MXPA99004274A - Process and apparatus for registering a continuously moving, treatable layer with another layer - Google Patents

Abstract

A process and apparatus for controllably registering two continuously moving layers of material is provided. One of the layers comprises a permanently settable material, and has a plurality of reference marks representing a pluraltiy of separate and distinct components, and the other of the continuously moving layers has a respective plurality of different components thereon. The process and apparatus controls the distance between reference marks to a selected distance, and controllably registers each reference mark to a respective component of the continuously moving second layer.

Description

as discrete objects.

Various methods and apparatus are available to carry the components of a single product together so that the components in the composite product are in a desired relationship with one another. In carrying these components properly together, various known methods and apparatuses have been used to note the position of a particular component, and then adjust the position of the subsequent components in order to place them properly.

A problem encountered with these types of methods and apparatuses is that they do not compensate adequately for the stretching or relaxing of a continuously moving layer. During manufacturing processes of this type, a continuously moving layer is subjected to various stresses caused by these being driven or pulled through the process for handling. This tension causes the continuously moving layer to stretch, or relax, resulting in some of the components being undesirably placed, or once placed, changing position. Since it is virtually impossible to maintain a constant tension on the continuously moving layer, the degree of stretching varies throughout the process. Consequently, even when a previously placed component could initially be within an acceptable range of position, stretching 3 or relaxing the layer continuously in motion may result in the product being outside the acceptable position range in the final composite product.

Another 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 with a pre-printed or pre-positioned component or the like-over the other layer during the manufacture of a plurality of products having a desired component match.

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 respective plurality of components on a continuously moving second layer. it comprises a permanently sealable material.

In one form of the present 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 second layer continuously in motion, comprising the steps of: (1) providing a continuously moving first layer including a plurality of components that are being spaced apart by a selected length, (2) providing a continuously moving second layer comprising a permanently sealable material, and including a plurality of components that are being spaced apart and separated by a length less than the selected length, (3) representing the components of the second layer continuously in motion with a respective plurality of reference marks, (4) perceiving each of the reference marks and generating a marking signal. of reference in response to this, (5) measure the distance between two signals of successive reference marks and generating a repetitive corrective control signal according to the reporred instructions, (6) pulling the second layer continuously in motion to adjust the distance between two successive reference marks in response to a corrective control signal of repetition generated, (7) superimposing the first layer continuously in motion and the second layer continuously moving together, (8) sensing a reference mark of the second layer continuously in motion and its corresponding component of the first layer continuously in motion, and generating a corrective positioning control signal according to the preprogrammed instructions, and 5 (9) adjusting the speed of the second layer continuously in motion in response to a corrective positioning control signal generated to controllably match a marking of reference on the second layer continuously in motion with its corresponding component on the first 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 that are being spaced apart by a selected length, (2) providing a continuously moving second layer comprising a permanently sealable material, and including a plurality of corresponding reference marks that are being spaced by a length less than the selected length, (3) perceiving each of the reference marks of the second layer continuously in motion and generating a reference mark signal in response to these, (4) measuring the distance between two signals of successive reference marks and generating a signal of repetitive corrective control according to preprogrammed instructions, (5) pulling the second layer continuously in 6 movement to adjust the length in response to a generated repetitive corrective control signal, (6) overlaying the first layer and the second layer continuously in movement together, (7) perceiving a reference mark of the second layer continuously in motion, and of its corresponding reference mark of the first layer continuously in motion and generating a corrective positioning control signal in accordance with preprogrammed instructions, and ( 8) adjust the speed of the second layer continuously moving in response to a corrective control signal of positioning n generated to controllably match a reference mark of the second layer continuously in motion with its corresponding reference mark 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 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 layer continuously in motion including a plurality of components that are being spaced apart by a selected length, (2) means for providing a continuously moving second layer comprising a permanently sealable material, and including a plurality of components being represented with a plurality 7 respective of reference marks being spaced by a length less than a selected length, (3) means for sensing each of the reference marks and means for generating a reference mark signal in response to these, (4) means for measure the distance between two signals of reference marks successive means and means for generating a repetitive corrective control signal in accordance with the preprogrammed instructions, (5) means for pulling the second layer continuously in motion to adjust the distance between two successive reference marks in response to a corrective control signal of repetition generated, (6) means for superimposing the first layer continuously in motion and the second layer continuously moving together, (7) means for perceiving a reference mark of the second layer continuously in motion and its corresponding component of the first continuously moving 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 motion in response to a positioning corrective control signal for controllably match a reference mark on the second layer c continuously moving 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 reference marks of a second layer continuously in motion: (1) means to provide a continuously moving first layer including a plurality of reference marks being spaced apart by a selected distance, (2) means for providing a continuously moving second layer comprising a permanently sealable material, and including a plurality of markings. corresponding reference points being spaced by a length less than the selected length, (3) means for sensing each of the reference marks of the second layer continuously in motion and means for generating a reference mark signal in response to this, ( 4) means to measure the distance between the two brand signals successive reference means and means for generating a repeating corrective control signal in accordance with preprogrammed instructions, (5) means for pulling the second layer continuously in motion to adjust the length in response to a generated repetitive corrective control signal, ( 6) means for superimposing the first layer continuously in motion and the second layer together, (7) means for sensing a reference mark of the second layer continuously in motion, and its corresponding reference mark of the first layer continuously in motion and means for generating a positioning corrective control signal 9 in accordance with preprogrammed instructions, and (8) means for adjusting the speed of the second layer continuously in motion in response to a positioning corrective control signal to controllably match a marking reference of the second layer continuously moving with its reference mark corr spondiente on the first layer continuously in motion.

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 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 illustrates the article of Figure 2 in a stretched and partially disassembled planar 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 graphs thereon.

Figure 5 schematically illustrates an apparatus and a process for manufacturing an article having a graph that has been matched thereon.

Figure 6 illustrates a schematic block diagram of the data flow used in conjunction with the apparatus and the process of Figure 5.

Figure 7 illustrates a block diagram of the electronic gearbox of Figure 6; Y Figure 8 illustrates graphically a placement control used in conjunction with the apparatus and the process of Figure 5. 11 Detailed Description The following detailed description will be made in the context of matching and controlling the coincidence of at least one layer continuously in motion with respect to at least one second layer continuously moving in the manufacture of disposable absorbent articles, and specifically of a Absorbent disposable learning underpants for children. Examples of other disposable absorbent articles include, but not limited to absorbent underpants, diapers, women's care products, incontinence products, or the like. The present invention also contemplates other products or devices unrelated to the 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, but is not limited to 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 panels, the layers of material or the like; or a graph. The term "graphic" may refer to, but is not limited to, any pattern, design, or the like.

A child-friendly training pant 12 can have, by way of example, multiple functional and / or appearance-related components that have been matched within ranges in the machine direction (MD) and / or in the transverse direction (CD) selected. The term "machine direction" refers to the primary direction of movement of layers continuously in motion in the manufacturing process, and the term "transverse direction" refers to a direction transverse to the machine direction. The example described here is that of matching a graph in the machine direction within a designated area of the underpants.

Thus, the present invention can provide a disposable child 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; the highlighting or emphasizing of leg and waist openings in order to make a product conformation 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; humidity indicators that match, temperature indicators, and similar in 13 the product; match a back label, or a front label, on the product; and match written instructions in a desired place on the product.

Examples of functional components include, but are not limited to leg elastics, waist elastics, breathable areas, fluid repellent areas, fluid wetting areas, adhesives or coatings, encapsulated inks, chemically sensitive materials, environmentally sensitive materials, heat sensitive materials, moisture sensitive materials, perfumes, odor control agents, inks, fasteners, fluid storage areas, 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 the elastic side panels which are attached to the outer cover in order to provide elasticity thereto. The liquid-impermeable outer cover may comprise two layers of material joined together properly, in which the innermost layer may be a liquid impervious layer and the outermost layer may be a non-woven layer having a fabric-like texture. . In this case, it is the innermost layer impervious to the liquid that has printed a graph in coincidence on it. The graphic that has been matched usually includes a visually pleasing pattern or pattern and is controlably matched in a designated area on the product. An example of a graphic that has been matched includes a graphic placed on the front center of the underpants, and includes a simulated elastic waist band, simulated elastic leg bands, a simulated "fly opening" for boys, simulated frills for girls , or similar. A more detailed description of the construction and design of a 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 separate components selectively positioned on a continuously moving first layer of material with a respective plurality of separate and distinct components selectively positioned on a second layer of continuously moving material are described herein. . The second layer of material has the components suitably represented by respective reference marks, both provided on a uniform repetition stretch that is shorter than a repetition length of machine product 15 as defined hereinafter. The distance between the two successive reference marks was determined, and then used to calculate a control signal for the current process conditions. When a control signal was calculated, the second layer of material is then pulled or controllably lengthened so that the distance between the two successive reference marks equal essentially the selected distance, which is in this case a product repeat length. of machine; 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 matched to a respective component; but this is called "placement circuit". The term "reference mark" may refer but is not limited to the structure such as leg or waist elastics, adhesive beads, corners or structure edges, means of transport such as conveyor belts, visual marks, magnetic marks, electrical marks, electromagnetic marks, 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 "product repetition length of the machine" refers to a selected distance, which in this example is the distance mediated between the successive similar components during manufacture. For example, between the successive waist bands 16, between the absorbent pads or the like. 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 made conical with a component of the first layer then the component represented by that reference mark is matched to the component of the first layer.

With respect to the repeating circuit, the second layer has reference marks selectively provided thereon to correspond to a respective plurality of separate and distinct components, such as the graphs. A first sensor generates a signal in response to each reference mark. The distance between each newly generated signal and the most recent preceding signal is suitably measured in units of a pulling or elongation mechanism, so that the mechanism can be operated to pull or lengthen the second layer so that the distance between a subsequent signal recently generated and 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 "pulled" and variations thereof, such as by way of example, "pulling" and "pulling" generally refers to selectively applying a force of a pressure 17 against a layer of moving material to controllably lengthen the material.

With respect to the placement circuit, a desired match of a reference mark with a component is carried out by comparing and controlling a value of data 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 fixed 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 preprinted layer of material including a plurality of separate and distinct graphics thereon, varying the length as necessary of the layer to coincide with a selected length, and then apply and match this to another layer that includes pre-assembled and pre-applied components, such as absorbent pads, thereby providing a manufacturing process for individual disposable absorbent articles having graphics that have been matched thereon in designated areas. The process and the apparatus may also be used to apply, during manufacturing, other functional and appearance-related components that have been printed, attached, placed, or the like, onto a layer at a location specified to be matched. selectively in the final product.

The second layer of material is preprinted with a plurality of separate and distinct graphics. 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 manufactured, suitably for its intended purpose. The material from which the second layer is made has a crystalline nature or property so that it can settle permanently. The term "permanently seated" or variations thereof such as by way of example "permanently settleable" refers to a property or nature that allows or causes the material to sustain or maintain a deformation. For example, a permanently sealable material moved between a pair of calendering rollers having a pressure point dimension smaller than the thickness of the material will have its thickness reduced or thinned or pulled to the dimension of the pressure point, and then maintain the thickness reduced. The length of the pulled material, as well as its possible width, will increase due to the pulling or thinning action on the thickness of the material. The reduced thickness of the material and the increased length is firmly fixed or settled permanently thereafter, at least for the purposes of and under the conditions of the manufacturing process. The material will not tend to return to its original form. These types of crystalline materials in nature, for example they have crystalline properties, and desirably are highly crystalline in nature. These generally do not have the properties of amorphous materials. Crystalline materials have a regular repeatable internal arrangement of particles, such as molecules or atoms. Examples of the crystalline materials are plastics such as, by way of example, oriented polypropylene, oriented polyester, oriented nylon, spunbonded fibers or the like. The more oriented and crystalline the material, the more permanent or more fixed it will settle later, for example when it is pulled or thinned. The more crystalline the material, the better it retains a selected deformation or settlement. Desirably, the selected deformation or settlement is firmly fixed and remains so through subsequent handling in a manufacturing process. Examples of warping or pulling or thinning include, but are not limited to, cold rolling, calendering, stretching and constricting, or the like.

The second layer is selectively pulled to extend it controllably, so that it appropriately matches the distance between two successive reference marks for the product's repetition length of the machine, and to control a data value related to the fixed target point. . This is done in order to match the reference marks with pre-processed and pre-positioned components, such as, by way of example, the absorbent pads. A sensor system is used in conjunction with a computer program and computer devices inspect for the coincidence location, repetition patterns and fixed point error. The data received from these sensors is used to control the pulling or lengthening as necessary for the desired match. The adjustments to the second layer are made so that the printed graphics are desirably matched with a respective plurality of components. The distance between the preprinted reference marks is determined with reference to the material of which the second layer is composed, since the material has to be lengthened to space the reference marks separating them in order to coincide with a repetition length of the machine's product. . If the reference marks are initially spaced very close together on the selected material, it may not be possible to increase their separation distance, by pulling or lengthening the material to coincide with a repeat section of the machine product.

These characteristics advantageously affect a layer that moves at 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 match of the reference marks and their associated components in the final product. The use of the term "layer" can refer to, but is not limited to, any type of substrate, such as a woven fabric, a non-woven 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 has a reference mark associated therewith. This means that each reference mark is selectively positioned relative to a respective graph, so that the reference mark can be properly perceived and matched on the product, thereby properly matching each graph on 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, whether an optical brightener or other means, can be configured in any desired 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 employed. It is understood that the various detection and perception means described herein will be appropriately compatible with the type of associated reference mark to be detected or perceived. The term "associated" refers to the reference mark either directly on a component it represents, such as a graphic, or is selectively spaced from it. The optical brightener is provided to be sensitive to ultraviolet radiation. The optical brightener is, for example, able to absorb ultraviolet radiation and then fluoresce to emit a spectrum of light that can be sensed by a compatible and appropriate detector or sensor. 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 Chemical Corporation.

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

Other suitable reference marks, as well as the 23 sensors, the computer devices, the motors and the like are described in the patent of the United States of America number 5,235,515; in U.S. Patent No. 5,359,525; and in the patent of the United States of America number 4,837,715; whose contents of these three patents mentioned above are incorporated herein by reference.

The process and apparatus described use several 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 a subsequent count and control. A signal counter receives a pulse train generated from an encoder, and counts the pulses for a subsequent question. A sensor perceives an occurrence or 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 rear panels 12 and 14 and a pair of panels elastic side panels 18. Each elastic side panel 18 is formed of two separate elastic parts (Figure 2A) and are suitably joined together, such as by ultrasonic attachment, to form a side seam 20. On the construction of the side seams 20, they form the waist openings 22 and the leg openings 24. The side seams 20 can be constructed to be manually ripped in order to allow the training underpants 10 to be disassembled manually by the caregiver, so that they can be easily removed from the body. 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 are incorporated herein by reference. The provision of the side seams 20 can be achieved in a 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 a 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 a pad absorbent 32 (Figure 4) positioned between an outer liquid impervious cover or lower sheet 34 (Figure 1) and an upper sheet or liquid permeable liner 36. The basic construction of a training underpants is well known in the art, and A particular construction is that described in U.S. Patent No. 4,940,464 issued July 10, 1990, the contents of which are incorporated herein by reference. U.S. Patent No. 4,940,464 also describes various materials from which a training underpants can be made, and methods for constructing the training underpants.

As illustrated in Figure 1, a matched graph 38 is suitably placed on the front panel 12, and in this illustration comprises a design of a "Simulated fly 23" opening, typical of a boy's underpants, and a rainbow, a sun, some clouds and some cars. The graph that has been matched 38 can be of any type of pattern, artistic characteristic, written instructions or the like and it is desired that it be placed in the article in a selected place. Naturally, the graphic that has been matched 38 comprising a simulated fly opening 23 would be totally unacceptable from an aesthetic and / or functional point of view if it were located in the crotch panel. 16 or on the back panel 14.

Referring to Figure 2, another training underpants 40 is illustrated, which can typically be used by young girls. In this design, a matching pattern 42 includes simulated waistlines 26, simulated leg 31 shades, a rainbow, a sun, clouds, a wagon and a balloon. Again, any suitable design can be used for the underwear that is intended for use by young girls, to be aesthetically pleasing and / or functionally for these and for the caregiver.

The graph that has been matched 38 in Figure 1 or the graph that has been matched 42 in Figure 2 can be made controllably match as desired, depending on the size and shape of the graph and that part of the article on which the graph will be matched. In Figure 1, the graph 38 has been controlably matched within with a designated area 39 which, as seen in Figure 1, is limited or defined by a front waist edge 116, panel seams 21 and a line crotch panel 17. The panel seams 21 are the seams in which the respective elastic side panels 18 are suitably attached 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 the aforementioned U.S. Patent No. 4,940,464. The crotch panel line 17 is, for the purposes of explanation given herein, simply the line or boundary formed at the bottom of the crotch panel 16 as illustrated in Figure 1. Thus described, the area designated 39 has 27 four limits defined 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 a crotch panel line 17. It is not necessary that a designated area 39 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 matched. In this case, the graph 38 can be controllably matched by a selected distance from the edge of. 116 front waist, and center between panel 21 seams.

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 flat and partially disassembled stretched condition. The 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 creases or creases caused by any built-in elastic members. In Figure 2A, the designated area 39 is defined or limited by the front waist edge 116, the 28 panel seams 21, the rear waist edge 118, and a pair of leg opening edges 25 that extend between the legs. respective panel seams 21. Thus, in Figure 2A, the designated area 39 is generally rectangular in shape, and the graph that has been matched 42 is coincides within and through the surface area of the designated area 39. The matched graph 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 Figure 2, the simulated leg swings 31 provide a perceived shape or curvature for the training underpants 40 which is one of the unique features here.

A very narrow tolerance for the matching of a desired component, such as graphs 38 and 42, is provided uniquely and advantageously within any selected area, such as the designated area 39. With reference to Figure 1, it is evident that the simulated fly opening 23 of the graphic 38 requires matching inside the front panel 12. It would be undesirable to have a training underpants 10 manufactured by a method and / or an apparatus that could not control the proper or simulated match of the opening of fly 23, otherwise the simulated fly opening 23 could appear on the rear panel 14 or in 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 tolerated area more particular 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 spacer means 48 which separates the continuous tissue wrapped absorbent 46 into a plurality of separate and distinct absorbent pads 32. The delivery means 44 can be any conventional mechanism to supply the absorbent 46. Generally, conventional supply means 44 will include a hammer mill to form the fluff fibers and, if desired, to provide a wrap for the superabsorbent material mixed with the fluff fibers, and then deposit the erases and superabsorbent material on a forming drum having a desired absorbent design. The forming drum then deposits the absorbent formed on a continuously moving tissue material, which is then delivered to a bending board to fold the tissue around the absorbent. This provides the absorbent wrapped with continuous tissue 46. The absorbent 46 30 may include any desired mixture or combination of absorbent materials, such as fluff and superabsorbent materials. Suitable superabsorbent materials are available from various commercial vendors such as Dow Chemical Company, Hoechst Celanese Coporation and Allied Colloids, Inc. Typically, a superabsorbent material is capable of absorbing at least about 15 times its weight in water, and desirably more. about 25 times its weight in water. A preferred eraser is one identified with the trade designation CR1654 available from Kimberly-Clark Corporation of Neenah, Wisconsin, and is a bleached highly absorbent wood pulp containing primarily softwood fibers.

A conveyor means 50, which can be any conventional conveyor means well known in the art and carries the absorbent 46 to the separator means 48. A supply means 52 provides a first layer of material 54 continuously in motion, on which any components, such as the separate and separate absorbent pads 32 formed by the spacer means 48 can be placed. The delivery means 52 can 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 tension and speed. An example of a standard unwinder mechanism 31 is an MB 820 model available from Martin Automatic Corporation of Rockford, Illinois. The first layer of material 54 continuously in motion 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 top sheet 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 aforementioned United States patents incorporated herein by reference.

When moving or surrendering to the separating media 48, the absorbent wrapped in continuous tissue 46 is cut into the separate absorbent pads and separated by means of a knife roller 56 and an anvil roller 58 comprising the spacer means 48. The knife roller 56 can have any number of blades on it, and in this example has two blades 60 placed diametrically thereon to form the absorbent pads 32. The knife roller 56 is driven and mechanically coupled through the gear to the anvil roller 58, which is driven operationally. by a main shaft line 128 (Figure 6) in any suitable manner well known in the art. A constant reference means 32, such as a proximity switch 62, are coupled to an anvil roller 58 to generate a reference signal for each cut absorbent pad 32. For the purposes given there, the separator means 48 is operated at a time. 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 purposes of comparison with other signals hereinafter described. 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.

Separate and separate 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 individually cut absorbent pads in a continuously moving layer. , and any such suitable mechanisms can be used here.

Supply means 64, which can provide a standard unwinding mechanism similar to that used with reference to the supply means 52, 33 provide a continuously moving second layer 66 of material which subsequently will join the first layer 54 continuously in motion . The second layer 66 continuously moving moves towards a pair of driven rollers 68 and 70 which form between them a compression point 72. The drive rollers 68 and 70 can be properly coupled and driven by any suitable motor, such as those described in the patents of the United States of America incorporated herein by reference. A suitable compression point motor is an HR 2000 brushless AC servo motor available from Reliance Electric Company of Cleveland, Ohio. As described above, the material from which the second layer 66 is made is elongated by, for example, pulling or compression, so that it can be lengthened, by way of example, by between about 0.5 percent to about 5.0 percent of a length, for example, a repetition length of the machine product. The second layer 66 continuously in motion, in this particular description, is a liquid impervious film which will subsequently form the liquid impermeable outer cover 34 (Figure 1) and such films are available from Edison Plastics Company of South Plainfield, New Jersey.

It is desired that the pressure point motor 148 (FIG. 6) and its drive system which operates the drive rolls 68 and 70 be one that is capable of performing two 34 types of controllable speed variations, 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 rotation speed to a faster rotation speed, or to decrease a present rotation speed at a slower rotation speed. This speed adjustment is used for the repeating circuit. The other adjustment or speed variation is a momentary speed adjustment or variation comprising an incremental advance phase movement, which is a momentary speed increase of the drive rolls 68 and 70 to provide a measured increased amount of the material layer, or an incremental delay phase movement, which is a momentary decrease in the speed of the idler rolls. drive 68 and 70 to provide a quantity of the material layer decreased and measured. The term "momentary speed increase" refers to increasing a first speed to a second higher 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 measured quantity. The term "momentary speed decrease" refers to decreasing a first speed to a second lower 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 the associated graphs towards 35 above the pressure point by a measured quantity. This momentary speed adjustment is used by the positioning circuit.

When an increase or decrease in speed is made, for any one loop of repetition or a change of speed of laying circuit, the material requires being controllably elongated to equalize the speed of the downstream tissue. This prevents the tissue tension from becoming too high, which would cause a tissue break, or it could be made too low, which would cause a loosening of the fabric and finally a wrapping. A compression regulation mechanism is used for this controlled elongation. The mechanism consists of a dancer assembly 79 which includes a position feedback sensor. When the compression pressure point 72 accelerates or decelerates, the dancer assembly automatically supplies or takes the material by changing position. The associated position feedback signal is used to increase or decrease the pressure on the compression point 72 by correspondingly increasing or decreasing the lengthening effect resulting in the associated advance or delay in the position of the layer 66.

The present invention can be used to match two layers continuously moving together, so that a reference mark and / or a product component of a layer is matched to a reference mark and / or a product component on a surface. the second layer. In this particular description, a component, such as a matched graph 38 (Figure 1) on a continuously moving second layer 66 (Figure 5) is matched to a component, such as an absorbent pad 32, on a first layer continuously in motion 54. By controllably matching a plot that has been matched 38 to an absorbent pad 32, the desired position of the matched graph 38 on the front panel 12 (FIG. 1) of the training underpants 10 can achieve 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 purposes of donning them, 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 such graphs 38 can be made to coincide with separate and distinct absorbent pads 32 on a continuously moving layer 54. Associated with each graph 38 is 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 known in the art.

With reference to Figure 3, 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 is illustrated. 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 placed outside the graphs 38, but can be printed directly on the graphs 38 so as 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. Also the detectable or similar marks can be printed as part of the graphics 38 and then used to appropriately match the graphs 38. However, for explanation and manufacturing purposes, the reference marks 74 are provided with 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 (Figure 5) of material in order to produce a two-layer laminate that will eventually form the cover exterior impermeable to liquid 34 38 (Figure 1). The material from which the layer 66 is made serves as a liquid impermeable barrier, while the third layer or material attached to the layer 66 will provide a cloth-like texture for the outer cover. The cloth type layer will be the outermost layer. There is no requirement, however for the third layer, and in some product designs, the cloth type layer will be removed.

From the supply means 64, the layer 66 moves through a pulling or angling means or mechanisms such as a variable press 65. The variable press 65 is adjusted to open or close the compression point 72 formed by the rollers. of drive 68 and 70 through any suitable control means such as a hydraulic cylinder arrangement, a servo motor arrangement, or the like. One such example is a linear actuator 67 operatively connected by a connecting rod 63 to a driven pressure roller 68 which acts on the driven support roller 70. The cylindrical outer surfaces of the rollers 68 and 70 may have any characteristic or Finished surface finish such as, by way of example, smooth surfaces, roughened surfaces, etched surfaces, or the like. The rollers 68, 70 can have the same or a different finish or surface characteristic. The characteristic or surface finish will generally depend on the material being pulled or lengthened, various processing parameters or the like. One of the purposes of the variable press 65 is to apply a force or compression against the layer 66 to controllably increase the distance between the reference marks 74. This can be achieved by controllably moving the roller 68 toward the roller 70 to adjust the dimension of the compression point 72 formed between the roller 68 and the roller 70. As long as the compression point 72 has a gap or dimension less than the thickness of the layer 66, the layer 66 will be pulled or lengthened when pulled or moved between the drive rollers 68 and 70. As the layer 66 is pulled or lengthened, its length is increased, thereby increasing the distance between successive and subsequent reference marks 74. Lengthening or pulling also results in a decrease in thickness of the layer 66. By controlling the movement of the driven pressure roller 68 toward or away from the driving support roller 70, the separation or dimension the point or compression 74 is selectively adjusted, thereby selectively controlling the pulling or elongation of the 66 layer and the distance between subsequent successive reference marks 74. This allows the distance between any two successive reference marks 74 to be controllably adjusted as to match a repetition length of the machine's product.

After the variable press 65, the layer 66 is moved through a dancer assembly 79, comprising a free roller 75, a dancer roller 69, and a free roller 77. The dancer assembly 79 provides a festoon for the layer 66 and a position feedback signal to be used by the linear actuator 67, which adjusts the separation of the compression point 72. A suitable dancer assembly is available from Martin Automatic Corporation of Rockford, Illinois. The layer 66 then moves towards a laminating cooling roller 86 and an associated support roller 88 which forms between them a laminating pressure point 90. A continuously moving layer 92 is provided and driven in any suitable manner for the roller cooling laminator 86. An adhesive applicator 94 applies a desired pattern of an amount of adhesive to the continuously moving layer 92. In this particular embodiment, the layer 92 is a non-woven fabric, such as a yarn-bound polypropylene fabric having a basis weight of about 20 grams per square meter (gsm). The adhesive applicator 94 can be any suitable applicator well known in the art which can provide or apply the desired pattern of adhesive. The adhesive used can be any suitable adhesive that is compatible with the layers towards an adjustment or deformation means or mechanism, for example, to a means or extension mechanism, such as a variable slot cutter 69 and an associated roller 71, operatively coupled the same. The variable cutter 69 may be any apparatus well known in the art of cutting or lengthening a desired material. A cutter roller 83 can move towards and away from the roller 71 by any suitable control means, such as a driven cylinder-piston arrangement, servo motor arrangement or the like. An example is a linear actuator 77 operatively connected by a connecting rod 79 to the cutting roller 83. The cutting roller 83 may comprise a plurality of projections extending outward from its cylindrical surface. These projections, in this embodiment, are a plurality of spaced and spaced apart discrete elongated cutting members oriented generally parallel to the axis of cutter roll 83. One of the purposes of variable cutter 69 is to elongate, when necessary, layer 66 to increase the distance between the reference marks 74. This can be achieved by controllably moving the slit cutter roll 83 against the layer 66 through the controlled operation of the linear actuator 77 and the connecting rod 79. By the controlling the movement of the slit cutter roll 83 against the layer 66, the pressure exerted by the slit cutter or cutter members of the slit cutter roll 83 against the layer 66 can be controllably adjusted to, by way of example, the slit layer 66, thereby lengthening it to increase the distance between the reference marks 74. In addition to cutting h In order to increase the distance, other methods include, but are not limited to, pressing, calendering, heat treatment, perforation, radiation treatment, marking 42, cold rolling or the like. If, however, the layer 66 is determined not to require an increase in the distance between the reference marks 74, the layer 66 will move between the slit cutter roll 83 and the roller 71 without being cut, since the roller 83 it will have been controllably moved in a direction away from the roller 71 to present a clear or unobstructed path between them.

After the variable slit cutter 69, the layer 66 is urged or moved towards the laminating cooling roller 86 and an associated support roller 88, which form between them a laminating pressure point 90. A continuously moving layer 92 is provides and is driven in any manner suitable to the laminator cooling roller 86. An adhesive applicator 94 applies a desired pattern of a 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 94 can be any suitable applicator well known in the art that the desired pattern of adhesive can be provided or applied. The adhesive 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 can be provided by the supply means (not shown) 43 similar to the supply means 52 and 64. The cooling roll 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. Again, if desired, the lamination or attachment of layer 92 to layer 66 can be eliminated.

Once the layers 66, and 92 are laminated and pass through the laminating pressure point 90, they are continuously moved to a chill roll construction 96, and have an adhesive applied to the outermost surface of the layer 66. The construction cooling roller 96 can also be driven by the line shaft 128. The adhesive applied by the adhesive applicator 98 will eventually join the layers 66 and 92 to the first layer 54 continuously in motion. Therefore, the adhesive applicator 98 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 of the adhesive applicator 98, as well as the adhesive applied by the it can be any type of applicator suitable for the desired adhesive pattern, and appropriate and compatible for the materials to be joined.

From the chill roller construction 96, the laminated layers 66 and 92 are then superimposed on a continuously moving layer 54 and together the layers pass through a product puncher 100 comprising a drive roller 102 driven by the spindle axis. line 128 (Figure 6) and a loose roller coated with rubber 104. The puncher 100 compresses the layers together in order to cause the adhesive applied by layers 66 and 92 to the continuously moving layer 54, thereby forming a composite layer 93 continuously moving as illustrated in Figures 4 and 5.

Continuing with reference to Figure 5, first sensor means, such as the sensor 106, are suitably positioned between the dancer assembly 79 and the laminating pressure point 90 to detect and generate a signal in response to each reference mark 74. Given that the reference marks 74 are optical brighteners sensitive to ultraviolet radiation, a suitable sensor is a SICK detector model LUT 2-6 available from SICK OPTIK ELEKTRONIK, INC., having a business office in San Paul, Minnesota.

Placed downwardly of the product puncher 100 are the second and third sensor means, such as a sensor 108 and a photo eye 110. The term "downstream" refers to a direction from left to right as seen in the Figure 5, and also the ess of the machine for the process.

The sensor 108 may be of the same type of ultraviolet detector as the sensor 106. The photo eye 110 is desirably an explorer block. Banner RSBF, based on RPBT wiring, an optical fiber pair device IR 2.53S, available from Banner Engineering Corporation of Minneapolis, Minnesota. The photo eye 110 is designed to optically detect a product component, such as an absorbent pad 32, and to generate an electrical signal in response thereto. In this particular description, both sensors 106 and 108 are designed to detect and generate a signal in response to a reference mark 74, and the photo eye 110 is designed to detect and generate a signal in response to an 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 graphic 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 detect a component of product or other structure in order to generate an appropriate signal.

With reference to Figure 4, a continuously moving composite layer 93 comprising the layers 46 66, 92 and 54 (Figure 5) is illustrated after these have been joined together by the product puncher 100. Each printed waistband 76 finally it will be cut along the 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 relative to a front edge of absorbent pad 112 (Figure 4). Naturally, other brands or product components may be in correspondence with other reference marks or different product components. For example, a simulated waist opener 29 (Figure 2) may be in correspondence in relation to a waist opening, or leg elastics, such as the leg elastics 30 (Figure 1) may desirably be matched in relation to a pad absorbent such as an 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 matching control system 124 which receives 47 various generated signals, processes them in accordance with the programmed instructions , and generates the output signals to ur. 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 controls, as necessary, the speed of the drive rolls 68 and 70 The linear actuator 67 of a variable press 65 is controlled in response to the position of the dancer roller 69 through suitable means well known in the art, separately from the main matching control system 124.

The main drive control system 126 may be designed to operate or control other areas or mechanisms.

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 electric and mechanical, indirectly drives other mechanisms. The line shaft 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 linear axis 128. Specifically, a supply compression point gear coder 48 and a line axis matching encoder 132 are operatively coupled to the line axis 128. Examples of the encoders include a H25D-SS-2500- ABZC-8830-LED-SM18 (which can be used as encoder 130) available from BEI Motor System, Company of Carlsbad, California, and 63-P-MEF-1000-T-0-00 (which may be a encoder 132) available from Dynapar Corporation of Gurnee, Illinois. The compression 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 instructions of the preprogrammed computer program and / or of the apparatuses, and can be represented, with reference to Figure 6, as comprising an input acquisition system of 134, a ratio control of gear 136, a relative position 138, an automatic fixed point generation 140, a difference block 142, and a positioning control 144. The main matching control system 124 includes a computer, which may comprise, for example, a VME-based microprocessor such as SYS68K / CPU-40B / 4-01 available from Forcé Computers, Inc., of Campbell, California.

As illustrated in Figure 6, the input acquisition system 134 can be designed to receive the following six generated signals: (i) a signal from the motor encoder 146 operatively coupled to a motor 148 that drives the drive rolls 68 and 70, (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 (Figure 5), and (vi) a signal from the photo eye 110 (Figure 5). An input acquisition system 134 receives and counts the pulses generated by the motor encoder 146 and the line axis matching encoder 132, and receives the signals from the sensors 106 and 108, of the proximity switch 62 and of the photo eye 110 Referring to the accumulated accounts of the encoder 146 and the accumulated accounts of the encoder 132, the input acquisition system 134 performs the preprogrammed instructions that are specific to the respective received signals, and stores the results of the instructions.

In a similar manner, the input acquisition system 134 may be designed to receive the signals from the motor encoders or the like operatively coupled to the motors that can drive other mechanisms, carry out specific preprogrammed instructions for the received signals, and store the results of the instructions.

For the gear ratio control 136, a signal counter in an 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 pulses 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 average calculation. The average 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 only a pair of reference marks 74. This averaging "smoothes" the measurements, and is required due to the variability of the apparatuses and processes. 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 performing a running average of the measured counts, the input acquisition system 134 performs a filtering function, which is preprogrammed, to filter the signal anomalies. Examples of such signal anomalies include a dirty photoeye 51, missing or extra reference marks 74, a movement or tissue of the layers, measurement of the quanta outside of a preprogrammed range for averaging purposes, inaccurate data known due to events of control of coincidence, 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 then determines and records the current accumulated number of beats upon receiving a signal from the sensor 106, and determines and records the current accumulated beat number upon receipt of 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. Then it determines and records the number of current accumulated pulses when receiving a signal from the sensor 108, and determines and records the number of current accumulated pulses upon receiving a signal from the photoeye 110. Next, the input acquisition system 134 calculates the difference between the number of current accumulated pulses 52 from a sensor signal 108 and the current cumulative number of pulses from an associated signal from photo eye 110; the "associated signal" refers to the signal generated by the photo eye 110 (Figure 5) with the sensor signal 108, for each repetition length of the machine product. With these calculated differences, the input acquisition system 134 carries out a standard deviation and a current averaging 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 print control system 126 (Figure 6). The main drive control system 126 generally comprises at least one control / logic processor 150, at least one electronic gearbox 152, and at least one motor controller 154. The main drive control system 126 includes a computer, which may comprise, for example, a Reliance Distributed Control System made by Reliance Electric Company. The distributed control system includes a Reliance Electric Automax processor and an associated device. Each electronic gearbox 152 (FIG. 6) comprises a two-axis card that is part of the distributed control system unit and is used to control the position of its respective motor, such as the motor 148.

The gear ratio control 136 asks the input acquisition system 134 for every 20 products, for example every 20 repetition lengths of machine product, with respect to the current running average of the measured counts representing a distance between the successive reference marks. 74 (Figure 5) which is the repetition value. The number of lengths of product lengths 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. The new gear ratio value is then transmitted to the control / logic 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 accounts from the pressure point gear encoder 130 (Figure 6) occurring in a repeat section of machine product. The purpose of this is to accumulate the repetition of reference marks without comparing them to a target value.

The relative position 138 of the main matching control system 124 interrogates the input acquisition system 134 with respect to the current accumulated number of beats 54 in relation to the sensor 106, and the number of current accumulated beats in relation to the proximity switch 62. relative position 138 then determines the difference between the two currently accumulated numbers of beats in order to calculate a relative position of a reference mark 74 (Figure 5) with respect to the associated proximity switch signal for that specific question for each stretch of repetition of machine product. 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 repeat section of machine product representing a single product. The occurrence of each product, or the repetition length of the machine product, was determined from the line axis coincidence 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 or a signal from the sensor 108 and the number of pulses. current accumulated from an associated signal 55 from the pad photo 110 for each product; the current running average of this calculation is the current 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 that data and will not determine a new one. fixed point since the standard deviation data is considered too variable to make an exact fixed point adjustment. If the standard deviation is within the preset 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 real position value. If the new calculated difference is determined, by means of an automatic fixed point generation 140 as being within the prescribed range, no further action or calculation will be made. 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 said fixed point of current control the difference between the target value and the current position value.

Once each machine repetition product length, a difference block 142 determines the difference between the current control fixed point value from the automatic fixed point generation 140 and the relative position value associated from the relative position 138, which is the placement error. The difference block 142 transmits this positioning error, in line axis encoder accounts, to the positioning control 144. The positioning control 144 compares the positioning error to a tolerance band 170 (Figure 8) which defines a acceptable deviation from the relative position value about 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 of this, even when the position control of the reference occurs at the pressure point, the fixed point for the position control is derived exactly from the signals generated by the sensor 108 and the photo eye 110.

With reference to Figure 8, there is illustrated a derived fixed point 168 having a prescribed tolerance band 170. For purposes of explanation, the fixed control point 168 has a value of 1000 counts, 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 product position value as calculated by the relative position 138. The waveform 156 represents signals generated by the proximity switch 62 , and the waveform 158 represents the signals generated by the sensor 106. If the setting error value remains within the tolerance band 170, a placement order will not be generated. However, if the setting error value is outside the tolerance band 170, then the positioning control 144 will generate a placement command. The placing order is directly proportional to the size of the difference represented by the value from the difference block 142 and requests an advance or delay measured at the position of the layer 66. The generated placing order is then transmitted to the control processor / logic 150 of the main drive control system 126. FIG. 8 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 an error of placement. The positioning error for each data point is compared to a tolerance band 170 to determine whether a placement order should be generated. In the example, point 176 is the only data point where the positioning error falls outside the tolerance band 170, which causes a placement order to be generated, thereby causing the next data point to fall inside. of the tolerance band 170.

The control / logic processor 150 (Figures 6 and 7) of the main drive control system 126 searches for and receives new commands from the main matching control system 124. Specifically, the processor 150 searches for and receives 58 commands of gear ratio and positioning commands from the matching control system main 124. For each gear ratio value update command, the processor 150 transmits a command according to the preprogrammed instructions to the electronic gearbox 152 to modify the value used in the gear ratio block 208 (FIG. ). For each positioning command received from the positioning control 144, the processor transmits a placement command according to the preprogrammed instructions for the electronic gearbox 152.

When an increase or decrease in speed is made, for any change of speed of placement circuit or repetition circuit, the material requires being controllably elongated to equalize the speed of the downstream tissue. This prevents tissue tension from becoming too high, which could cause tissue breakage, or become too slow, which could cause loosening of the tissue and eventually a wrapping. A compression regulation mechanism is used for this controlled elongation. The mechanism consists of a dancer assembly 79 which includes a position feedback sensor. When the pressure point 72 accelerates or decelerates, the dancer automatically supplies or takes the material by changing the position. The associated position feedback signal is used to increase or decrease the pressure on the compression point 72 correspondingly by increasing or decreasing the lengthening effect resulting in the associated advance or delay in the position of the layer 66.

Upon receiving a repetition or placing order from the main matching control system 124, the main drive control system 126 will execute the associated speed changes on the drive rolls 68 and 70 (Figure 5). When a speed change is executed on the drive rollers 68 and 70, the material requires being controllably elongated to equalize the tissue speed downstream. For example, when the speed of the drive rolls 68 and 70 increases, the dancer assembly 79 automatically takes the excess material by changing the position of the dancer roll 79. The corresponding position feedback signal is used by the controller for the linear actuator 67 for increasing the separation or dimension of the compression point 72. Through this separation or increase in dimension, the layer 66 is elongated less, thereby returning the dancer roller 79 to its normal operating position. When the speed of the drive rolls 68 and 70 decreases, the dancer assembly 79 automatically supplies additional material by changing the position of the dancer roller 69. This corresponding position feedback signal is used by the controller for the linear actuator 67 to increase the separation or dimension of the compression point 72.

Through this separation or decrease in dimension, the layer 66 is further elongated, thus returning the dancer roll 69 to its normal operating position. These changes are made through the linear actuator 67 which drives the driven print roller 68 through the connecting rod 63 towards or away from the driven support roller 70 to controllably adjust the separation or dimension of the compression point 72. Regulated spacing in turn controls the amount of elongated pull of layer 66 to compensate for differences in speed between the compression point 72 and the rolling point 90.

Referring to Figure 7, the electronic gearbox 152 may comprise a gear ratio block 208, a difference block 210, a speed regulator 212, and an incremental movement block 214. The gear ratio block 208 receives a gear ratio value from the control / logic processor 150 (Figure 6), and receives a pulse train from the pressure point pick-up encoder 130. The gear ratio block 208 scales the pulse train from the gear encoder 130 and applies the gear ratio value to this in order to generate a reference signal to the difference block 210. The difference block 210 receives both the reference signal from the gear ratio block 208 and also receives a supply feedback signal from the motor encoder 146, which communicates the current speed of the motor 148. The difference block 210 determines the difference between the signals and generates a command signal for the speed controller 212 which generates a speed reference signal for the motor controller 154. both, the electronic gearbox 152 precisely links the speed of the compression point drive motor 148 to the speed of the line axis 1 28 through an electronically changeable gear ratio. This effectively synchronizes the speed of the pressure point motor 148 with the axis e line 128 and allows subsequent changes to the gear ratio and thus to the speed of the motor 148. These changes in the speed of the motor 148, and therefore of the drive rollers 68 and 70 are desirable to accommodate the coincidence of layer 66.

With reference to Figures 6-7, the electronic gearbox 152 also receives a setting value from the logic / control processor 150, and this setting value is received by an incremental motion block 214. The incremental motion block 214 performs a "once" movement to appropriately change the reference signal by a measured amount of the compression point motor encoder counts, thereby calculating an exact increase or decrease in the amount of the layer of material being supplied to the pressure point motor 148. This can be done by relating the number of encoder counts of the motor encoder 146 to a current amount of the material layer supplied to the compression point 72 (FIG. ). In response to the placing order, an incremental movement signal is generated and the difference block 210 is added temporarily, which increases or decreases, the reference signal received from the gear ratio block 208, thereby resulting in a momentary change in the speed command signal sent to the speed controller 212. The motor controller 154 receives the speed command signal from the electronic gearbox 152 (Figure 6) and varies the speed of the motor 148, which is represented by the pulse train of motor encoder, in response to this.

As described, the desired match of the graph 38 (Figure 1) or of the graph 42 (Figure 2) in the respective training pants 10 and 40 can be achieved. By selectively controlling the distance between the successive reference marks 74 (Figure 5), each mark 74 can be desirably matched to an associated component, such as an absorbent pad 32. Controlling the distance between the reference marks 74 with a selected distance , such as a repetition length of machine product, is accommodated or corrected for variations or other types of anomalies that may be present in the apparatus or process.

By controllably adjusting the speed and separation of the compression point 72 and the resultant elongation of the continuously moving second layer 66, the layer 66 is properly matched to the first continuously moving layer 54, thereby ensuring adequate matching of the desired component, such as a graph 38, with another component, such as a front panel 12 (Figure 1).

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

Claims (16)

64 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 continuously moving first layer that includes a plurality of components being spaced apart by a selected length, providing a continuously moving second layer comprising a permanently sealable material and including a plurality of components being spaced apart by a length less than the selected length, represent the components of the second layer continuously in motion with a respective plurality of reference marks, perceive each of the reference marks and generate a benchmark signal in response to these, measuring the distance between two successive reference mark signals and generating a corrective control signal of 65 repetition according to preprogrammed instructions, pulling the second layer continuously in motion to adjust the distance between two successive reference marks in response to a generated repetitive corrective control signal, superimpose the first layer continuously in motion and the second layer continuously moving together, perceiving a reference mark of the second layer continuously in motion and of its corresponding component of the first layer continuously in motion, and generating a corrective positioning control signal in accordance with the preprogrammed instructions, and adjusting the speed of the second layer continuously in motion in response to the 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.

2. The process as claimed in clause 1 characterized in that the pull step adjusts the distance between two successive reference marks with the selected length.

3. The process as claimed in clause 2 characterized in that the pulling step includes the thinning of the second layer of material.

4. The process as claimed in clause 3, characterized in that the selected distance is a repetition length of the machine product.

5. 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 continuously moving first layer that includes a plurality of reference marks that are being spaced apart by a selected length, providing a continuously moving second layer comprising a permanently sealable material, and including a plurality of corresponding reference marks spaced apart by a length less than the selected length, 67 perceiving each of the reference marks of the second layer continuously in movement and generate a benchmark signal in response to this, measure the distance between two successive reference mark signals and generate a repetitive corrective control signal according to preprogrammed instructions, pull the second layer continuously in motion to adjust the length in response to a generated repeating corrective control signal, superimpose the first layer and the second layer together continuously in motion, perceiving a reference mark of the second layer continuously in motion and of its corresponding reference mark of the first layer continuously in motion and generating a corrective positioning control signal in accordance with preprogrammed instructions, and adjusting the speed of the second layer continuously in motion in response to a corrective positioning control signal generated to controllably match a reference mark of the second layer continuously in motion with its corresponding reference mark 68 on the first layer continuously in motion .

6. The process as claimed in clause 5 characterized in that the step of the pull adjusts the distance between two successive reference marks with the selective distance.

7. The process as claimed in clause 6 characterized in that the pulling step includes the thinning of the second layer of material.

8. The process as claimed in clause 6 characterized in that the second layer is impermeable to liquid.

9. The process as claimed in clause 5 characterized in that the selected distance is a repetition length of machine product.

10. 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: means for providing a continuously moving first layer including a plurality of components that are being spaced and separated by a selected length, means for providing a continuously moving second layer comprising a permanently sealable material, and including a plurality of components that are being represented with a plurality of the respective reference marks that are being spaced apart by a length less than a selected length , 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 two successive reference mark signals, and means for generating a repeating corrective control signal in accordance with preprogrammed instructions, means for pulling the second layer continuously in motion to adjust the distance between two successive reference marks in response to a generated repetitive corrective control signal, means for superimposing the first layer continuously in motion and the second layer continuously moving together, means for sensing a reference mark of the continuously moving second layer and its corresponding component of the first 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 second layer continuously in motion in response to a corrective positioning 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.

11. The apparatus as claimed in clause 10 characterized in that the means for pulling adjust the distance between the two successive reference marks with the selected distance.

12. The apparatus as claimed in clause 11 characterized in that the means for pulling thin the second layer of material. 71

13. 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 second layer continuously in motion, comprising: means for providing a continuously moving first layer including a plurality of reference marks that are being spaced apart by a selected distance, means for providing a continuously moving second layer comprising a permanently sealable material, and including a plurality of reference marks that are being spaced apart by a length less than the selected length, means for sensing each of the reference marks of the second layer continuously in motion, 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 pulling the second layer continuously in motion to adjust the length in response to a signal of repetitive corrective control generated, means for overlaying together the first layer and the second layer continuously in motion, means for sensing a reference mark of the second layer continuously in motion, and its corresponding reference mark of the first layer continuously in motion and means for generating a corrective positioning control signal in accordance with preprogrammed instructions, and means for adjusting the speed of the second layer continuously in motion in response to a positioning corrective control signal generated to controllably match a reference mark of the second layer continuously in motion with its corresponding reference mark on the first layer continuously in movement .

14. The apparatus as claimed in clause 13 characterized in that the means for pulling adjust the distance between two successive reference marks with the selected length.

15. The apparatus as claimed in clause 14 characterized in that said means for pulling thin the second layer of material.

16. The apparatus as claimed in clause 14 characterized in that the selected distance is a repetition length of machine product. 74 R E S U M E N A process and apparatus are provided to controllably match two layers of material continuously in motion. One of the layers compresses a permanently sealable material, and a plurality of reference marks representing a plurality of separate and distinct components and the other of the continuously moving layers has a respective plurality of different components thereon. The process and apparatus control the distance between the reference marks at a selected distance and controllably match each reference mark with a respective component of the second layer continuously in motion.