MXPA99004222A - Variable tension process and apparatus for continuously moving layers - Google Patents

Abstract

A process and apparatus for controllably registering two continuously moving layers of material is provided. A continuously moving first layer has a plurality of components, and a continuously moving second layer has a plurality of reference marks representing a respective plurality of components. The process and apparatus control the distance between reference marks of the second layer to a selected distance, and then controllably registers each reference mark of the second layer to a respective component of the continuously moving first layer.

Description

PROCESS AND VARIABLE TENSION APPARATUS FOR COATS CONTINUOUSLY IN MOTION Background of the Invention The present invention relates generally to processes and apparatuses for making disposable absorbent articles, and particularly to processes and apparatuses for making disposable absorbent articles having components that are matched.

Several products are manufactured in a continuous production line by sequentially adding components to previously supplied components. This is particularly advantageous when one or more of the components can be supplied in the form of a single continuous layer. For example, in the formation of disposable absorbent articles, such as training underpants, diapers, incontinence articles, women's care products, or the like, a layer is normally supplied at a point on the line of manufacture in the form of a continuous roll, and absorbent pads, elastic waistbands, elastic leg bands, stretchable side panels, and / or other elements or components may be supplied separately and individually at different points on the line of manufacturing as discrete objects for that layer.

Various methods and apparatus are available to carry these separate and individual components of a single product together so that the components in the composite product are in a desired ratio with respect to each other. In carrying these separate and individual components properly together, various known methods and apparatus are used to sense the position of a particular component, and then adjust the placement of the subsequent components in order to place them properly.

A problem with current methods and apparatuses is that they do not provide adequate means for matching two layers continuously in motion, and particularly when one of the layers has a pre-printed or pre-positioned component or the like which is to be matched to a pre-printed or pre-positioned component or the like on the other of the layers during the manufacture of a plurality of products having a desired correspondence of components.

Synthesis of the Invention In response to the difficulties and problems discussed in the prior art, the present invention provides a process and apparatus for matching a plurality of components on a continuously moving layer with a plurality of respective components on the other layer continuously in motion.

In one form of the invention, there is provided a process for controllably matching a plurality of components of a first layer continuously in motion with a plurality of components on a continuously moving second layer, comprising the steps of: (1) providing a continuously moving first layer including a plurality of components, (2) providing a continuously moving second layer that includes a plurality of components, (3) representing the components of one of the continuously moving layers with a respective plurality of markings of reference, (4) perceive each of the reference marks and generate a reference mark signal in response thereto, (5) measure the distance between two successive reference mark signals and generate a corrective control signal of repetition of according to the preprogrammed instructions, (6) selectively apply pressure to the one layer continuously in motion in response to the repetitive corrective control signal generated to adjust the distance between two successive reference marks, (7) superimpose together the first layer continuously in motion and the second layer continuously in motion, (8) perceive a reference mark and its corresponding component of the other layer and generate a corrective positioning control signal in accordance with the preprogrammed instructions, and (9) adjusting the speed of the one layer continuously in motion in response to a corrective positioning control signal generated for controllably matching the reference mark on the one layer continuously in motion with its corresponding component on the other layer continuously in motion.

In another form of the present invention, there is provided a process for controllably matching a plurality of reference marks of a first layer continuously in motion with a plurality of corresponding reference marks of a second layer continuously in motion, comprising the steps of : (1) providing a continuously moving first layer including a plurality of reference marks selectively placed thereon, (2) providing a continuously moving second layer including a plurality of corresponding reference marks selectively placed thereon, (3) perceive each of the reference marks of one of the continually moving layers and generate a reference mark signal in response to them, (4) measure the distance between two successive reference mark signals and generate a Recurrent corrective control signal according to the preprogram instructions das, (5) print the one layer continuously in motion in response to a generated repeating corrective control signal, (6) overlap the layers continuously in motion together, (7) perceive a reference mark of the one layer continuously in motion and its corresponding reference mark of the other layer continuously moving and generating a corrective positioning control signal in accordance with the preprogrammed instructions, and (8) adjusting the speed of the one layer continuously in motion in response to the signal of corrective positioning control generated to controllably match a reference mark of one layer continuously in motion with its corresponding reference mark on the other layer continuously in motion.

In still another form of the present invention there is provided an apparatus for controllably matching a plurality of components of a first layer continuously in motion with a plurality of components on a continuously moving second layer, comprising (1) means for providing a first continuously moving layer including a plurality of components, (2) means for providing a continuously moving second layer including a plurality of components being represented by a respective plurality of reference marks, (3) means for sensing each of the reference marks and means for generating a reference mark signal in response to these, (4) means for measuring the distance between two successive reference mark signals, and means for generating a repetitive corrective control signal in accordance with preprogrammed instructions, (5) means to selectively apply pressure to the u a layer continuously in motion in response to a repetitive corrective control signal generated to adjust the distance between two successive reference marks, (6) means for overlaying together the first layer continuously in motion and the second layer continuously in motion, (7) ) means for perceiving a reference mark and its corresponding component of the first layer, and means for generating a corrective positioning control signal in accordance with the preprogrammed instructions, and (8) means for adjusting the speed of the second layer continuously in movement in response to a positioning corrective control signal generated to controllably match a reference mark on the second layer continuously in motion with its corresponding component on the first layer continuously in motion.

In still another form of the present invention, there is provided an apparatus for controllably matching a plurality of reference marks of a first layer continuously in motion with a plurality of corresponding reference marks of a continuously moving second layer, comprising: 1) means for providing a continuously moving first layer including a plurality of reference marks selectively placed thereon, (2) means for providing a continuously moving second layer including a plurality of corresponding reference marks selectively placed thereon, (3) means for sensing each of the reference marks of one of the continuously moving layers, and means for generating a reference mark signal in response thereto, (4) means for measuring the distance between two successive reference mark signals, and means for generating a repetitive corrective control signal in accordance with the preprogrammed instructions , (5) means for printing or marking the one layer continuously in motion in response to a generated repetitive corrective control signal, (6) means for overlaying together the layers continuously in motion, (7) means for perceiving a reference mark. of the one layer continuously in motion and its corresponding reference mark of another layer continuously in motion, and means for generating a corrective positioning control signal according to the preprogrammed instructions, and (8) means for adjusting the speed of a layer continuously moving in response to the positioning corrective control signal generated to controllably match a reference mark of the one layer continuously in motion with its corresponding reference mark on the other layer continuously moving.

Brief Description of the Drawings The above-mentioned and other features of the present invention and the manner of achieving them will become more apparent, and the invention itself will be better understood with reference to the following detailed description of the invention, taken in conjunction with the accompanying drawings in which : Figure 1 illustrates a front view of an article having a graph that has been matched thereon; Figure 2 illustrates a front view of another article having a graph that has been matched thereon; Figure 2A representatively shows the article of Figure 2 in a partially disassembled flat and stretched state; Figure 3 illustrates a continuously moving layer having a plurality of separate and distinct graphics thereon; Figure 4 illustrates a continuously moving composite layer having a plurality of separate and distinct graphics thereon; Figure 5 schematically illustrates an apparatus and a process for manufacturing an article having a graph that has been mapped thereon; Figure 6 illustrates a schematic block diagram of the data flow used in conjunction with the apparatus and the process of Figure 5; Y Figure 7 illustrates graphically a placement control used in conjunction with the apparatus and the process of Figure 5.

Detailed description The following detailed description will be made in the context of matching and controlling the matching of components on a continuously moving layer with the components on at least one second layer continuously moving in the manufacture of disposable absorbent articles, and specifically a brief underpants. Disposable absorbent learning for children. Examples of other disposable absorbent articles include, but are not limited to, absorbent underpants, diapers, women's care products, incontinence products, or the like. The present invention also contemplates other products not related to disposable absorbent articles. For the purposes of this description, the term "product" may refer to, but is not limited to, any article, device, laminate, composite or the like. The term "component" may refer to, but is not limited to, the designated selected regions, such as edges, corners, sides or the like; the structural members, such as the elastic strips, the absorbent pads, the stretchable layers or the panels, the layers of material or the like; or a graph. The term "graphic" may refer to, but is not limited to, any design, pattern or the like.

A child's disposable training underpants can have, by way of example, multiple appearance-related and / or functional components that have been mapped within the machine's direction (MD) and / or transverse direction (CD) ) selected. The term "machine direction" refers to the primary direction of movement of the layers continuously moving in the process of manufacturing processes, and the term "transverse direction" refers to a direction transverse to the direction of the machine . The example described here is that of matching a graph in the machine direction within a designated area of the underpants.

Therefore, the present invention can provide a child's disposable learning underpants having one or more functional components or related to the appearance that have been matched with other components. Examples of components that are related to appearance include, but are not limited to, the matching of graphs; to highlighting or emphasizing leg and waist openings in order to make a conformant product more evident or visible to the user; highlighting or emphasizing product areas to simulate functional components, such as elastic leg bands, elastic waistbands, simulated "fly openings" for boys, frills for girls; highlighted areas of the product to change the appearance of the product size; coincident moisture indicators, temperature indicators, and the like in the product; matching a back label, or a front label, on the product; and matching written instructions in a desired place on the product.

Examples of functional components include, but are not limited to, waist elastics, leg elastics, breathable areas, fluid repellent areas, fluid moistening areas, adhesives or coatings, encapsulated inks, chemically sensitive materials, environmentally sensitive materials, heat sensitive materials, moisture sensitive materials, perfumes, odor control agents, inks, to fasteners, to fluid storage areas, to textured or etched areas, or the like.

The training underpants described herein comprise an absorbent pad placed between an outer liquid-impervious cover and a liquid-permeable liner. The training underpants also include elastic side panels which are attached to the outer cover in order to provide elasticity thereto. The liquid impervious outer cover may comprise two layers of material suitably joined together, in which the innermost layer may be a liquid impervious layer and the outermost layer may be a nonwoven layer having a fabric-like texture. In this case, it is the layer that is impermeable to the innermost liquid that has a printed graphic coinciding on it. The map that has been mapped generally includes a visually pleasing pattern or pattern and is controllably mapped to a designated area on the product. An example of a map that has been mapped includes a graphic placed on the front center of the underpants, and includes a simulated elastic waist band, simulated elastic leg bands, or a simulated "fly opening" for children, the simulated waves for girls, or similar. A more detailed description of the construction and design of the disposable absorbent training underpants is in United States of America Patent No. 4,940,464 issued July 10, 1990, the contents of which are incorporated herein by reference.

A distinctive process and apparatus for matching a plurality of distinct and selectively separated components positioned on a continuously moving first layer of material with a respective plurality of separate and selectively separated components positioned on a second layer of continuously moving material are described herein. . The second layer of material has the components suitably represented by the reference marks or associated with said respective reference marks, both provided therein at a uniform repetition length which is the same, or essentially the same as the repetition length of the product of machine, defined hereinafter. The distance between two successive reference marks is measured or determined, and then used to determine or calculate, if necessary, a repeatable corrective control signal for the current process conditions. The repeating corrective control signal will either be a signal to elongate the layer, for example, an elongating repetitive corrective control signal, or a signal to pick up the layer, for example, a pickup repeat corrective control signal. If a repeating corrective control signal is generated or calculated, the second layer of material is then elongated or controllably collected so that the distance between the two successive reference marks essentially equals the selected distance, which in this case is a repetition length of machine product; This is called the "repeating circuit".

The second layer has been controllably matched to the first layer of material so that each reference mark is selectively placed or reciprocated with a respective component of the first layer; this is called the "placement circuit", and the generated control signal is the placement corrective control signal. Even though the reference marks are preprinted on the layer so that any two successive reference marks are desirably at a repetition length separation of machine product, their separation distance may vary due to printing variations or errors, process conditions, such as variable speeds, atmospheric conditions, variations in the material from which the layer is made, or the like. The repetitive corrective control signal is combined with the corrective positioning control signal. If the resulting corrective control signal is within an acceptable tolerance and the two layers are matched together. If a resulting corrective control signal is outside the acceptable tolerance, the second layer of material is then collected or elongated in a controlled manner so that the two layers can be matched together. The term "reference mark" may refer, but is not limited, to components such as, by way of example, leg or waist elastics, adhesive beads, corners or edges or sides of the structure, the means of transport such as conveyor belts; the visual marks; magnetic markings, electrical markings, electromagnetic markings, optical brighteners sensitive to ultraviolet radiation, or the like, all of which may be perceived, detected or otherwise identified by an appropriate device. The term "machine product repetition length" refers to a selected distance, which in this example is the distance measured between successive similar components during manufacture, for example, between successive waistbands, absorbent pads or Similar. Or in other words, the repetition length of machine product is the length of a product during the manufacturing process. Therefore, when a reference mark is mapped to a component of the first layer, then the component represented by the reference mark is mapped to the component of the first layer.

With respect to the repeating circuit, the second layer has the reference marks selectively provided thereon to correspond to a respective plurality of separate and distinct components, such as graphs. A first sensor generates a reference mark signal in response to each reference mark. The distance between each newly generated signal and the most recently preceding signal is suitably measured by a mechanism or means of printing or marking, so that the mechanism or means can be operated, if necessary, to adjust the length between the two marks. successive reference signals by either picking up or lengthening the second layer, so that the distance between a newly generated signal subsequent to its most recently preceding signal is a repetition length of machine product. Therefore, the repeating circuit refers to repeatedly duplicating a product length between two successive reference marks.

The term "printing or markings" and variations thereof such as, by way of example, "printing", "printing", "printing" or the like, generally refer to the selective application of pressure, for example, to a layer of material or layers of material. The amount of pressure can be selectively applied either to pick up the layer or layers, or to lengthen the layer or layers. In addition, the area over which the pressure can be applied can be selected in any suitable manner. For example, the pressure can be applied through the entire surface area, or a part only, or a layer or layers; it can be applied as a single point line, a pattern or the like; it may be applied as a plurality of points, lines, patterns or the like, or it may be applied in any desirable combination of the foregoing.

With respect to the positioning circuit, a desired correspondence of a reference mark with a component is carried out by comparing and controlling a data value related to a fixed target point. A "data value" refers to a distance measured between a reference mark and a constant reference signal generated by the machine. A "target point" refers to a selected value within which the data value is maintained.

Described here, by way of example, is a distinctive process and apparatus for using a second layer of preprinted material including a plurality of separate and distinct graphics thereon, varying the length as necessary of the second layer to coincide with a length selected, and then applied and matched to another layer that includes preassembled and pre-applied components, such as absorbent pads, thereby providing a manufacturing process for individual disposable absorbent articles having graphics that have been mapped thereon in designated areas . The process and the apparatus may also be used to apply, during manufacturing, other components related to the appearance and various functionalities that have been printed, attached, placed or the like, on a layer of a specified location so as to be selectively matched on the Final product .

The second layer of material can be a continuous pre-printed polyethylene film with a plurality of separate and distinct graphs. The printed graphics are arranged so that they will finally be placed in the same designated area in each finished product. The term "finished" or "final" when used with reference to a product, means that the product has been adequately manufactured for its intended purpose.

The second layer is controllably collected or lengthened, when necessary, to appropriately match the distance between two successive reference marks with the repetition length of the machine product, and adjusted to control a data value related to an established target point. . This is done in order to match the reference marks with the previously processed and pre-positioned components, such as, for example, absorbent pads. A sensor system used in conjunction with a computer apparatus and a computer program inspects for corresponded location, repetition patterns, and fixed point error. The data received from these sensors is used to control the manufacturing process as necessary for the desired correspondence, so that the preprinted graphics are desirably made to coincide with a plurality of respective components.

These characteristics advantageously affect a layer that moves at a high speed in order to make it coincide with another layer. In particular, real-time and accurate information is provided during the production process, and rapid adjustments to the process to provide the desired configuration and correspondence of the reference marks and their associated components in the final product. The use of the term "layer" can refer, but is not limited, to any type of substrate, such as a woven fabric, a nonwoven fabric, films, laminates, composites, elastomeric materials, or the like. A layer may be permeable to liquid and air, permeable to air, but impermeable to liquids, impermeable to both, air and liquid, or the like.

Each of the separate and distinct graphs selectively placed on the continuously moving layer is represented by or associated with a reference mark. This means that each reference mark is placed selectively in relation to a respective graph, so that the reference mark can be perceived and appropriately matched in the product, therefore appropriately matching each graph in its product. Initially, a reference mark was described in terms of specific examples, and in the following description the reference mark is selected as an optical brightener. A reference mark, either an optical brightener or other means, can be configured in any shape or size. The reference mark may comprise a generally rectangular region having a machine direction dimension of about 19 millimeters and a dimension in the transverse direction of about 37 millimeters. Other dimensions may optionally be used. It should be understood that various detection and perception means described herein are appropriately compatible with the type of associated reference mark to be detected or sensed. The term "represented" or "associated" refers to the reference mark either directly on a component that it represents, such as a graphic or being selectively spaced from it. The optical brightener is provided to be sensitive to ultraviolet radiation. The optical brightener, for example, is capable of absorbing ultraviolet radiation and then fluorescing to emit the spectrum of light that can be perceived by a compatible and appropriate sensor or detector. Ultraviolet radiation is generally understood to include electromagnetic radiation having wavelengths ranging from about 20-400 nanometers. Suitable optical brighteners include, for example, UVITEX OB manufactured by Ciba-Geigy, and LEUCOPURE EGM manufactured by Sandoz Chemicals Corporation.

Where the reference mark comprises optical brighteners sensitive to ultraviolet light, a suitable sensor or detector is a UV activated detector, such as a SICK detector, model LUT-2-6 available from SICK OPTIK ELEKTRONIK, INC., A business having offices in St. Paul, Minnesota.

Other suitable reference marks, as well as sensors, computer devices, motors and the like are described in the patents of the United States of America Nos. 5,235,515; 5,359,525; and 4,837,715; the contents of the patents of the United States of America are incorporated herein by reference.

The described process and apparatus use various devices, and representative devices include encoders, signal counters and sensors. An encoder generates a pulse train, which is a selected number of pulses per revolution of the encoder axis, for the subsequent count and control. A signal counter receives a pulse train generated from an encoder and counts the pulses for subsequent queries. A sensor perceives an occurrence or an interruption in a process and generates a signal in response to this.

Referring now to Figure 1, there is illustrated a child's disposable training underpants 10 generally comprising a front panel 12, a back panel 14, a crotch panel 16 interconnecting the front and back panels 12 and 14, and a pair of elastic side panels 18. Each elastic side panel 18 is formed of two separate elastic portions (Figure 2A) and are suitably joined together, such as by ultrasonic joining, to form a side seam 20. With the construction of the side seams 20, a waist opening 22 and leg openings 24 are formed. The side seams 20 can be constructed to be manually torn in order to allow the training underpants 10 to be disassembled manually by the caregiver, so that they can be easily removed from the child after a bowel movement. The elastic side panels 18 (figure 1) and the side seams 20 can be provided in any suitable manner. A specific way of supplying the elastic side panels 18 is described in U.S. Patent No. 5,224,405 and U.S. Patent No. 5,104,116, both of which have been incorporated herein by reference. The provision of side seams 20 can be achieved in the manner described in U.S. Patent No. 5,046,272, which is incorporated herein by reference.

The training underpants 10 further comprises a front waist elastic 26 suitably attached to the front panel 12, a rear waist elastic 28 suitably attached to the back panel 14, the leg elastics 30 suitably attached to the crotch panel 16, and an absorbent pad 32 (Figure 4) positioned between an outer liquid impermeable cover or backing sheet 34 (Figure 1) and a liquid permeable liner or upper sheet 36. The basic construction of a training underpants is well known in the art, and A particular construction is that described in United States of America Patent No. 4,940,464 issued July 10, 1990, the contents of which are incorporated by reference herein. U.S. Patent No. 4,940,464 also describes various materials from which a training underpants can be made and the methods for constructing the training underpants.

As illustrated in Figure 1, a map that has been mapped 38 is selectively placed on the front panel 12, and in this illustration comprises a "fly-out 23" design typical of underwear for a child, and a rainbow , a sun, some clouds and some cars. The corresponded graphic 38 can be any type of desired pattern, artistic feature, written instructions or the like, and it is desired that it be placed in the article in a selected location. The naturally-matched graphic 38 comprising a simulated fly opening 23 will be totally unacceptable from a functional and / or aesthetic point of view if it were located in a crotch panel 16 or a rear panel 14.

Referring to Figure 2, another underpants 40 is illustrated, which can typically be used by young girls. In this design, a map that has been mapped includes the simulated waistlines 29, the simulated leg steps 31, a rainbow, a sun, clouds, a car and a balloon. Again, any suitable design can be used for the underpants of learning understood to be used by young girls, to be aesthetically pleasing and / or functional to these and the caregiver.

The graph that has been matched 38 in figure 1 or the graph that has been made to coincide 42 in the figure 2 can be made controllably correspond as desired, depending on the size and shape of the graph and that part of the article on which the graph is to be matched. In figure 1, the graph 38 is controllably mapped within a designated area 39, which, as seen in Figure 1 is limited or defined by a front waist edge 116, by the panel seams 21 and a crotch panel line 17. The panel seams 21 are the seams in which the respective elastic side panels 18 are suitably joined to the front panel 12 and the back panel 14. Again, a more specific description of the construction and manufacture of this design of a training underpants 10 is contained in United States of America Patent No. 4,940,464. The crotch panel line 17 is for the purposes of explanation herein, simply the line or boundary formed at the bottom of the crotch panel 16 as illustrated in Figure 1. Thus, as described, the designated area 39 has four defined boundaries. comprising the front waist edge 116, the panel seams 21, the crotch panel line 17, and those portions of the leg openings 24 that extend between a respective panel seam 21 and the crotch panel line 17 It is not necessary for a designated area 39 to be completely defined or limited by a closed line or a closed limit. For example, in Figure 1, the designated area 39 can be defined by only the front waist edge 116, the panel seams 21, which sufficiently define a designated area 39 in which a graph 38 can be controllably mapped. In this case, the graph 38 can be controlably matched at a selected distance from the front waist edge 116, and centered between the panel seams 21.

Another example of the flexibility to choose a designated area 39 is illustrated in Figure 2A, which illustrates the training underpants 40 in Figure 2 in a stretched and partially disassembled planar state. This stretched flat state can be achieved by taking the finished training underpants 40 of Figure 2 and manually tearing the seams 20, and then placing the underpants 40 flat and stretching them sufficiently to remove any folds or pleats caused by any built-in elastic members. In Figure 2A, the designated area 39 is defined or limited by a front waist edge 116, the panel seams 21, the rear waist edge 118, and a pair of leg opening edges 25 that extend between the seams. of respective panel 21. Thus, in Figure 2A, the designated area 39 is generally rectangular in shape, and the map that has been mapped 42 is mapped into and through the surface area of the designated area 39. The graph which has been reciprocated 42 comprises several component designs, such as the simulated leg flanges 31 and the simulated waist flanges 29. As seen in Figure 2A, the leg opening edges 25 are linear or straight lines. However, in FIG. 2, the simulated leg flights 31 provide a perceived shape or curvature for the training underpants 40, which is one of the unique features here.

A very narrow tolerance in matching a desired component, such as graphs 38 and 42, is provided in a unique and advantageous manner within any selected area, such as a designated area 39. With reference to FIG. 1, it is evident that the simulated fly opening 23 of the graphic 38 requires matching within the front panel 12. It would be undesirable to have the training underpants 10 manufactured by a method and / or apparatus that could not control proper matching of the fly opening. simulated 23, otherwise, the simulated fly opening 23 could appear on the rear panel 14 or the crotch panel 16. The present invention provides a highly controlled match of a desired component, such as a graph 38 or 42 within a desired designated area, such as the designated area 39 within a tolerance of about plus or minus 12 millimeters, and within a greater tolerance s about between about 3 millimeters.

Referring now to Figure 5, there is schematically shown an apparatus and a process for partially assembling a plurality of training underpants. Supply means 44 continuously supplies an absorbent wrapped with continuous tissue 46 to the spacer means 48 that separate the wrapped absorbent with continuous tissue 46 into a plurality of separate and separate absorbent pads 32. The delivery means 44 can be any conventional mechanism for supplying the absorbent 46. Generally, conventional delivery means 44 will include a hammer mill to form the fluff fibers and, if desired, to provide a wrap for the mixed superabsorbent material with the fluff fibers, and then depositing the fluff and the superabsorbent material onto a forming drum having a desired absorbent design. The forming drum then deposits the formed absorbent on a continuously moving tissue material, which is then delivered to a folding board to fold the tissue around the absorbent. This provides the continuous tissue wrapped absorbent 46. The absorbent can include any desired mixture or combination of absorbent materials, such as erasers and superabsorbent materials. Suitable superabsorbent materials are available from various commercial vendors such as Dow Chemical Company, Hoechst-Celanese Corporation and Allied Colloids, Inc. Typically, a superabsorbent material is capable of absorbing at least about 15 times its weight in water, and more desirably more than about 25 times its weight in water. A preferred label is that identified with the trade designation CR1654 available from Kimberly-Clark Corporation, of Neenah, Wisconsin, and is highly absorbent and bleached sulphate wood pulp containing primarily softwood fibers.

Conveyor means 50, which can be any conventional conveyor means well known in the art, carry absorbent 46 to spacer means 48. Supply means 52 provide a first layer of material 54 continuously in motion, on which it can any desired component, such as the separate and distinct absorbent pads 32 formed by the spacer means 48, may be placed. The delivery means 52 may be any standard unwinding mechanism which generally comprises a pair of spindles, a festoon assembly, and a dancer roller to provide a first layer 54 at a desired speed and tension. An example of a standard unwinding is an MB 820 model, available from Martin Automatic Corporation of Rockford, Illinois. The first layer of continuously moving material 54 can be any desired material suitable for the particular product being assembled. In this description of a training underpants 10 (Figure 1) the first continuously moving layer 54 is a liquid permeable material that will subsequently be formed or become the liquid permeable topsheet 36.

(Figure 1) . The topsheet 36 can be made of any suitable materials well known in the art, and examples of suitable materials are described in the patents of the United States of America mentioned here above.

Upon moving or being delivered to the separating means 48, the absorbent wrapped with continuous tissue 46 is cut into the separate and distinct absorbent pads by a knife roller 56 and by an anvil roller 58 comprising the spacer means 48. The knife roller 56 may have any desired number of blades thereon, and in this example has two blades 60 placed diametrically thereon to form the absorbent pads 32. The blade roller 56 is driven by and mechanically coupled through a gear to the anvil roller 58, which is operatively driven by a main line shaft 128 (Figure 6) in any suitable manner well known in the art. Constant reference means, such as a proximity switch 62 are coupled to the anvil roller 58 to generate a reference signal for each cut absorbent pad 32. For the purposes given here, the separator means 48 is operated at an essentially constant speed during the manufacturing process so that each reference signal generated by the proximity switch 62 is considered a constant machine reference signal for the purposes of comparison with other signals described herein. The constant reference signal generated by the machine from the proximity switch 62 is transmitted to a main control system for further processing as described hereinafter.

The separate and distinct absorbent pads 32 formed by the spacer means 48 are selectively placed on the first layer of material 54 continuously in motion provided by the supply means 52. It is well known in the art to selectively separate and position the absorbent pads individually cut on a continuously moving layer, and any suitable mechanism of these can be used here.

Supply means 64, which can be a standard unwind, similar to that used with reference to the supply means 52, provide a continuously moving second layer 66 of material which will subsequently be attached to the first continuously moving layer 54. The supply means 64 comprises a central driven unwinding spindle 69, a plurality of stationary rollers 71, and an air dancer assembly 77, a driven supply roller 79, a dancer roller 83., and a stationary roller 85. The supply means 64 operates in a conventional manner well known in the art in which the air dancer assembly 77 provides festoons for cutting layers and a speed input signal for the central driven unwinding spindle. 69, as well as for the dancer roller 83 providing a speed input signal to the driven supply roll 79. The second continuously moving layer 66 is moved to a pair of rolls comprising a drive roller 68 and a support roll 70. which form between them a supply pressure point 72. The drive roller 68 can be driven by any suitable motor, such as those described in the patents of the United States of America incorporated herein by reference. A suitable supply pressure point motor is a HR 2000 brushless AC servo motor available from Reliance Electric Company, of Cleveland, Ohio. The material of which second layer 66 is made foldable and stretchable, in the sense that it can be collected or lengthened, by way of example only, between about 0.5% to about 5.0% of a length, for example, a length of repetition of machine product. In being stretchable, the material from which the second layer 66 is made has the property of being thinned or stretched by breaking the joints within the layer when it is stretched. This thinning refers to the thickness of the material rather than its length or width. Other materials having a greater or lesser shrinkage and elongation can be used as the material or materials for the second layer 66. The second continuously moving layer 66, in this particular description, is a liquid impervious film which will subsequently form the outer shell liquid impermeable 34 (figure 1), and such films are available from Edison Plastics Company, of South Plainfield, New Jersey.

If it is desired that the supply pressure point motor 148 (FIG. 6) and its drive system, which operates the drive roller 68, be one that is capable of carrying out two types of controllable variations or speed adjustments. , as controlled by the main control system, which will be described in more detail hereafter. A variation or speed adjustment is to increase a present speed of rotation to a faster speed of rotation, or to decrease the present speed of rotation at a slower speed of rotation. The other adjustment or variation of speed is a momentary variation or speed adjustment comprising an incremental advancing phase movement, which is a momentary speed increase of the drive roller 68 to provide a measured increased amount of the material layer, or an incremental phase phase movement, which is a momentary speed decrease of the drive roller 68 to provide a decreased amount of mediated material layer. The term "momentary speed increase" refers to increasing a first speed to a second speed for a selected period of time, and then causing the speed to return to the first speed, in order to advance the position of the layer and the associated graphs up the pressure point by a mediated amount. The term "momentary speed decrease" refers to decreasing a first speed at a slower second speed for a selected period of time, and then causing the speed to return to the first speed, in order to retard the position of the layer and of the associated graphs upwards of the pressure point by a measured quantity.

The present invention can be used to match two layers continuously moving together, so that a reference mark and / or one component of a layer is matched to a reference mark and / or component on the second layer. In this particular description, a component such as a graph that has been mapped 38 (figure 1) on a second layer continuously in motion 66 (Figure 5) is placed in register with a component, such as an absorbent pad 32, on the first layer 54 continuously in motion. By controllably matching a matched graph 38 with an absorbent pad 32, the desired position of the matching graph 38 on the front panel 12 (Fig. 1) of a training underpants 10 can be achieved. An important function of a graph that has been matched 38 on a front panel 12, is that it visually informs the user of the proper orientation of the training underpants 10 for the purposes of lay, thereby allowing the underpants to Work properly, for example, absorb waste, among other functions. The continuously moving layer 66 has, by way of example, preprinted thereon a plurality of separate and distinct graphs 38, so that the graphs 38 can be made to coincide with the separate and distinct absorbent pads 32 on a continuously moving layer 54. There is associated with each graphic 38 a preprinted reference mark 74, which in this case is an optical brightener. The graphs 38 and their respective reference marks 74 may be provided on the layer 66 in any suitable manner well known in the art.

With reference to Figure 3, there is illustrated a portion of a continuously moving layer 66 having a plurality of the graphics 38 and of the reference marks 74 preprinted or pre-positioned thereon. Associated with each graph 38 is a printed waistband 76 with a printed front edge 78 and a printed back edge 80. Similarly, each reference mark 74 has a reference front edge 82 and a rear reference edge 84. Each reference mark 74 it will be used to properly place an associated graph 38 with an absorbent pad 32. The reference marks 74 are located outside the graphs 38, but they can be printed directly on graphs 38 to be within the design of the graphs. In addition, the reference marks 74 can be eliminated, and a part of a graph 38 can be used as the reference mark. The detectable or similar marks can also be printed as part of the graphics 38 and then used to properly match the graphics 38. However, for explanation and manufacturing purposes, the reference marks 74 are provided at a selected distance of the respective graphs 38.

In the following description, the second continuously moving layer 66 will be described, by way of example, as being joined or laminated to another third layer 92 (FIG. 5) of material, in order to produce a two-layer laminate which will eventually form the outer cover impervious to liquid 34 (Figure 1) . The polyethylene film material from which the layer 66 is made serves as a liquid impervious barrier, while the third layer of material attached to the layer 66 will provide a fabric-like texture to the outer cover. The fabric type layer will be the outermost layer. There is no requirement, however, for the third layer, and in some product designs, the fabric type layer can be removed.

From the supply means 64, the layer 66 moves through the supply pressure point 72 formed by the rollers 68 and 70 and towards a printing or engraving means or mechanism, such as the variable printer or recorder 65, with a roller printer 81 and an associated receiver roll 67 operatively coupled thereto. The receiving roller 67 may be a recessed roller having a plurality of complementary recesses on its cylindrical outer surface. The printing roller 81 of the variable printer 65 can move towards the receiving roller 67 and move away from it by any suitable control means, such as the piston-driven cylinder array, the servo motor arrangement, or the like. One such example is a linear actuator 73 operatively connected by means of a connecting rod 75 to a printing roller 81. The printing roller 81 may comprise a plurality of projections extending outward from its cylindrical outer surface. These projections, in this embodiment, are a plurality of spaced apart discrete elongate flange members oriented generally parallel to the axis of the printing roller 81. These flange members and recesses in the receiving roller 67 are complementary in the sense that each member Flange fits or fits into a respective recess. The printing roller 81 and the receiving roller 67 are operatively coupled together to provide this adjustment or complementary fit. Other design projections and recesses are contemplated by the present invention, and include, but are not limited to, cylindrical or conical shapes, to intersecting flange members, to a plurality of flange members, in any geometric or non-geometric pattern. desired, or combinations thereof.

One purpose of the variable printer or recorder 65 is to process, when necessary, the layer 66 to decrease the distance between the reference marks 74. This can be achieved by controllably moving the printing roller 81 against the layer 66 to through the controlled operation of the linear actuator 73 and connecting rod 75. By controlling the movement of the printing roller 81 against the layer 66, the pressure exerted by the flange members of the printing roller 81 against the layer 66 it can be adjusted controllably to the fold layer 66, by way of example, thereby picking it up to decrease the distance between the reference marks 74. Furthermore, the speed of the drive roller 66 can be controllably adjusted or varied by the motor 148. (Figure 6) in order to selectively change the thickness of layer 66. For example, the speed of the drive roller 66 needs to be increased to decrease the tension on the layer 66 down from, or beyond the drive roller 68, thereby causing a slight contraction of the layer 66 and a slight increase in its thickness to facilitate folding. In addition to bending to decrease this distance, other methods include, but are not limited to curling, radiation treatment, chemical treatment, corrugation, elasticizing, ultrasonic bonding or the like. If, however, it is determined that the layer 66 does not require a decrease in the distance between the reference marks 74, the layer 66 will move through a variable printer 65 without being treated, since the printing roller 81 will be Controllably moved in an outward direction of the receiving roller 67 to present a clear or unobstructed path between them.

Another purpose of the variable printer 65 is to treat, when necessary, the layer 66 to increase the distance between the reference marks 74. This can be achieved by controllably moving the printing roller 81 against the layer 66 through the controlled operation of the linear actuator 73 and the connecting rod 75. By controlling the movement of the printing roller 81 against the layer 66, the pressure exerted by the flange members of the printing roller 81 against the layer 66 can be adjusted controllably, by way of example to cut slits or weaken the layer 66, thereby lengthening it to increase the distance between the reference marks 74. Furthermore, the speed of the driving roller 68 can be adjusted or controlled by the engine 148 (FIG. 6). ) in order to selectively change the thickness of layer 66. For example, the speed of the drive roller 68 may require to be decreased to increase the tension on the layer 66, thereby causing a slight elongation of the layer 66 and a slight thinning or thinning on its thickness. In addition to making slits to increase the distance, other methods include, but are not limited to pressure point, calendering, chemical treatment, opening, radiation treatment, marking, cold rolling or the like. If, however, it is determined that the layer 66 does not require an increase in the distance between the reference marks 74, the layer 66 will move through the printer 65 untreated, since the printing roller 81 will have been controllably moved. in an outward direction of the receiving roller 67 to present a clear or unobstructed path between them.

After the variable printer 65, the layer 66 is driven or moved to a cooling roll 86 and an associated support roll 88 which will form between them a rolling pressure point 90. A continuously moving layer 92 is provided and it is driven in any manner suitable to the laminator cooling roller 86. An adhesive applicator 94 applies a desired amount of suitable adhesive to the continuously moving layer 92. In this particular embodiment, the layer 92 is a non-woven fabric, such as a polypropylene fabric bonded with yarn having a basis weight of about 20 grams per square meter (gsm). The adhesive applicator 44 can be any suitable applicator well known in the art that can provide or apply the desired amount of adhesive. The adhesive used can be any suitable adhesive that is compatible with layers 66 and 92 in order to ensure proper lamination together. The continuously moving layer 92 may be provided by a supply means (not shown) similar to the supply means 52 and 64.

The roller cooling laminator 86 is driven by the line shaft 128 (figure 6) and helps move the layers in the process. The roller cooling laminator 86 also serves to cool the adhesive applied by the adhesive applicator 94 for processing purposes, thus preventing the adhesives from bleeding through the layers 66 or 92.

Once the layers 66 and 92 are laminated and pass through the laminating pressure point 90, they are continuously moved to a construction cooling roll 96, and have an adhesive applied to the outermost surface of the layer 66. The construction cooling roller 96 is also driven by a line shaft 128. The adhesive applied by the adhesive applicator 98 will eventually join the layers 66 and 92 to the first continuously moving layer 54. Thus, the adhesive applicator 98 It is designed to apply the appropriate adhesive pattern and the amount of adhesive to ensure the desired bonding of the layers 66, 92 and 54. The construction adhesive applicator 98, as well as the adhesive applied thereto, can be any type of adhesive. Applicator suitable for the desired adhesive pattern and appropriate and compatible for the materials to be joined.

Of the construction cooling roll 96, the laminated layers 66 and 92 are then superimposed on the continuously moving layer 54, and together the layers pass through a product puncher 100 comprising a drive roller 102 driven by the line shaft 128 (FIG. 6) and the rubber-free free roller 104. The puncher 100 compresses the layers together in order to cause the adhesive applied to the layers 66 and 92 to the continuously moving layer 54, thereby forming a composite layer continuously. in motion 93 as illustrated in Figures 4 and 5.

Continuing with reference to Figure 5, first sensing means, such as a sensor 106, are suitably positioned between the drive roll 68 and the cooling roll 86 for sensing or detecting a reference mark 74 and generating a signal, for example. example, a reference mark signal, in response to each reference mark 74. Optionally, the sensor 106 can be located in close proximity to the roller cooling roller 86 and either up or down the roller 86. Since the reference marks 74 are optical brighteners sensitive to ultraviolet radiation, a suitable sensor is a detector SICK model LUT 2-6, available from SICK OPTIK ELEKTRONIK, Inc., having a business office in St. Paul, Minnesota.

Placed downwardly of the product puncher 100 are the second and third sensor means, such as a sensor 108 and the photo eye 110. The sensor 108 may be of the same type of ultraviolet detector as the sensor 106. The photo eye 110 is desirably an examiner block. RSBF banner, RPBT wiring base, 2.53S IR optical fiber pair device, available from Banner Engineering Corporation of Minneapolis, Minnesota. The photo eye 110 is designed to optically sense or detect a component, such as the absorbent pad 32, and to generate an electrical signal in response thereto. In that particular description, both sensors 106 and 108 are designed to sense or detect, and generate a signal in response to a reference mark 74; and the photo eye 110 is designed to sense or detect and generate a signal in response to the absorbent pad 32.

If desired, the photo eye 110 can perceive other components such as the waist elastics, the leg elastics, the fastening tapes used in the diapers or the like. A reference mark may also be associated with each absorbent pad 32 in the same manner that a reference mark 74 is associated with a graph 38; and in this case, the pad photoeye 110 can be replaced with a sensor similar to the sensors 106 and 108. Similarly, the sensors 106 and 108 can be replaced with other sensors, similar to the photo eye 110, in order to optically sense or detect a component or other structure in order to generate an appropriate signal.

With reference to Figure 4, there is illustrated a continuously moving composite layer 93 comprising layers 66, 92 and 54 (Figure 5) after they have been joined together by means of the product puncher 100. Each printed waistband 76 finally it will be cut along a respective cut line 120 in order to form individual products. In Figure 4, once the cutting lines 120 have been separated, a front waist edge 116 and a rear waist edge 118 are formed for each assembled product. One of the important features in Figure 4 is the relative placement of a graph 38 with respect to each product that will eventually be formed. Each graph 38 is located on the front panel 12 (Figure 1) and is located in the same position in relation to the front edge of the absorbent pad 112 (Figure 4). Naturally, other product components or brands may be in coincidence with other brands or different reference product components. For example, a simulated waistband 29 (Fig. 2) may be in relative correspondence with a waist opening, or with leg elastics, such as leg elastics 30 (Fig. 1), and may be desirably put in correspondence in relation to an absorbent pad, such as the absorbent pad 32 (Figure 4).

Referring to Figure 6, there is schematically illustrated a main control system with a mechanical side 122. The main control system comprises a main correspondence control system 124 that receives several signals generated, processes them in accordance with the programmed instructions, and generates output signals to a main drive control system 126. The main drive control system 126 receives the signals from the main matching control system 124, and in response to this operates, as necessary, the variable printer 65. and the drive roller 68.

The main drive control system 126 may be designed to operate or control other areas or mechanisms; for example, it is desired that the printing roller 81 be suitably coupled to the drive roller 68 so that it is driven at relatively the same speed.

The mechanical side 122 comprises a main line axis 128 that directly drives the selected mechanisms, or through a system of gears and other coupling devices, both mechanical and electrical, and indirectly drives other mechanisms. The shaft line 128 is driven at a constant speed by any suitable means known in the art, and those mechanisms driven by the line shaft 128 are also driven at a constant speed which may or may not be the same speed as that of the shaft. of line 128. Specifically, a supply pressure point gear encoder 130 and a line axis matching encoder 132 are operatively coupled with the line axis 128. Examples of the encoders include an H25D-SS-2500- ABZC-8830-LED-SM18 (which can be used as encoder 130) available from BEI Motor System, Co. of Carlsbad, California, and a 63-P-MEF-1000-T-0-00 (which can be the encoder 132) available from Dynapar Corporation, of Gurnee, Illinois. The supply pressure point gear encoder 130 is operatively coupled to the line shaft 128 to rotate at a constant speed, so that four revolutions of the encoder 130 represent a repetition length of the machine product.

The main matching control system 124 comprises the preprogrammed program instructions and / or apparatus instructions, and may be represented, with reference to FIG. 6, as comprising an input acquisition system 134, a gear ratio control 136, a relative position 138, an automatic fixed-point generation 140, a difference block 142, and a positioning control 144. The main match control system 124 includes a computer, which may comprise, for example, a microprocessor-based VME, such as SYS68K / CPU-40B / 4-01 available from Forcé Computers, Inc., of Campbell, California.

As illustrated in Figure 6, the acquisition system 134 may be designed to receive the following six general signals: (i) a signal from the motor encoder 146 operatively coupled to a motor 148 that drives the drive roller 68, (ii) a signal from the sensor 106 (FIG. 5), (iii) a signal from the proximity switch 62 (FIG. 5), (iv) a signal from the line axis matching encoder 132, (v) a signal from the sensor 108 (FIG. 5), and (vi) a signal from photo eye 110 (figure 5). The input acquisition system 134 receives and counts the pulses generated by the motor encoder 146 and the line axis coincidence encoder 132, and receives the signals from the sensors 106 and 108, from the proximity switch 62 and from the photo eye 110 Referring to the accumulated accounts of the encoder 148 and the accumulated encoder accounts 132, the input acquisition system 134 carries out preprogrammed instructions that are specific to the respective received signals, and stores the results of the instructions.

For gear ratio control 138, a signal counter in the input acquisition system 134 counts the pulses from the motor encoder 146 and receives the signals from the sensor 106 in response to each reference mark 74 (FIG. 5). The input acquisition system 134 then measures the beats counted by representing a distance between each two successive reference marks 74, and performs a running average of those measured counts. The term "running average" refers to averaging the same number of data; for example, for each data entry received recently, the oldest data is removed from the averaging calculation. The averaging of the counts between two successive reference marks 74 creates an average measurement on which the next gear ratio value will be derived by the gear ratio control 136, as opposed to basing a control decision on the measurement of fairness. only a pair of reference marks 74. This averaging "smoothes" the measurements, and is needed due to the variability of the apparatus and the process. The number of measurements for averaging is controllable, and is set or determined by providing an appropriate instruction through manual input in any suitable manner well known in the art. In conjunction with carrying out a running average of the measured counts, the input acquisition system 134 performs a filtering function, which is preprogrammed, to filter signal anomalies. Examples of such signal anomalies include a dirty photo eye, extra or missing reference marks 74, movement or waving of the layers, measurement of the beads outside of a preprogrammed range for averaging purposes, inaccurate data known due to Match control or similar.

For the relative position 138, the input acquisition system 134 counts the pulses received from the line axis matching encoder 132, and receives the signals generated by the sensor 106 and the proximity switch 62. The input acquisition system 134 it then determines and records the number of current accumulated pulses upon receiving a signal from the sensor 106, and determines and records the current accumulated number of pulses upon receiving a signal from the proximity switch 62.

For the automatic fixed point generation 140, the input acquisition system 134 counts the pulses received from the line axis coincidence encoder 132, and receives the signals generated by the sensor 108 and the photo eye 110. It then determines and records the number of current accumulated pulses upon receipt of a signal from the sensor 108, and determines and records the number of current accumulated pulses upon receipt of a signal from the photoeye 110. Next, an input acquisition system 134 calculates the difference between the current cumulative number of pulsations from a signal sensor 108 and the current cumulative number of beats from an associated signal from photo eye 110; the "associated signal" refers to the signal generated by the photo eye 110 (FIG. 5) with the signal of the sensor 108, for each repetition length of the machine product. With these calculated differences, the input acquisition system 134 performs a running average and a standard deviation for those differences.

The various calculations and functions carried out by the input acquisition system 134 are used by other parts of the main matching control system 124 in order to generate commands for the main drive control system 126 (FIG. 6), which it generally comprises a control / logic processor 150, a pressure motor controller 154, and a print engine controller 149. The main drive control system 126 includes a computer, which comprises, for example, a Distributed Control System Reliance made by Reliance Electric Company. The Distributed Control System includes a Reliance Automax Electric Processor and associated appliances.

The gear ratio control 136 interrogates the input acquisition system 134 for every 20 products, for example, every 20 machine product repetition lengths, with respect to the current running average of measured counts representing a distance between the successive reference marks. (figure 5), which is the repetition value. The number of product sections determining a question from the gear ratio control 136 is adjustable, and can be manually changed by the operator. After determining the repetition value, the gear ratio control 136 performs a gear ratio calculation in accordance with preprogrammed instructions to determine a new gear ratio value if necessary. That new gear ratio value is then transmitted to the logic control processor 150 of the main drive control system 126. The gear ratio value is calculated by dividing the repetition value by the number of encoder counts from the encoder of supply pressure point gear 130 (FIG. 6) that occurs in the repeat section of the machine's product. The purpose of this is to achieve the repetition of reference marks without comparing them to a target value.

The relative position 138 of the main matching control system 124 asks the input acquisition system 134 about the current accumulated number of beats in relation to the sensor 106, and the number of current accumulated beats in relation to the proximity switch 62. The position Relative 138 then determines the difference between the two current accumulated beat numbers in order to calculate a relative position of a reference mark 74 (FIG. 5) for the associated proximity switch signal for that specific question for each product repetition length. of machine. The relative position 138 then generates and transmits to the difference block 142 a relative position value.

The automatic fixed point generation 140 interrogates the input acquisition system 134 with respect to each repetition length of machine product representing a single product. The occurrence of each product, or the repetition length of machine product, was determined from the line-axis matching encoder 132, in which two revolutions of the line-axis matching encoder 132 are equivalent to a product length. In this particular example, two revolutions of the line axis coincidence encoder 132 are 2000 counts. The input acquisition system 134 responds to each question from the automatic fixed point generation 140 with the current average current and the standard deviation of the difference calculated between the current accumulated number of pulses for a sensor signal 108 and the number of pulses. current accumulation of an associated signal from pad photo 110 for each product; the current running average of this calculation is the actual position value. The automatic fixed point generation 140 then compares a standard deviation with a preset limit, which has been manually entered, and if the standard deviation is outside the preset limit, the automatic fixed point generation 140 will ignore the data and will not determine a new one. point of play since the standard deviation data are considered highly variable to make an exact point adjustment. If the standard deviation is within the present limit, the automatic fixed point generation 140 will then determine the difference between the current position value and a manually entered target value, which is the desired current position value. If the new calculated difference was determined, by generating automatic fixed point 140 as being within a prescribed range, no further action or calculation will be carried out. However, if the difference is outside the prescribed range, the automatic fixed point generation 140 will determine a new fixed control point. This new fixed control point is derived by adding to the current fixed point the difference between the target value and the current position value.

Once each repetition length of machine product, a difference block 142 determines the difference between the current control fixed point value from the automatic fixed point generation 140 and the associated relative position value from the relative position 138, the what is the placement error. The difference block 142 transmits this positioning error, in the accounts of the line axis encoder, to the positioning control 144. The positioning control 144 compares the positioning error with a tolerance band 170 (FIG. 7). which defines an acceptable deviation from the relative position value around the current fixed control point. The tolerance band 170 remains constant around the fixed control point, but the fixed control point can vary as calculated by the automatic fixed point generation 140.

As a result, while the position control of the reference marks occurs at the pressure point 72, the fixed point for this position control is derived exactly from the signals generated by the sensor 108 and the photo eye 110.

With reference to Figure 7, a fixed fixed point 168 having a prescribed tolerance band is illustrated. 170. For purposes of explanation, the fixed control point 168 has a value of 1000 accounts, and the tolerance band 170 represents a deviation of plus or minus 12 accounts. Each of the data points 172, 174, 176, 178, 180 and 182 represents a relative position value of the product as calculated by the relative position 138. The waveform 156 represents the signals generated by the proximity switch 62 (FIG. 6), and waveform 158 represents the signals generated by sensor 106 (FIG. 6). If a setting error value remains within tolerance band 170, a placement order will not be generated. Nevertheless, if a placement error value is outside the tolerance band 170, then the placement control 144 (Figure 6) will generate a placement order. This order of placement is directly proportional to the size of the difference represented by the value of the difference block 142 and requests an advance or delay measured at the position of layer 66. The generated placement order is then transmitted to the control / logic processor 150 of the main drive control system 126. FIG. 7 illustrates an example of how the positioning control 144 (FIG. 6) compares each data point 172-182 with a current fixed control point in order to generate a positioning error. . The positioning error for each data point is compared to the tolerance band 170 to determine if a placement order should be generated. At example point 176, there is the single data point where the positioning error falls outside the tolerance band 170, which causes a positioning command to be generated, thereby causing the next data point to fall inside the tolerance band 170.

The logic control processor 150 (FIG. 6) of the main drive control system 126 searches for and receives new commands or signals from the main match control system 124. Specifically, the processor 150 investigates and receives the commands or signals of the ratio of engages and places commands or signals from the main matching control system 124. The signals or gear ratio commands and positioning commands or signals are used in accordance with preprogrammed instructions to transmit an order or signal to the point motor controller pressure 154 and the printing motor controller 149.

Upon receiving a gear ratio command from the main matching control system 124, the logic control processor 150 will send a speed command to the pressure point motor controller 154 which controls the speed of the drive roller 68. The ordered gear ratio will be compared simultaneously with the predetermined limits based on the material characteristics of layer 66. If the gear ratio is above or below the predetermined limits, the printer will be engaged until the gear ratio is within limits.

Upon receiving a placement order from the main matching control system 124, the logic control processor 150 will send a momentary speed command to the pressure point motor controller 154 which controls the speed of the drive roller 68. Since The placement corrections are generally larger than what the material can handle within its elastic range, the printer is always engaged during a placement correction. The order of placement will be limited to a maximum value determined by the material capacity that will be folded or lengthened by the printer. After each successful placement, the main matching control system will collect data and calculate if an additional placement correction is required.

Upon receiving a gear ratio command from the main matching control system 124, the logic control processor 150 will send a speed command to the pressure point motor controller 154 which controls the speed of the drive roller 68. The The proportion of ordered gear will be compared simultaneously with the predetermined limits based on the material characteristics of layer 66. If the gear ratio is above or below the predetermined limits, the printer will latch until the gear ratio is within limits.

When the logic control processor 150 engages the printer, it sends a signal to the printer driver controller 149 to operate the line driver motor 73. The linear driver 73 then drives, through the rod 75, the printer roller 81 against layer 66 to apply a selected pressure for a predetermined period of time necessary to fold or elongate layer 66. At the end of the predetermined time period, the main drive control system 126 will cause the linear actuator 73 to remove the print roller 81 from the layer 66.

The logic control processor 150 precisely links the speed of the poly pressure point drive motor 148 to the line shaft speed 128 through an electronically changeable gear ratio in accordance with preprogrammed instructions. This effectively synchronizes the speed of the pressure point motor 148 with the line axis 128 and allows frequent changes of the gear ratio, and therefore the speed of the motor 148. These changes in the speed of the motor 148, and therefore of the drive rod 68 and the printing roller 81, which will be suitably coupled together, are desirable to accommodate the folding or elongation of the layer 66.

As described, this results in a desired match of the graph 38 (FIG. 1) or of the graph 42 (FIG. 2) in the respective training briefs 10 and 40. By selectively controlling the distance between the successive reference marks. (figure 5), each mark 74 can be matched respectively with a corresponding associated component, such as an absorbent pad 32. The control of the distance between the reference marks 74 with a selected distance, such as a repetition length of machine product, accommodates or corrects for variations or other types of anomalies that may be present in the device or process. By adjusting the gathering or elongation of the second layer continuously in motion 66, using the printing in conjunction with the tension on the layer 66, it can be made to properly match the first layer continuously in motion 54, thus ensuring adequate correspondence of a desired component, such as a graph 38 with another component, such as the front panel 12 (Figure 1).

Although the invention has been described as having preferred embodiments, it will be understood that this is capable of further modifications. It is therefore intended to cover any variations, equivalents, uses or adaptations of the invention following the general principles thereof, and including such items of the present description as they may fall within the known or customary practice in art to the art. which belongs the invention and fall within the limits of the appended claims.

Claims (24)

R E I V I N D I C A C I O N S

1. A process for controllably matching a plurality of components of a first layer continuously in motion with a plurality of components on a second layer continuously in motion, comprising the steps of: providing a first layer continuously in motion that includes a plurality of components, providing a second layer continuously in motion that includes a plurality of components, represent the components of one of the layers continuously in motion with a plurality of respective reference marks, perceive each of the reference marks and generate a benchmark signal in response to them, measuring the distance between two signals of successive reference marks and generating a repetitive corrective control signal according to the pre-programmed instructions, selectively applying pressure to the one layer continuously in motion in response to a repetitive corrective control signal generated to adjust the distance between two successive reference marks, superimpose the first layer continuously in motion and the second layer continuously moving together, perceive a reference mark and its corresponding component of the other layer, and generate a corrective placement control signal in accordance with preprogrammed instructions, and adjusting the speed of the one layer continuously in motion in response to a corrective positioning control signal generated to controllably match a reference mark on the one layer continuously in motion with its corresponding component on the other layer continuously in motion.

2. The process as claimed in clause 1, characterized in that the step of generating a repeating corrective control signal includes generating a recrawling corrective control signal, and wherein the step of selectively applying pressure includes picking the one layer.

3. The process as claimed in clause 1, characterized in that the step of generating a repetitive corrective control signal includes generating an elongating repetitive corrective control signal, and wherein the step of selectively applying pressure includes elongating the one layer.

4. The process as claimed in clause 2, characterized in that the recollection step includes folding the one layer.

'5. The process as claimed in clause 3, characterized in that the elongation step includes thinning the one layer.

6. The process as claimed in clause 1, characterized in that the components of the one layer are spaced apart by a distance essentially the same as the repetition length of the machine product, and the same components of the other layer are spaced apart and separated by a distance essentially the same as the repetition length of machine product.

7. A process for controllably matching a plurality of reference marks of a first layer continuously in motion with a plurality of corresponding reference marks of a second layer continuously in motion, comprising the steps of: providing a first layer continuously in motion including a plurality of reference marks selectively placed thereon, providing a second layer continuously in motion including a plurality of corresponding reference marks selectively placed thereon, perceive each one of the reference marks of one of the continually moving layers and generate a reference mark signal in response to these, measure the distance between two successive reference mark signals and generate a repetitive corrective control signal according to preprogrammed instructions, print the one layer continuously in motion in response to a generated repeating corrective control signal, overlaying the layers together continuously in motion, perceiving a reference mark on the one continuously moving layer and its corresponding reference mark of the other layer continuously in motion and generating a corrective positioning control signal in accordance with preprogrammed instructions, and adjusting the speed of the one layer continuously in motion in response to a corrective positioning control signal generated to controllably match a reference mark of the one layer continuously in motion with its corresponding reference mark on the other layer continuously in motion.

8. The process as claimed in clause 7, characterized in that the step of generating a repetitive corrective control signal in accordance with preprogrammed instructions includes generating a recursive corrective control signal or a repetitive corrective control signal of lengthening, and wherein the step of printing the one layer continuously in motion includes decreasing the tension on the one layer continuously in motion in response to a corrective repeat pickup control signal, or increasing the tension on the one layer continuously in motion in response to a lengthening repetitive corrective control signal.

9. The process as claimed in clause 8, characterized in that the step of decreasing the tension includes increasing the thickness of the one layer continuously in motion.

10. The process as claimed in clause 8, characterized in that the step of increasing the tension includes decreasing the thickness of the one layer continuously in motion.

11. The process as claimed in clause 8, characterized in that the reference marks of the first layer are spaced apart by a selected distance and wherein the reference marks of the second layer are spaced apart by a selected distance.

12. The process as claimed in clause 11, characterized in that the reference marks of the first layer are spaced apart by a distance essentially the same as the repetition length of the machine product, and wherein the reference marks of the second layer is spaced apart by a distance essentially the same as the repetition length of the machine product.

13. An apparatus for controllably matching a plurality of components of a first layer continuously in motion with a plurality of components on a second layer continuously in motion, comprising: means for providing a first layer continuously in motion that includes a plurality of components, means for providing a continuously moving second layer including a plurality of components being represented with a respective plurality of reference marks, means for perceiving each of the reference marks, and means for generating a reference mark signal in response to this, means for measuring the distance between the two successive reference mark signals and means for generating a repetitive corrective control signal according to preprogrammed instructions, means for selectively applying pressure to the one layer continuously in motion in response to a control signal Rectifier generated to adjust the distance between two successive reference marks, means for superimposing together the first layer continuously in motion and the second layer continuously in motion, means for sensing a reference mark and its first component of the first layer and means for generating a corrective positioning control signal in accordance with preprogrammed instructions, and means for adjusting the speed of a second layer continuously moving in response to a positioning corrective control signal to controllably match a reference mark on the second layer continuously in motion with its corresponding component on the first layer continuously in motion.

14. The apparatus as claimed in clause 13, characterized in that the means for generating a repeating corrective control signal generates a recrawling corrective control signal, and wherein the means for selectively applying pressure include means for collecting the Second layer.

15. The apparatus as claimed in clause 13, characterized in that the means for generating a repetitive corrective control signal generates an elongate repetitive corrective control signal, and wherein the means for selectively applying pressure include means for elongating the second layer.

16. The apparatus as claimed in clause 14, characterized in that the means for collecting include means for folding the second layer.

17. The apparatus as claimed in clause 15, characterized in that the means for elongation include means for thinning the second layer.

18. The apparatus as claimed in clause 13, characterized in that the components of the second layer are spaced apart by a distance essentially the same as the repetition length of the machine product, and the components of the first layer are separated for a distance substantially the same as the repetition length of the product of the machine.

19. An apparatus for controllably matching a plurality of reference marks of a first layer continuously in motion with a plurality of reference marks of a second layer continuously in motion, comprising: means for providing a continuously moving first layer including a plurality of reference marks selectively placed thereon, means for providing a continuously moving second layer including a plurality of corresponding reference marks selectively placed thereon, means for perceiving each of the reference marks of one of the continually moving layers and means for generating a reference mark signal in response to this, means for measuring the distance between two successive reference mark signals and means for generating a repetitive corrective control signal according to preprogrammed instructions, means for printing the one layer continuously in motion in response to a repetitive corrective control signal generated , means for overlapping the layers together continuously in motion, means for perceiving a reference mark of the one continuously moving layer and its corresponding reference mark of the other layer continuously in motion, and means for generating a corrective positioning control signal in accordance with the preprogrammed instructions, and means for adjusting the speed of the one layer continuously in motion in response to a positioning corrective control signal generated to controllably match a reference mark of one continuously moving layer with its corresponding reference mark on another layer continuously in motion.

20. The apparatus as claimed in clause 19, characterized in that the means for generating a repetitive corrective control signal in accordance with the preprogrammed instructions generates a recrawling corrective control signal or a repeatable corrective control signal of elongation, and wherein the means for printing the one layer continuously in motion includes means for decreasing the tension on the one layer continuously in motion in response to a recrawling correction corrective control signal, and means for increasing the tension on the one layer. layer continuously moving in response to a corrective control signal of repetition of elongation.

21. The apparatus as claimed in clause 20, characterized in that the means for decreasing the tension increase the thickness of the one layer continuously in motion.

22. The apparatus as claimed in clause 20, characterized in that the means for increasing the tension decreases the thickness of the one layer continuously in motion.

23. The apparatus as claimed in clause 20, characterized in that the reference marks of the first layer are spaced and separated by a selected distance, and wherein the reference marks of the second layer are spaced and separated by a selected distance .

24. The apparatus as claimed in clause 20, characterized in that the reference marks of the first layer are spaced apart by a distance essentially the same as the repetition length of machine product, and wherein the reference marks of the second layer are spaced apart by a distance essentially the same as the repetition length of the machine product. R E S U E N A process and apparatus are provided to controllably match two layers continuously in motion. A first layer continuously in motion has a plurality of components, and a second layer continuously in motion has a plurality of reference marks representing a plurality of respective components. The process and apparatus control the distance between the reference marks of the second layer with a selected distance, and then controllably match each reference mark of the second layer with a respective component of the first layer continuously in motion.