festoons before the next cycle.

Another method is the so-called "slip separation" method in which the parts or components are cut from a fabric of material moving at a slower speed than that of the fabric of the product. When the component parts of the first material fabric are cut, they are held in either the anvil roller or the cutting roller through a vacuum means. By passing the pieces tangentially to the product fabric continuously in motion which is moving at a different speed, the parts or components temporarily slip until they are transferred with vacuum to the product fabric continuously in motion.

These known methods for transferring component parts, moving at a speed, to a continuously moving tissue moving at a different speed, do not refer to the problem of ensuring a careful correspondence of the component parts deposited on the tissue continuously in motion. The problem is exacerbated when there is a need to deposit two or more components, one on top of the other on a continuously moving tissue while ensuring careful correspondence of one component with the other, or with the tissue in movement.

SYNTHESIS In one embodiment, the present invention provides a process for manufacturing a multi-component workpiece comprising at least two components cut from fabrics of moving material, matching the components one with respect to the other, and depositing the components that they have been matched on a fabric of moving material. The process comprises the steps of a) cutting the first discrete workpiece components of a fabric of the first material moving at a first fabric speed, b) cutting the second discrete workpiece components of a fabric of the second material moving at a second tissue speed, c) matching the first and second discrete workpiece components and making them correspond to one another, and d) depositing the first and second workpiece components with correspondence on a third tissue of material that moves at a constant third speed.

In another embodiment, the invention provides a machine for cutting the first and second discrete workpiece components, respectively, of the first and second material fabrics that run at different speeds tissue constants, the first and second workpiece components being optionally of different lengths, made to correspond to one another, and deposited with correspondence on a third tissue of material moving at a third constant tissue speed.

The machine comprises a first apparatus for cutting the discrete components of a fabric of material moving at a first speed, and a second apparatus for cutting discrete components of a second fabric material of the second material moving at a second tissue speed. . The speed matching apparatus comprises a first speed matching roller for receiving the first discrete workpiece components from the first cutting apparatus and a second speed matching roller for receiving the second discrete workpiece components from the second cutting apparatus, and matching and matching the work piece components first and second one with respect to the other and depositing them with correspondence on the third fabric of material moving at a third constant speed.

The non-constant drive means drives the first and second speed cassette rollers independently, each at a higher constant residence speed and at a lower constant residence speed with appropriate periods of acceleration and deceleration between the highest and lowest constant residence rates. One of the higher or lower constant residence velocities of the first velocity-matching roller equals the constant velocity of the third weaving material and the other of the higher or lower constant residence velocities of the first velocity-matching roller equals the velocity of constant tissue of the first tissue material. One of the higher or lower constant residence velocities of the second velocity-matching roller equals the constant velocity of the first weaving material, and the other of the higher or lower constant resisting velocities of the second velocity-matching roller equals the velocity. constant tissue velocity of the second tissue material.

In another embodiment, the present invention provides a method for manufacturing a multi-component absorbent personal hygiene article comprising a transmission or distribution component layer, a fluid transfer delay component layer, and an absorbent, deposited layer. on a backing layer, the distribution, fluid retention and absorbent layers are of a different length and are placed correspondingly with respect to each other on the lower layer.

BRIEF DESCRIPTION OF THE DRAWING FIGURES Figure 1 shows, in a perspective view, a schematic representation of a machine according to an embodiment of the invention.

Figure 2 shows an anvil roll and die cutting assembly for cutting a fabric of material by the "butterfly cut" method.

Figure 3 shows an anvil roll and die cut assembly for cutting a fabric of material by the "stair cut" method.

Figure 4 is a partially schematic side view of the machine shown in Figure 1.

Figure 5 shows an amplified part of the side view of the machine of Figure 4.

Figure 6 shows a generalized velocity profile diagram for the non-linear drive gears for a mode of a machine of the invention.

Figure 7 is a generalized view of non-circular gears.

Figure 8 is a schematic representation of the drive train for a machine of the invention.

Figure 9 shows cross-sectional views of a collector vacuum system.

Figure 10 shows a cross-sectional view of the manifold of Figure 9 taken along the cut line AA.

Figure 11 shows a cross-sectional view of a central vacuum collector system.

Figure 12 shows a cross-sectional view of the manifold of Figure 11 taken along the cutting line BB.

Figure 13 shows a velocity profile of the speed-matching rollers of the machine of Figure 1.

Figure 1 shows a plan view of the elements of an ultra-thin sanitary napkin manufactured by the machine of the processes of the present invention.

Figure 15 shows in a side section view the elements of the ultra-thin feminine sanitary towel of the Figure 14 Figure 16 shows in the side cut view the elements of a female "maxi" towel.

The invention is not limited in its application to the details of construction or arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other incorporations or of being practiced or carried out in various other ways. Also, it is understood that the terminology and phraseology used herein are for the purpose of description and illustration and should not be viewed as limiting. Like reference numbers in the figures of the drawings are used to indicate similar components.

DESCRIPTION OF THE ILLUSTRATED INCORPORATIONS An embodiment of a machine according to the present invention is shown in Figure 1 which schematically shows a machine for depositing two components of differing lengths, cut from the material tissues moving at different speeds, which makes them correspond carefully one with respect to another, and deposit them on a moving fabric at a constant speed. Since the two components have different lengths, the 0 fabric from which each one is cut and the apparatus to cut each tissue, must move at different speeds. The machine of the invention provides the coincidence and careful correspondence of the two components as well as the deposit of the married components with a careful correspondence on a tissue which moves at a speed different from that of any of the two tissues of which They cut the components.

The machine comprises as its main components, a transport apparatus 100. a first component die cutting apparatus 400. a second component die cutting apparatus 300. a component velocity matching apparatus 200. and an etching apparatus optional 600. The rollers 102 and 104 of the tissue transporting apparatus 100. 402 and 404 of the first component die cutting apparatus 400. 302 and 304 of the second component die cutting apparatus 300. and 602 and 604 of the apparatus. of optional engraving 600. are driven at a constant speed equal to the axis speed of the machine line, measured in terms of product per minute. The rollers 125 and 150 of the component speed matching apparatus 200 are driven at a variable speed in the manner detailed below.

Referring to Figure 1, a tissue is delivered 202 of a second material under a light tension to the roller 510. The material then passes between the anvil roller 302 and the die cutting roller 304 to cut the tissue 202 of the second material into the component parts 204 having the desired dimensions and shape.

The die cutter 300 may be configured to cut component parts by any "butterfly cut" method or a "stair cut" method as shown in Figures 2 and 3, respectively. The ladder cutting method is shown in Figure 3, wherein an advancing fabric 808 of material passes between the anvil roller 802 and the cutting die roll 804. The "ladder" of material 810 of the cutting fabric is shows moving up and out of cutting roll 804 and anvil roller 802. Cutted component parts 808 are shown moving along the process stream outwardly of anvil roller 802 and roller die cut 804. The lengths of the cut component parts 808 are indicated by the dimension Lc. The repetition length of the component, for example, the distance between the leading edge of a cut component and the leading edge of the next cut component, is indicated as LCR and the repetition length of the product, for example the distance between the leading edge of the component. a completed workpiece and the leading edge of the next workpiece that follows in the product stream is indicated as 1, r? which may or may not be the same as the repetition lengths of component.

Although they have been shown as pieces having parallel sides and semicircular ends, component parts 808, cut by the ladder cutting method, can be of any desired shape. Since the fabric 806 is of a width greater than the width of the cut component pieces 808, there is a region of material on the ladder 810 along the sides of each component part. Similarly, there is a region of material of length L,; R - Lc between the successive component parts. As a result of this, component parts 808 can be cut into any desired shape by the ladder cutting method, as well as for example the circular, elliptical, "dog bone", meshed, etc. shape. Although it has the advantage of allowing the component parts to be cut in any desired shape, the ladder cutting method suffers, however, from the disadvantage of having more waste than the butterfly cutting method, which is shown in FIG. Figure 2 In Figure 2, a moving tissue 706 of material is shown as passing between an anvil roll 702 and the die cutting roller 704 to produce the component parts 708 cut by the butterfly method. Waste pieces 710 are smaller than those derived from the ladder cutting method. The component length, the 1 component repetition length, and product repetition length, are indicated as Lc, or ,, and L ", respectively, as in Figure 3.

Since in the butterfly cutting method, the material fabric 706 is the same width as the final cut component pieces 708, there is less waste but the cut pieces are constrained to have the parallel sides of the fabric 706. However, alternatively, the advancing material fabric to be cut by the butterfly cutting method can be previously cut so that the sides of the fabric have a repeating pattern of any desired shape. It is an easy matter to match the cutting frequency on the die cutting roller with the repetition frequency of the cutting side pattern on the fabric to produce component parts cut by the butterfly cutting method, but having the side edges shaped . This alternative increases, however, the cost and complexity of the process and the option of cutting the component parts of a fabric having parallel sides is preferred. The butterfly cutting method is also preferred in those cases where the fabric of material to be cut into component parts is expensive, and the amount of waste generated by the cutting process will be minimized.

Referring again to Figure 1, a tissue 212 of a first material is delivered under light tension to the roller 520. The material then passes between the anvil roller 402 and the die cutting roller 404 to cut the tissue 212 of the first material into the first discrete workpiece components. 214 that have the desired shape and dimensions. Again, as discussed above, the components of the workpiece 214 can be cut from the fabric 212 by any method of butterfly cutting or stair cutting, as desired.

The first discrete workpiece components 214, which are displaced without essentially any tension, are maintained on the surface of the die cut roll 404 through the vacuum means discussed below. Similarly, the second discrete workpiece components 204 that move essentially without tension are held on the surface of the die cutting roller 304 through the vacuum means.

The first discrete workpiece components 214 are displaced with the die cutting roller 404 until they enter the void or gap X between the die cutting roller 404 and the speed matching roller 150 as shown in FIG. Figure 4. This hollow X is at least equal to the uncompressed thickness of the tissue 212 of the first material. When a component 214 enters the hole X, the vacuum is released onto the die cutting roller 404 and applied to the speed matching roller 150 causing the component parts 214 to be transferred from the die cutting roller 404 to the speed matching roller 150. Similarly, the second components of the discrete workpiece 204 are moved with the die cutting roller 304 until they enter the gap Y between the die cutting roller 304 and the speed matching roller 125. This gap Y is at least equal to the thickness non-compressed tissue 202 of the second material. The vacuum is released on the die cutting roller 304 and applied to the speed matching roller 125 causing the cut pieces 204 to be transferred from the die cutting roller 304 to the speed matching roller 125.

As the first and second discrete component parts 214 and 204, respectively, move with the rotating speed-matching rollers 125 and 150 and enter the gap Z between the first and second velocity cassette rollers 150 and 125, they are matched. The gap Z is at least equal to the combined uncompressed thickness of the fabric 212 of the first material and the fabric 202 of the second material. The vacuum that holds the second component part 204 in the speed-matching roller 125 is released from the speed-matching roller 125, and the second component-part 204 is transferred to the speed transfer roller 150 by means of a upper vacuum which in turn is operated in the speed matching roller 150 to hold both first workpiece components 214 and second 204 in the roll 150. The first component 214, now in sandwich form between the second component 204 and the surface of the speed-matching roller 150 and the component 214 are both maintained by the vacuum in the speed-matching roller 150.

By indexing the die cutting rollers 304 or 404 one with respect to the other, the first component part 214 can be made controllably correlated with respect to the second component part 204 so that the first part is centered on the second or, in such that the leading end of the first advancing piece directs or follows the leading edge of the second piece by any desired amount. This indexing is achieved in a manner well understood in the mechanical arts such as by interposing between the machine line shaft and the shaft driver any or both of the die cutting rollers 304 or 404 a phase change differential of the type manufactured by Fairchild Industrial Products Company, 1501 Fairchild Drive, inston-Sale, North Carolina, United States of America under the trademark "Specon®". This allows adjustment of the phase angle between the die cutting rollers 304 and 404 to advance or delay the cutting of one of the components 204 or 214 with respect to each other. ^ £ j ^ £ _ ^ & M Referring still to Figure 1, a fabric 222 of a third material is supplied under light tension from a roll of material, not shown, to the tissue transporting apparatus 100 which comprises the rolls 102 and 104 and the endless band 106 passing on the rollers. The fabric 222 is held by conventional vacuum means, not shown, on the surface of the endless belt 106 which moves in the direction shown by the arrow.

As the first and second matched or even discrete component parts, shown as 224 in Figures 1 and 4, continue to travel, with the speed matching roller 150, they enter the recess W (Figure 4) and meet the advancing tissue 222 and they are transferred by releasing the vacuum which previously held the married pair 224 in the speed-matching roller 150. The vacuum applied to the endless belt 106 makes the two pieces, still married and in correspondence in their relative positions one to the other , are transferred to the fabric 222. Optionally, an adhesive 112, applied to the fabric 222 by a slot or spray layer applicator 110 serves to further bond the first and second married component parts 224 to the advancing fabric 222.

Optional additional operations are applied to the work pieces as they are advanced through the machine, such as recording the first and second components. -.to- " married and superimposed with a pattern 256 by means of an engraving roller with pattern 602 and an anvil roller 604, and applying additional components to the workpiece in subsequent operations. It should be noted, however, that in the case where a pattern 256 is to be engraved on the fabric 222 and the overlapping components 224, a close correspondence of the components and the engraved pattern must also be maintained. This is achieved by the machine of the invention by means of a close correspondence of the components constituting the 224 and the firm adherence of the components 224 to the moving tissue 222.

Diecutting apparatuses 300 and 400. Recording apparatus 600 and rollers 510 and 520 are all driven from a common line shaft using conventional pulleys and gearboxes. The die cutting apparatus 300 and 400 and the engraving apparatus 600 perform a function with each revolution of the line axis, while the transport of the receiving tissue 100 and the rollers 510 and 520 advance the various tissues passing respectively on these a repetition length of product with each revolution of the line axis. In contrast, speed-matching rollers 125 and 150 move at non-linear speeds during parts of each revolution in a manner which is described in detail below.

Having described the overall operation of the machine of the invention, the operation details of the speed-matching rollers 125 and 150 will now be described. Reference is now made to Figure 4 which shows a side view of the machine elements of the Figure 1. Identical reference numbers are used to denote the same elements in both Figures 1 and 4.

The roller 520, the anvil roller 402 and the die cutter roller 404 are driven at a constant surface velocity equal to the constant velocity of the material 212 through the first die cutter component 400, that is at a speed of LCR1 per repetition where LCR, is the repetition length of component of the first workpiece component 214. (The workpiece speed expressed as repetition length per repetition is a convenient unit of workpiece speed since it is independent of the speed of the real machine). As the front ends of each discrete component part 214 approach the point of the narrowest gap X between the die cutting roller 404 and the speed matching roller 150, the speed matching roller 150 decelerates further to move with an equal surface velocity at the surface speed of the die cutting roller 404. The speed equalizing roller 150 remains at this speed by a fraction f of the workpiece repetition for the discrete component part 214. Üg ^^^ ^ fraction of a repeat, f, is typically selected to provide a sufficient time to turn off or remove the vacuum holding the first workpiece component 214 on the die cutting roller 404 and to turn on or put on the vacuum holding the component 214 in the speed-matching roller 150. The length of the leading end of the component 214 which advances during the period t is released from the die cutting roller 404 and is transferred to the speed-matching roller 150 by the vacuum now applied to the matching roller. of speed 150.

The duration of time corresponding to f is chosen to be generally greater than one tenth of repetition. If the fraction of a repetition is very small, the time is too short to effectively put or remove the two vacuum controls, and the fraction of the length of the workpiece component transferred and held by the receiving roller is too short to ensure an effective transfer. Preferably f is from about 0.2 to about 0.4 repetition, more preferably from a value of about 0.25 for reasons which will be elaborated down below.

After the length of component 214 corresponding to the repeat fraction f has been transferred to the velocity matching roller 150, and that the vacuum that previously held the component 214 in the die cutting roller 404 has been turned off or has been removed, the speed matching roller accelerates to match that of the fabric 222 to which the two components 204 and 214 are eventually transferred, for example a speed of L ^ by repetition where pg is the repetition length of the final product, and the speed with which the fabric 222 is moving.

Simultaneously with this course of events, a fabric of the second material 202 passes over the roller 510 and passes between the anvil roller 302 and the die cutting roller 304 to cut the fabric 202 into discrete second workpiece components 204. . The roller 510, the anvil roller 302 and the die cutting roller 304 are driven at a constant surface velocity equal to the constant velocity of the material 202 through the first component die cutting apparatus 300. for example to a LCR2 velocity per repetition where LCR2 is the component repetition length of component 204. As the leading end of each discrete component 204 approaches the point of the narrowest gap Y between the die cutting roller 304 and the nip roll speed 125, the speed-matching roller 125 decelerates at a surface velocity equal to the surface speed of the die-cutting roller 304, eg, LQ per repetition. The velocity matching roller 125 remains at this speed for a fraction f of a repetition for the part discrete component 204 to allow the transfer of a leading fraction of the length of a second workpiece component 204 from the die cutting roller 304 to the speed matching roller 125. This is done in the manner described above, ie, by turning off or removing the vacuum holding the component 204 on the die cutting roller 304 and turning on or putting the vacuum holding the component 204 on the speed matching roller 125.

The speed matching roller 125 then accelerates to equalize the speed of the speed matching roller 150, for example LCRi by repetition. As the front ends of both the first 204 and second 214 components approach the narrower gap Z between the speed-matching rollers 125 and 150, the vacuum holding the component 204 is turned off or removed and a higher vacuum is applied to the bonding roller. speed 150 and, as a consequence, the component 204 is transferred to the speed-matching roller 150, having in the form of a sandwich the component 214 between the component 204 and the surface of the speed-matching roller 150.

As the leading end of the sandwich-like components 204 and 214, designated 224 in Figure 4, approaches, the narrowest gap point between the speed-matching roller 150 and the endless belt 106 leads to the tissue 222, the speed matching roller 150 accelerates to equalize the speed of the endless belt 106 and the product fabric 222, for example, a speed of Lra per repetition. The vacuum that holds the pair of sandwich components 224 in the speed cassette roll 150 is turned off or removed and the continuous vacuum applied to the endless belt 106 serves to transfer and hold the pair of components 224 sandwiched or "stacked" in the web. In addition, an adhesive 112, optionally applied to the fabric 222 by application of groove or spray coating 110 also serves to hold the lower element of the sandwich pair 224 in the fabric 222.

Having generally described the operation of speed cassette rolls 125 and 150, its orientation is explained in greater detail with reference to Figure 5 which shows an amplified element of Figure 4.

In Figure 5, the speed-matching rollers 125, 150 and the endless belt 106 are shown with the direction of movement of each indicated by the arrows with half a head. The speed matching roller 125 is driven by the non-linear driving means described in greater detail below, to move it at a faster speed which is equal to the repetition length per repetition of the first component workpiece 214, for example LCR1 by repetition, and at a slower speed which is equal to the repetition length per repetition of the second component, for example Leu by repetition. The non-linear drive means appropriately accelerates and decelerates the speed-matching roller 125 between these upper and lower speeds of the second speed-matching roller.

Similarly, the speed-matching roller 150 is driven by the non-linear driving means to move at a faster speed of the first speed-matching roller which is equal to the speed of the product fabric 222, that is at a speed of the length of repetition of product per repetition, Lre per repetition and at a slower speed which is equal to the highest speed of the second speed-matching roller 125, for example LCR2 per repetition.

In Figure 5, a first work piece component 214 is shown entering the point of the narrowest gap Z between the speed-matching roller 150 and the speed-matching roller 125 just as a second part component is entering similarly. 204 on the Z-axis. The radial marker arrow 155 on a speed marker roller 150 points to "S," indicating that, at this point in time, the roller 150 is beginning its residence at the slowest speed LCRI by repetition. As mentioned above, the speed-matching roller 150 resides or remains at this constant slower speed for a period f until the roller has been turned in the direction of the arrow to the point in where the radial marker arrow 150 now points to the point between "Sl" and "Fl". By continuing to rotate the speed-matching roller 150, the non-linear drive means accelerates the first speed-matching roller 150 until the radial arrow 155 points to the "F" marker. As the roller 150 continues to rotate in the direction of the arrow, the non-linear drive means causes the first speed-matching roller to remain at the upper speed, Lre per repetition, for the duration of the rotation between "Fl" and the point between "Fl" and "82". As the roller 150 continues to rotate, the non-linear drive means decelerates the roller until the radial arrow 150 points to S2. Therefore when running the machine, the first speed matching roller 150 remains at high speed Lre by repetition, decelerates, remains at low speed Lf. ,, 2 by repetition and accelerates, in a repetitive or cyclic manner.

In this manner, the second speed-matching roller 125 undergoes residencies or cyclical or repetitive stays at a higher constant speed LCR1 per repetition, designated "F.", "Fb", and "Fc" in Figure 5, and stays at speed slowest constant of LCR2 per repetition, designated "St", "Sb", and "Sc", with appropriate periods of acceleration and deceleration between them.

Figure 5 shows the speed-matching rollers 125 and 150 in a position in which the radial arrow 155 on the speed-matching roller 150 points to the start of the slower speed stay S, for a first speed-matching roller 150. The radial arrow 130 on the second speed-matching roller 125 is pointing to the start of the higher speed stay F. for a second speed-matching roller 125. When the rolls are turned in the direction indicated by the half-head arrow, the arrow radial 155 on the speed cassette roll 150 will point to the point between "Sl" and "Fl" indicating the start of acceleration of the speed-matching roller 150. During this period, the speed-matching roller 125 has been turned so that the radial arrow 130 now points to the point between "Fa" and "Sa" indicating the start of deceleration of the speed-matching roller 125. At this moment in time, there is a lack of responsiveness of the speeds between the speed-matching rollers 125 and 150. This mismatching of the speeds is made possible by the fact that the rollers 150 and 125 are not in contact, but have a Z-gap between them. This gap is chosen to be at least equal to the combined uncompressed thickness of the two stacked workpiece components 204 and 214. In other words, the rollers 125 and 150 are not pressure point rollers, which apply pressure to the components to pull them through the Z separation. The movement of the components of work piece is controlled, instead of this, by being kept on a particular roller by means of the vacuum methods described above and which are described in more detail below.

The work piece component 214 is being maintained in the roll 150 by means of the vacuum, while the leading end of the work piece component 204 is being transferred to the roll 150 by the vacuum applied to roll 150, the vacuum that it previously held the work piece component 204 on the roller 125 has been removed. In this form, the work piece component 204 is literally slidably pulled out of the roll 125. The tail portion of the component 204 slides across the surface of the roll 125. This action has the advantage that the work piece work 204 can not be "piled up" on the roll 150 during the transfer of the component from the roll 125 to the roll 150 which would be the consequence if the relative high and low speeds of the two rolls were to be inverted.

The first speed cassette roll 150 is shown in the embodiment illustrated in Figures 1, 4 and 5 as having a circumference equal to five times the length corresponding to the area under the speed profile curve for roll 150. (A generalized velocity profile curve is shown in Figure 6, and will be discussed further below). The second speed matching roller 125 has a circumference equal to three times the area under the velocity profile curve for roll 125. The circumference of any roll may independently take any integral multiple value, n, from the area under its velocity profile curve, even when as a practical matter , not all values are possible. Depending on the length of the workpiece component, of course, the speed cassette rolls having a value of n = 1 can be of a very small diameter to easily accommodate the required internal vacuum elements for the roll. However, in those cases where a repetition length of workpiece is appreciable, rollers having a circumference corresponding to n = 1 may be possible.

At the opposite end, the rollers having equal circumferences to a large integral manifold of the workpiece component become so large and massive that their acceleration and deceleration continue between their slower and faster dwell speeds at higher machine rates puts tension on your nonlinear drive systems.

A generalized velocity profile curve is shown in Figure 6. The discussion of the generalized velocity profile curve shown in Figure 6 which follows will be for the velocity caster roll 150 or for the purposes of illustration. The upper speed j of Figure 6 is specifically L ,,, per repetition for the final work piece. The lowest speed, designated L, in Figure 6, is e, per repetition for workpiece component 214. The tilt portions of curve b4 and b5 represent, respectively, the deceleration and acceleration portions of the profile speed for roll 150. As indicated by the dotted line, the current acceleration and deceleration portions of the velocity curve are not linear, but the area under the curve is equal to that bound by the heavier solid straight lines. The area under this curve, for the velocity caster roll 150 then becomes simply the sum of the rectangular area joined by the line L, and the repetition 1, plus the area under the trapezoidal region of the velocity curve joined by the curve of speed and Ll. If the slow and fast speed dwell times, b, and b2, respectively, and the acceleration and deceleration times b5 and b4 respectively, are chosen to be all equal, this is all repeats of 0.25, the area under the speed curve is simply made the average of L, and L, or, specifically for rollers 150,. { Lm + LCR1) / 2. This is the distance traveled by the roller 150 in a cycle of product repetition.

Given this distance, the circumference (and the diameter) of the roller 150 can be determined with a given choice for the value n, mentioned above. This is, the roller velocity caster 150 can be constructed with a circumference n (L "<LCR1) / 2.

Similarly, by applying the generalized velocity profile curve of Figure 6 to the speed-matching roller 125, and using the fair analysis presented for roll 150, the circumference of the speed-matching roller 125 is simply made n (LCR1 + LCR2) / 2.

Having discussed in detail the operation of the speed-matching rollers, there follows a discussion of the nature of the non-linear drive system for the speed-matching rollers 125 and 150.

The impellers and joints for an incorporation of a machine of the present invention are shown in Figure 8. The corresponding components in Figures 1, 4, 5 and 8 are given the same reference numerals for clarity.

Various means can be used to drive the speed caster rolls 125 and 150 in a non-linear manner, including electronically controlled servomotors, follower and cam mechanisms, and non-circular gear systems. The driving system must be capable, they are nevertheless responsive to the demanding work cycle. The drivers of Non-circular gears are preferred because of their hardness and their time rates between long faults compared to servomotor systems and follower and cam mechanisms.

The use of a separate non-circular gear drive for each of the speed caster rolls 125 and 150 in the incorporation of the machine illustrated in the Figures of the drawing therefore provides a cheap and adaptable method for driving the two speed cassette rolls. .

The non-circular gear drive for each speed-matching roller comprises a pair of gears: a non-circular input gear (impeller) and a non-circular output drive gear. In each case the input gear is driven by the machine line shaft at a constant rate. To provide the variable angular speeds required by the speed-matching rollers, the radius of the input gear or non-circular drive varies. Furthermore, since the center-to-center distance between the non-circular gears remains constant, the radius of the non-circular output or driven gear changes to correspond to the changes in the radius of the non-circular drive or input gear so that the two gears remain engaged or engaged during rotation.

Two respective designs of the non-circular drive or input and output or driven gears are chosen to obtain the desired output function, for example, the velocity profile for the typical velocity caster roll as shown in Figure 6, discussed above.

The non-circular gears, such as those employed in the machine and in the process of the present invention, may be purchased from Cunningham Industries, Inc., located in Stamford, CT, United States of America. Alternatively, an ordinary expert in the art of mechanical engineering can manufacture the desired set of complementary non-circular gears, provided that the analytical representation of the desired output works.

For example, the design of a non-circular gear set, as representatively shown in Figure 7, is developed as follows. First the output function is presented, including the speeds and process residences required, as illustrated in Figure 6 to determine the appropriate radius of the orbital trajectory taken by the velocity casters. Secondly, the coefficients are computed which establish the transition or acceleration / deceleration parts of the non-circular gears. Once the angles, proportions and coefficients are known, the distance from center to center of gear is chosen which follows the radii required for the non-circular gears.

The radius, R, of the orbital path was determined by first calculating the total area under the output function curve illustrated in Figure 6: Area = L, + 0.5 (b, + b2) (j - L,) (equation 1) R = rea / 2 * (equation 2) where: R = The radius of the orbital path (mm) Area = Area under the output function curve L, = The low speed of the speed-matching roller driven by the output gear (for example the mm / repeat for the component being transferred) L2 = The high speed of the speed-matching roller driven by the output gear (for example the mm / repetition for the product) b, = Total time (repetitions) during the part trapezoidal curve of output function b2 = Total residence time (repetitions) at high speed bj = Total residence time (repetitions) at low speed Once the radius of the orbital trajectory is determined, the proportions and gear angles for the non-circular gears are determined as follows, wherein the input gear is shown with the number 920 and the output gear with the number 922 in Figure 7: 'ENTA For the input gear (drive) = 2tbj (equation 3) "RAUDA for the input gear (drive) = 2n * b2 (equation 4) 'ACCELERATE the input gear (impeller) = 2t (b5-b2) (equation 5) 'DECELERATE for the input gear (impeller) = 2? R- (' SLOW + ÍRAPT + 'ACCELERATE) (equation 6) 'SLOW For the output gear (drive) = (L, b3) / R (equation 7) • -FAST for the output gear (impeller) = (L.b2) / R (equation 8) 'ACCELERATE for the output gear (driven) = [2b5 (L, / 2 4- (L2 - L,) / 4)] / R (equation 9) 'DECELERATE for the output gear (impeller) = 2' - (+ 'RAUDA +' ACCELERATE) (equation 10) Slow speed ratio = Y, = ('SLOW for the output gear) / (_U TA for «1 input gear) = L, / 2trR (equation 11) Fast speed ratio = Y2 = ('QUICK a to the output gear) / (HAND P *? To the input gear) = L2 / 2 »tR (equation 12) Once the appropriate gear ratios and gear angles have been determined, the coefficients can be computed which define the shape of the non-circular gears. The segments of the peripheries of the input (impeller) and output (driven) gears by the 'SLOW AND' FAST gear angles in each case will define the arc of a circle to ensure that the slow and fast residence times will be of constant velocity. However, the segments of the peripheries of the input and output gears for the transition regions defined by the gear angles 'ACCELERATE' and 'DECELERATE' must define non-circular arcs. Non-circular gears designed using a sinusoidal function to define the acceleration and deceleration transitions have been found to give good results in practice. The equation that defines the shape of the transition part of the non-circular gears is: IACBXERATION = A - B COS Cí (equation 13) where ^ ACCELERATION is the gear ratio as a function of the angular position during the transition, and A = (Y, + Y2) / 2 (equation 14) B = (Y2 + Y,) / 2 (equation 15) C = 2 * 7 ') ACCELERATION for the input gear (equation 16) The current tilt line radius, p, for each non-circular gear can be determined once a choice of the center-to-center distance between the two gears has been made. The gear spokes are given by: P INJECTED DRIVE = DCENTER (l * P ACCELERATE '(ßCUATION 17) = nCENTRO "P DRIVEED GEAR (ßCUATION 18) where p PULSE DRIVEN = the radius of the non-circular driven gear, p PICKED GEAR = the radius of the non-circular drive gear, and DCENT = the desired center to center gear distance or D ^ in Figure 7.

By computing the gear ratios at intervals along the transition using equation 13 given above, a smooth curve can be derived by defining the tilt line using equations 17 and 18. The resulting smooth curve of the tilt line is used to build a gear section which is then used to make the non-circular gears.

Referring to Figure 8, the overall drive train for the illustrated embodiment of the machine of the present invention is illustrated schematically. The driving system 1000 drives the first speed-matching roller 150 and the driving system 1100 drives the second speed-matching roller 125. The driving system 1000 comprises a non-circular driving gear 1002 and the non-circular driven gear 1004. The non-circular driving gear 1002 is rotated at a constant angular velocity of the machine line shaft 1010. The non-driven or driven gear 1004 drives a gear joint constituted of the drive shaft 1012, the gear 1018, the gear 1022 and the belt. of articulation gear 1026. Gear 1022 drives the casting roller of speed 150 by means of a shaft 1030. As discussed above, the circumference of the speed-matching roller 150 can be any possible integral multiple, n, of the area under the speed profile designated for the speed-matching roller 150. This value for n then it becomes the gear ratio for the gears 1022 and 1018. For example, if the speed-matching roller 150 completes five repetitions per revolution, then n = 5, and the gear ratio of the gear 1022 to 1018 is of 5: 1 In a similar manner, the impeller system 1100 comprises the non-circular drive gear 1006 and the non-circular driven gear 1008. The non-circular drive gear 1006 is flipped to the constant angular velocity of the line axis of the machine 1014. The non-circular driven or output gear 1008 drives a multiplier gear constituted of the drive shaft 1016, the gear 1020, the gear 1024, and the articulation gear band 1028. The gear 1024 drives the speed-matching roller 125 by means of the shaft 1032. The gear ratio for the gears 1024 and 1020 in the gear joint is the value of n for the speed-matching roller 125. As discussed above, n is any integral multiple of the area under the velocity profile curve for the speed matching roller 125. As shown in the embodiment shown in Figure 8, the speed matching roller 125 is shown as having do one circumference equal to three repetitions per revolution. Correspondingly, the gear ratio of the gear 1024 to 1020 is 3: 1.

Having discussed the design and construction of the non-circular gear sets for driving the speed-matching rollers, vacuum mechanisms will now be described to support the work piece components 204 and 214 on their anvil and die cutting rollers. respective and the respective speed cassette rollers.

Two conventional vacuum systems are known in the art, which can be used in the rollers of the machine of the invention, and are illustrated in Figures 9, 10, 11 and 12. Figure 9 shows an end view cross section of a vacuum system called "side-collector" 1200. Figure 10 shows the vacuum system of Figure 9 in the cross-section taken along the line of cut AA.

Referring to Figure 10, the vacuum system comprises a stationary collector 1202 and the rotor 1204 has a series of tubular holes 1208 drilled therein, parallel to the axis of rotation 1204. The holes 1206, radially driven in the rotor 1204 connect the tubes axial or holes 1208 with the outer surface of the rotor 1204. The vacuum is introduced into the manifold through the inlet pipe 1210 in the area between pieces or vacuum chips 1212.

Referring to Figure 9, the vacuum pieces 1212 block the connection of the manifold 1202 to the axial tubes 1208 in the rotor 1204 for a fraction of each rotation of the rotor 1204. Therefore, a vacuum is introduced into the tubes 1208 of the rotor 1204 only during that part of each rotation of the rotor 1204 designated by the arc ß when a chip or vacuum chute 1212 is not interposed between the collector 1202 and the rotor 1204. The moving vacuum tabs 1212 determine the ends of the area of vacuum defined by the ß arc. The sections of the arcs a and ß can be adjusted by the appropriate placement of the vacuum tabs 1212. The collector system laterally 1200 is very adapted for the rollers in the machine of the invention where it is necessary only to put or remove the vacuum, as for example in die cutting rolls 304 and 404.

Figure 11 shows an end view cross section of the so-called "center manifold" vacuum system 1300. Figure 12 shows a cross section of the system 1300 taken along the cut line BB.

Referring to Figure 12, the 1300 system comprises a stationary collector consisting of two sections 1302 and 1318. The upper section in Figure 12 comprises a chamber 1308 and tube 1312 through which the high vacuum was introduced into chamber 1308. Lower section 1318 of the manifold in Figure 12 comprises a chamber 1310 into which a low vacuum is introduced through tube 1314.

Referring to Figure 11, spacers 1316 are shown which divide the collector into three chambers: a chamber in which no vacuum is introduced, a low vacuum chamber, and a high vacuum chamber. These chambers correspond to the arcs a, ß, and y, respectively. Unlike the side manifold system described above, in the central manifold system, the vacuum is maintained in the low and high vacuum chambers at all times while the radial holes 1306 in the concentric rotor 1304 move beyond each camera. In this manner, the non-empty, low vacuum or high vacuum is introduced to the outer surface of the rotor 1304 in sequence as the rotor 1304 rotates through each revolution. The lengths of the arcs a, ß, and?, Are determined, and can be changed by, the movement of the separators 1316. The central collector system 1300. with its ability to have zones of no vacuum, low vacuum and High vacuum, is very well adapted for the rollers in the machine of the invention where it is necessary to put or remove the vacuum, and to have high vacuum regions as, for example in the speed-matching roller 150.

Although an embodiment of the machine of the invention for depositing and matching two workpiece components of different lengths from each other and subsequently on a fabric of continuously moving material, will be readily shown and illustrated, it will be easily seen by one with a Ordinary skill in the mechanical arts that the machine can be modified to introduce and match the work piece components third, fourth, fifth, etc. , by simply introducing additional anvil roller and die cutting components and speed-matching roller assemblies either adjacent to the speed-matching roller 150, or in the machine downstream in the process from the corresponding elements shown. In this manner, the machine of the present invention provides an efficient and low-cost device for manufacturing multi-component articles of manufacture where there is a need to "stack" and match two or more work piece components and subsequently deposit them with correspondence on a tissue continuously in motion. The speed-matching roller system of the invention, with its non-linear gear drive, provides a means for carrying out this operation with workpiece components of different lengths.

The process for making an article of manufacture using the machine of the invention will be described now with reference to the drawing of Figures 4 and 13.

Referring to Figure 4, in the process of the invention, a fabric of a first material 212 passes between a first die cutting roller 404 and a first anvil roll 402 for cutting the tissue of the first material in the first part components. discrete work pieces 214 having a component length of L,., and a repetition length between the leading edge of a cut workpiece component and the leading edge of the next successive CSF workpiece component. The tissue of the first material, the first die cutting roller and the first anvil roller are moving at a constant surface velocity of LCR1 per repetition. The discrete workpiece components cut from the fabric of the first material are held on the surface of the first die cutting roller through vacuum means while the waste parts, not shown in Figure 4, of the first material fabric. they move out from the surfaces of the first die cutting roller.

A first discrete workpiece component 214 in the train of successive components cut from the first fabric is transferred to a first speed matching roller 150 which is spaced apart from the first die cutting roller by a separation X of at least the thickness not compressed from the first fabric of material.

Upon entry of the first discrete workpiece component cut into the gap X between the first die cutting roll 404 and the first speed matching roll 150, the first speed matching roll moves at a surface speed equal to LCR1 by repetition for a residence period An, preferably around a one-quarter workpiece repetition cycle as shown in the velocity profiles of the first and second velocity caster rolls in Figure 13. During this residence period , a portion of the length of a first cut discrete workpiece component moves inside the gap X separating the first die cutting roll 404 and the first speed setting roll 150 and is transferred from the die cut roll 404 to the first speed caster roll 150. The transfer is effected by turning off the vacuum means holding the first work piece component Discrete cutout 214 in the first die cutting roll 404 and placing the vacuum to hold the front fractional part of the first discrete workpiece component 214 in the first speed matching roll 150.

After the transfer of the front part of a first discrete workpiece component from the first die cutting roller 404 to the first cassette roll of speed 150, the surface velocity of the first speed-matching roller 150 is accelerated for a period (B "in Figure 13), again preferably about one quarter of the workpiece's repetition cycle, at a speed of top surface equal to the speed of a third material product fabric 222, pg by repetition where Lra is the distance between the leading edge of one piece of work product and the leading edge of the next work piece over the third material product fabric.

Upon acceleration of the first speed matching roller 150 at its top speed of Lp ,, per repetition, the tail portion of the first discrete workpiece component is slidably pulled outward from the slower moving surface of the first cutting roller 404 die in which this is being held lightly with vacuum.

After accelerating, the first speed-matching roller 150 then remains at this upper surface velocity, Lre per repetition, for a period of time, preferably about one quarter of a workpiece repetition cycle (C "in the Figure 13). Since, in the embodiment shown, the first speed matching roll 150 is of a circumference equal to a multiple number of product repetitions, a pair of first and second work piece components 224 previously cut and which have been correspondingly enter the gap W between the first speed-matching roller 150 and the third moving tissue of the product material 222. The first and second discrete and cut-out workpiece components 224 that have been matched, held on the surface of the first speed cassette roll 150, are transferred to the third fabric of moving product material 222 by turning off the vacuum holding the first and second discrete and cut workpiece components 224 on the first speed cassette roll 150. The continuous vacuum action holding the third fabric of product material on the surface on which it is passing, adheres the pair of components 224 to the moving tissue.

After the residence period (C "in the Figure 13) at the upper linear surface velocity of pg per repetition, the first speed-matching roller 150 decelerates for a period of time (D "in Figure 13), preferably about one quarter of a workpiece repetition cycle. , at a surface speed of LCR1 per repetition, and the cycle repeats.

By decelerating the first speed-matching roller, the first and second discrete and cut-out workpiece components 224 that have been mapped and stacked, now resting on the third moving tissue. of the product material 224 are slidably pulled out of the first speed-matching roller in which they are slightly held in vacuum.

Even though the steps described above are occurring in relation to the first discrete workpiece components, simultaneously a fabric of a second material 202 passes between a second die cutter roll 304 and a second anvil roll 302 to cut the tissue of the second. material 202 in discrete second workpiece components 204 having a component length of LC2, with a repetition length between the leading edge of a cut workpiece component and the next successive workpiece component of RJ. The tissue of the second material 202, the second die cutting roller 304 and the second anvil roller 302 are moving at a constant surface velocity of LCR2 per repetition where LCR2 is the distance between the leading edge of one of the second cut workpiece components and the leading edge of the second workpiece component following the cutting of the fabric components of the second material.

The discrete workpiece components 204 cut from second material fabric 202 are held on the surface of the second die cutting roller 304 through vacuum means while the waste parts of the fabric of the second material are moved out of the surface of the second die cutting roller.

The second cutter roll 304 and the second speed caster roll 125 are spaced apart by a gap or gap Y of at least the uncompressed thickness of the second fabric 202 of material. The second speed-matching roller 125 moves at a slower linear surface velocity equal to LCR2 per repetition for a residence period (C, 2 in Figure 13), preferably about one quarter of the repeating cycle of the piece of work, sufficient to advance a discrete work piece component and cut 204 through the gap Y separating the second die cutting roll 304 and the second speed matching roll 125. A workpiece component cut earlier in the train of successive components cut from the second fabric of material is simultaneously moving through the gap Z between the second speed-matching roller 125 and the first speed-matching roller 150. The transfer is effected by turning off the holding vacuum means the second discrete workpiece component in the second die cutting roller and placing the vacuum to hold the fractional part forward of the second discrete workpiece component in the second speed-matching roller.

After transfer of the fractional front portion of the second discrete workpiece component from the second die cutting roller 304 to the second speed-matching roller 125, the linear surface velocity of the second speed-matching roller is accelerated for a period of time. (D, 2 in Figure 13) again, preferably about a quarter of a workpiece repetition cycle, at a higher linear surface velocity equal to the slower speed of the first speed-matching roller, for example, LCR1 by repetition. During this acceleration period, the second discrete workpiece component is slidably pulled out of the surface of the second die cutting roller in which it is being lightly held by vacuum.

The second speed-matching roller 125 then remains at this upper linear surface speed, LCR1 per repetition, for a period of time (A ^ in Figure 13), preferably about one quarter of a workpiece repetition cycle, sufficient to advance a part of the length of the second discrete workpiece component through the gap between the second speed-matching roller 125 and the first speed-matching roller 150. The first and second speed-matching rolls are separated by a gap or Z spacing at least equal to the combined uncompressed thickness of the fabrics of the materials first and second 202 and 212.

Upon entering the second cut discrete workpiece component 204, held by vacuum in the second speed cassette roll, in the gap Z between the first and second speed cassette rolls, this is transferred to the first speed cassette roll 150 in a Such as to overlap a first cut discrete workpiece component 214 that is being held by vacuum in the first speed matching roll 150.

Upon entering the leading edge of a first discrete work piece component and cut into the gap Z between the first speed matching roller 150 and the second speed matching roller 125, the leading edge of a second discrete workpiece component 214 it also enters the Z-gap between the first and second speed cassette rolls. The desired offset, if any, between the advancing leading edges of the first and second discrete workpiece components is adjusted through the differential means by driving the first and / or second die cut rolls indicated as 405 and 305 in Figure 8.

The transfer of the second discrete workpiece component 204 from the second speed-matching roller 125 to the first speed-matching roller 150 is performed by removing the vacuum holding the second work piece component 204 in the second speed matching roller 125 and placing the upper vacuum in the first speed matching roller 150 which serves to continue holding the first work piece component discrete cut 214 on the first speed cassette roll 150 while also holding the second discrete workpiece component 204 lying on the first component 214 on the first speed cassette roll 150.

After this residence period (A22 in Figure 13) at this upper surface velocity, the second speed-matching roller 125 decelerates for a period of time (Ba in Figure 13), preferably about one quarter of a cycle. repetition of workpiece, at surface speed, LCR2 per repetition. By decelerating the second speed-matching roller 125, the tail portion of the second discrete workpiece component 204 is slidably pulled out of the second speed-matching roller 125 in which the latter is held lightly by vacuum.

A fabric 222 of a third material is conveyed on an endless belt 106 which moves at a constant speed of Lre by repetition and is held in the endless belt by means of vacuum. The endless belt 106 is separated from the first speed matching roller 150 by a separation of at least the combined thickness of the uncompressed thickness of the materials 202, 212, and 222. As the leading edges of the stacked first and second workpiece components 224 move within the gap H between the first casting roll speed 150 and the endless belt 106, the web and the first speed-matching roller are turning at the same surface speed of Lre by repetition. The first speed matching roller 150 resides at this higher constant speed of n per repetition for a period, preferably about one quarter of a workpiece repetition cycle to move a portion of the lengths of stacked workpiece components to through the gap W separating the first speed-matching roller and the endless belt. Upon entering the leading edges of the workpiece components stacked in the gap, the top vacuum holding the stacked components 214 on the first speed cassette roll 150 is turned off or removed. By decelerating the first speed-matching roller 150 to its lowest speed of LCR1 by repetition, the fastest moving worm 106, holding the stacked components in the third fabric 222 of moving material through the vacuum means, pull the stacked components 224 slidably outward of the first speed cassette roll 150 and on the fabric 222 of the movable material. The first and second stacked and overlapping workpiece components, now held by vacuum and the optional adhesive 112 to the tissue 222 of the third material move down in the process stream to subsequent operations.

Having thus described the process for cutting and stacking with correspondence two discrete workpiece components of different lengths and depositing them on a constantly moving tissue, the following example illustrates the use of the process and the machine of the invention for the manufacture of a sanitary towel for multi-layer feminine hygiene.

Example A towel of ultra-thin or "mini" calls, suitable for use by a woman during the days of light menstrual flow, is shown schematically in the plan view in Figure 14 and in the schematic side view of Figure 15. A thicker towel or so-called "maxi" towel suitable for use by a woman during the days of superior menstrual flow, is shown in a schematic side view of Figure 16. In Figure 14, the towel elements are shown in FIG. a plan view, constructed of the lowest "barrier component" to the component of "Cover" more upper than the towel. The cover component of the towel is the towel component used closest to the wearer's body during use, and the barrier component It is the most used away from the user's body.

The towel 900 shown in Figure 14 and described in this example, comprises a unique distribution feature which serves to disseminate, or distribute the body fluids before they reach the absorbent component of the towel in order to provide a more efficient towel It has a longer service life before the need for replacement and resulting in greater comfort for the user. The distribution feature includes distributing and delaying components not found in prior art towels. The specific materials used for the various components of the towel are described in detail in the co-pending application No. No. (Attorney's Case No. 13303.10), the contents of which are incorporated herein by reference.

In this example, the specific sections of the towel and each component will be given to assist in the understanding of the invention. However, it should be understood that the specific dimensions are cited merely for illustrative purposes and that they should not be read as limiting the scope of the invention as it is defined by the appended claims.

Referring to Figure 14, towel 900 has, when it is finally cut along dotted line 913, H.H-,, a dog bone shape and an overall length Lr equal to about 300 mm. With a concession, for example, for a tension in process of 2 percent and a waste of 0 mm between the successive finished towels when they are cut along dotted line 913, the product repetition length p ,, is 306 mm. The towel 900 comprises an upper cover 222 which is permeable to body fluids. The cover 222 constitutes the movable fabric of the material 222 mentioned in the general process discussed above.

Directly under cover 222 is a length distribution component 204, LC2 / of about 254 mm and a repeat length component, LCR2, of about 260 mm made of a material which serves as a distribution agent to assist in the more or less uniform distribution of the fluids of the body to the absorbent component that is below.

Directly below the distribution component 204 is a transfer delay component 214 of length LC1, of about 268 mm and a component repetition length, LCR1, of about 275 mm which is somewhat less permeable to body fluids. that the cover layer 222. The transfer delay component 214 acts to slightly retard the flow of body fluids to allow the distribution component 204 mentioned above to carry out effectively its transmission function before the passage of body fluids through the absorbent component that is below.

Using the example lengths of each component just mentioned and referring to Figure 1, the fabric 222 travels at a constant linear velocity of 306 mm / repetition, which is the highest speed of the first speed-matching roller 150 in the Figure 1 and in the general process described above.

The fabric of the first material 212 of Figure 1, using the exemplary dimensions of this model, is displaced at a linear velocity of 275 mm / repeat which is the surface speed of the anvil and die cutting rolls 402 and 404 and the slowest speed of the 150 velocity roller.

The fabric of the second material 202, the anvil and die cutting rollers 302 and 304 are moved at a constant surface speed of 260 mm / repetition which is also the low constant residence speed of the speed-matching roller 125.

These component dimensions and speeds of the speed-matching roller are given in Tables 1 and 2, respectively.

T b l a 1 Component Lengths and Tissue Speeds T b l 2 Velocities Speed Roller Referring again to Figure 14, below the transfer delay component 214 is the absorbent component 908. The barrier component 912, which lies under the absorbent component 908, is typically made of a polymeric material which is not permeable to the fluids of the body and which serves to shield the interior garments of the wearer from the spotting by body fluids.

In the towel 900 shown in Figure 14, the cover component is generally translucent and is typically made of a white material. To provide the consumer with visual cues that the towel being purchased has the distribution feature mentioned above, the absorbent layer 908, the transfer delay component 214 and the distribution component 204 are made of materials of different colors. For example, the absorbent component 908 and the distribution component 204 may be white, while the transfer delay component 214 may be light blue, pink, elba or some other pleasing color. The various components, seen through the preferably translucent cover component 222 therefore form a pleasing pattern. The transverse shaded region of the delay to transfer component 214 in Figure 14 appears as a uniform band of color through the translucent top cover component 222. To add to the visual cues, the finished towel 900 may also be engraved with a pattern. of visual key 256.

It is highly desirable that the distribution component 204 and the transfer delay component 214 be carefully mapped with respect to each other, and with the optional recorded visual key 256. If the distribution component 204 and the transfer delay component 214 are not in correspondence, the colored band looks like a non-uniform band and harms the overall aesthetic appearance of the finished product. Furthermore, if the optional recorded visual key pattern 256 is similarly not corresponding to the color band, the overall pleasing appearance of the product is diminished.

Referring to the specific components with the example dimensions given above, the details of the general process for making the female towel of this invention will be made clear with reference to Figure 1.

A fabric of cover material 222 for the towel 900 is supplied to the machine of the invention at a constant speed of LP per repetition or 306 mm / repetition. A fabric of the first material 214 from which the transfer delay components 214 are cut is fed to the pair of die cutting and anvil rolls 402 and 404 at a constant rate of LCR1 per repetition, or 275 mm / repetition. A fabric 202 of the second material is supplied to the anvil and die cutting rollers 302 and 304 at a constant linear velocity of L ^ per repetition, or 260 mm / repetition to be cut into the distribution components 204.

The transfer delay component 214 and the distribution components 204 are matched and matched by means of the speed transfer rollers 125 and 150 and transferred to the moving tissue of the material. of deck 222. The speed-matching rollers 125 and 150 repeatedly undergo acceleration at their respective higher constant residence speeds of 275 mm / repetition and 306 mm / repetition, and deceleration at their respective low residence speeds of 260 mm / repetition and 275 mm / repetition in a cyclic pattern which is 180 degrees out of phase. By "180 degrees out of phase" it is meant that, as shown in Figure 13, when the speed caster roll 150 is moving at its highest residence speed, the roll 125 is moving at its speed of residence more low. Similarly, the speed-matching roller 150 is moving at its lowest residence speed, the roller 125 is moving at its highest residence speed. In this way, the components are controllably corrected by marrying them at a married speed.

Optionally, an application of slot covering adhesive 112 is applied to the moving tissue of the cover material, preferably in a scratch pattern, to help support the components in the fabric of the cover material after they leave the region. of emptiness. The adhesive also serves to hold the stacked distribution components 204 and transfer delay 214 in the fabric 222 of the cover material and in the constantly moving tissue 106.

As shown in Figure 1, the engraving and anvil rollers 602 and 604 apply a recorded and optional visual key pattern 256 to the partially finished towel. Downstream operations, not shown, apply the barrier component 912, the lightweight adhesive which serves to attach the towel to a woman's undergarment, and the strip of peeling, all shown in Figures 15 and 16 On the towel "maxi" shown in Figure 16, a downward operation in the process, also not shown, inserts an absorbent or superabsorbent applicator component 918 into the towel prior to the addition of the barrier component 912, the garment adhesive 914 and the strip of peeling 916.

While the preferred embodiments of the machine and the process of the present invention have been shown and exemplified, it will be clear to those skilled in the art that various deviations from the preferred embodiments of both the process and the machine can be made without departing from the scope. of the invention as defined by the appended claims.

Claims (30)

1. R E I V I N D I C A C I O N S 1. A process for manufacturing a multi-component workpiece comprising at least two components cut from fabrics of moving material, to match the components one with respect to the other, and to deposit the components that have been mapped onto a fabric of moving material comprising the steps of: a) cutting the first discrete workpiece components having a length Lcl and a repeating cut length between the leading edge of a workpiece component from a first material fabric moving at a first fabric speed; discrete work and the leading edge of the next work piece component immediately following LCR1; b) cutting from a second material fabric, moving at a second fabric speed, the second discrete workpiece components having a length LC2 and a repeating cut length between the leading edge of a workpiece component discrete work and the leading edge of the immediately following workpiece component of LCR2; c) transferring the first discrete workpiece component to a moving receiving surface, for a fraction of a workpiece repetition cycle of a product, at a constant first residence speed equal to the speed of the first web of work. moving material; d) transferring the second discrete workpiece component to a second receiving surface which is moved, for a fraction of a product workpiece repetition cycle, to a constant first residence speed equal to the speed of the second fabric of the workpiece. moving material; e) adjusting the speed of said second receiving surface holding said second discrete workpiece component to move, for a fraction of a repeating cycle of workpiece of a product, to a second constant residence speed equaling that of the first constant residence speed of the first receiving surface; f) transferring, with correspondence, the second discrete workpiece component from said second receiving surface to the first receiving surface during the fraction of the workpiece repetition cycle of the product so that the constant residence speeds of said receiving surfaces first and second are equal, for putting said first discrete workpiece component with correspondence on said first receiving surface; g) adjusting the speed of said first receiving surface by bringing said second discrete workpiece component covering said first discrete workpiece component to move it at a second constant residence speed, during a fraction of a one piece repetition cycle of product work, to match that of a third fabric of material in motion; Y h) transferring the first and second discrete workpiece components matched and matched to said third fabric of moving material during a fraction of the repeating cycle of the workpiece of the product so that the constant residence speeds of the first receiving surface and said third fabric of material are equalized; i) readjusting the speed, during a fraction of a product workpiece repetition cycle and after the transfer of the first and second discrete workpiece components that have been matched and that have been mapped to the third material fabric, for move them to said first constant residence speed; Y j) readjusting the speed of said second receiving surface to move it, during a fraction of a product workpiece repetition cycle and after the transfer of the second discrete workpiece component to said first receiving surface, at said speed of constant residence.
2. 2. The process as claimed in clause 1 characterized in that said fractions of a repeating cycle of product workpiece during which the first and second receiving surfaces are moving at their respective first and second constant residence rates and during wherein the speeds of said first and second receiving surfaces are readjusted between their respective first and second constant residence rates comprise equal parts of a product workpiece repeat cycle.
3. 3. The process as claimed in clause 1 characterized in that said equal portions of a product workpiece repetition cycle comprise a quarter of a product workpiece repetition cycle.
4. 4. A process as claimed in clause 1 characterized in that said fabrics of first, second and third material move at constant speeds but independent.
5. 5. A process as claimed in clause 1 characterized in that said length, Lc2, of said second discrete workpiece component is smaller than that of the length, Lcl, of said first discrete workpiece component.
6. 6. A process as claimed in clause 5 characterized in that said second discrete workpiece component lies on and is matched with respect to said first discrete workpiece component to leave a band of said first workpiece component discrete protruding around the periphery of said second discrete workpiece component.
7. 7. A process as claimed in clause 6 characterized in that said third fabric of material comprises a semi-transparent material.
8. 8. The process as claimed in clause 7 characterized in that said second discrete workpiece component lies on and is matched with respect to said first discrete workpiece component to leave a band of said first workpiece component discrete protruding around the periphery of said second discrete and visible work piece component through the semitransparent material comprising said fabric of the third material.
9. 9. The process as claimed in clause 1 characterized in that said fabrics of first, second and third material are independently selected colors.
10. 10. The process as claimed in clause 9 characterized in that said second discrete workpiece component lies on and has been matched with respect to said first discrete workpiece component to leave a color band of said first component of discrete workpiece projecting around the periphery of said second workpiece component discrete and visible through the semitransparent material comprising said fabric of the third material.
11. 11. The process as claimed in clause 10 characterized in that said second discrete workpiece component lies on and has been symmetrically matched with respect to said first discrete workpiece component to leave a symmetrical color band of said first workpiece. discrete workpiece component projecting around the periphery of said second component part of discreet and visible work through the semitransparent material comprising said fabric of the third material.
12. 12. A method for manufacturing a multi-component absorbent personal hygiene article comprising a fluid permeable cover layer, a fluid distribution component layer adjacent to the cover layer, and a fluid transfer delay component layer contiguous with said layer of fluid distribution component, the layers being deposited on the cover layer, with the distribution component, fluid retention and absorbent layers being of a different length and being placed in a matching shape with respect to each other. to the others; The method comprises the steps of: a) cutting of a fluid transfer delay component of length Lc, and of a first fabric of moving material; b) cutting a fluid distribution component of length Lc2 from a second fabric of moving material; c) transferring the fluid transfer delay component to a first speed moving roller, for a part of a revolution, at a first constant residence speed equal to the speed of said first fabric of moving material; d) transferring the fluid distribution component to a second speed moving roller, for a portion of one revolution, at a first constant residence speed equal to the speed of the second fabric of moving material; e) adjusting the speed of said second speed-matching roller carrying said fluid distribution component to move it, by a portion of one revolution, at a second constant residence speed equaling that first constant residence speed of the first speed-matching roller; f) transferring the fluid transfer delay component from the second speed-matching roller to said first speed-matching roller during a portion of the revolution so that the constant residence speeds of the first and second speed cassette rolls are married , to cover said fluid distribution component with correspondence on said first speed caster roll; g) adjusting the speed of the first speed-matching roller bearing the fluid transfer delay component covering said fluid distribution component to move it at a second constant residence speed, during a part of a revolution, equaling that of a third moving fabric of said outer cover material; Y h) transferring said fluid transfer delay component covering said fluid distribution component to said third fabric of moving cover material during a portion of the revolution so that the constant residence speeds of said first speed matching roller and of the third fabric of material are matched, to cover, with correspondence, said cover material.
13. 13. A method as claimed in clause 12 characterized in that said cover layer is made of a semi-transparent material.
14. 14. A method as claimed in clause 12 characterized in that said distribution component and the fluid transfer delay component are made of materials that have independently selected colors.
15. 15. A method as claimed in clause 14 characterized in that said distribution component is smaller than those of the fluid transfer delay component.
16. 16. A method as claimed in clause 12 characterized in that said distribution component is matched with respect to said fluid transfer delay component in such a way that a uniform band of said fluid transfer delay component protrudes around of the periphery of said fluid distribution component.
17. 17. A method as claimed in clause 12 characterized in that said cover layer is made of a semitransparent material and said distribution component and said fluid transfer delay component are manufactured materials having independently selected colors.
18. 18. A method as claimed in clause 17 characterized in that said distribution component is matched with respect to said delay component of fluid transfer in a manner such that a uniform band of the color of said fluid transfer delay component is visible through the semitransparent cover layer around the periphery of said fluid distribution component.
19. 19. The method as claimed in clause 12, characterized in that it comprises the step of engraving said cover layer with a pattern.
20. 20. The method as claimed in clause 19 characterized in that said engraving pattern has been matched with respect to said fluid distribution and fluid transfer delay components.
21. 21. The method as claimed in clause 20 characterized in that said engraving pattern is centered with respect to the fluid distribution and fluid transfer delay components.
22. 22. A method for manufacturing a multi-component absorbent personal hygiene article comprising a semitransparent fluid-permeable cover layer, a fluid distribution component layer adjacent said cover layer, and said layer of transfer delay component. fluid contiguous to said fluid distribution component layer, the layers being deposited on the cover layer, with the distribution component, fluid retention and absorbent layers being of a different length and which have been mapped in position relative to each other the others; the method comprising the steps of: a) cutting a fluid transfer delay component of a first fabric of moving material having a first color; b) cutting a fluid distribution component of smaller dimensions than those of the fluid transfer delay component of a second fabric of moving material having a second color; c) transferring the fluid transfer delay component to a first speed-matching roller that moves, for a portion of a revolution, at a first constant residence speed equal to the speed of the first fabric of moving material; d) transferring the fluid distribution component to a second speed-matching roller that moves, by a portion of a revolution, at a first speed of constant residence equal to the speed of said second tissue of moving material; e) adjusting the speed of said second speed-matching roller carrying said fluid distribution component to move it, by a portion of one revolution, at a second constant residence speed equaling that first constant residence speed of the first speed-matching roller; f) transferring the fluid transfer delay component from the second speed-matching roller to said first speed-matching roller during a portion of the revolution so that the constant residence velocities of the first and second speed-matching rolls are equalized , to cover said fluid distribution component with correspondence on said first speed-matching roller; g) adjusting the speed of the first speed matching roller carrying said fluid transfer delay component covering said fluid distribution component to move it at a second constant residence speed, during a portion of a revolution, equaling that of a third moving tissue of said cover layer material; Y h) transferring said fluid transfer delay component covering said fluid distribution component to said third moving fabric of cover material during a part of the revolution so that the constant residence speeds of said first speed matching roller and said third fabric material are matched, to cover, correspondingly, said cover material; wherein a band of the first color of said fluid transfer delay component is visible through said semitransparent cover layer around the periphery of said fluid distribution layer.
23. 23. A method as claimed in clause 22 characterized in that said fluid distribution component is put in correspondence with respect to said fluid transfer delay component to produce a symmetrical band of said first color of said transfer delay component of fluid around the periphery of said fluid distribution component.
24. 24. A machine for manufacturing a multi-component workpiece of at least two discrete components of different lengths cut from the first and second moving material fabrics, to match g | j ^^ K¡u ^ the discrete components with respect to each other, and depositing the discrete components that have been coincidentally corresponded on a receiving fabric of moving material, the machine comprises: a) a first cutting apparatus for cutting the first workpiece components of a first fabric of moving material; b) a second cutting apparatus for cutting the second discrete workpiece components of a second fabric of moving material; c) a tissue transport apparatus for transporting a moving tissue of a third material; Y d) a component speed matching apparatus positioned on one side of the first and second cutting apparatus and on one side of the receiving tissue transporting apparatus for receiving the first and second discrete workpiece components from the respective first and second cutting devices , matching and matching the work piece components first and second one with respect to another and depositing, the components that have corresponded correspondence on the third fabric of moving material.
25. 25. A machine as claimed in clause 24 characterized in that the first workpiece component cutting apparatus comprises a first die cutting roll and a first anvil roll configured to cut the first workpiece components from a first fabric. discrete work of length e, with a repeating length of component LCR ,, measured from the leading edge of a discrete component to the leading edge of the next discrete component.
26. 26. A machine as claimed in clause 24 characterized in that the second workpiece component cutting apparatus comprises the second die cutting roller and the second anvil roll configured to cut the second part components of a second tissue from a second tissue. discrete work of length Lf.2 with a repeating length of component LCR2, measured from the leading edge of a discrete component to the leading edge of the next discrete component.
27. 27. A magic as claimed in clause 24 characterized in that the receiving tissue transport apparatus comprises an endless belt having vacuum means for holding the tissue of the third material in the endless belt.
28. 28. A machine as claimed in clause 25 characterized in that said first workpiece component cutting apparatus comprises vacuum means for holding said first discrete workpiece components cut on said first die cutting roller for a fraction of a rotation of said die cutting roller.
29. 29. A machine as claimed in clause 26 characterized in that said first workpiece component cutting apparatus further comprises vacuum means 31. A machine as claimed in clause 30 characterized in that said first speed-matching roller further comprises the lower vacuum means for transferring said first cut-and-discrete workpiece component from the first die cutting roller and holding said first cut and discrete workpiece component on the surface of said first speed-matching roller for a fraction of a rotation of the speed-matching roller, and upper vacuum means for transferring said second and discrete work-piece component from the second speed cassette roller for covering said first cut and discrete workpiece component by holding said first and second cut and discrete workpiece components on the surface of the first speed cassette roll by a fraction of a rotation of the cutting roll to die 32. A machine as claimed in clause 30 characterized in that said second speed-matching roller further comprises vacuum means for transferring said second cut-and-discrete workpiece component from the second die-cutting roller and holding said second component of work piece cut and discrete on the surface of said second speed-matching roller for a fraction of a rotation of said speed-matching roller. 33. A machine as claimed in clause 30 characterized in that the slower constant residence speed of the first speed-matching roller is equal to the fastest constant residence speed of the second speed-matching roller. 34. A machine as claimed in clause 30 characterized in that the fastest constant speed of residence of the first speed-matching roller is equal to the constant speed of the endless belt of the third fabric of moving material.
30. 30. A machine as claimed in clause 30 characterized in that the slower constant residence speed of the second speed-matching roller is equal to the speed of the second fabric of moving material. 36. A machine as claimed in clause 24 further characterized in that it comprises means for recording a pattern on said work piece. R? ? V M E N This invention relates to a machine and a process for cutting discrete workpiece components from fabrics of material, making them correspond precisely with respect to each other, and depositing them with a precise correspondence on a fabric of constantly moving material, the fabrics of material optionally all move at different speeds. In a particular embodiment of the invention, a process for the manufacture of an article for personal hygiene absorbent of multiple components is described.