US3745947A

US3745947A - Diaper machine

Info

Publication number: US3745947A
Application number: US00140783A
Authority: US
Inventors: C Brocklehurst
Original assignee: Riegel Textile Corp
Current assignee: Riegel Textile Corp
Priority date: 1971-05-06
Filing date: 1971-05-06
Publication date: 1973-07-17
Anticipated expiration: 1990-07-17

Abstract

A diaper machine having folding, sewing, cutting, conveyor, and hemming sections which incorporates novel means for centering during folding, for regulating the overall width during sewing of a center fold and for conveying diaper segments in a novel manner while hemming.

Description

United States Patent 1191 Brocklehurst July 17, 1973 [541 DIAPER MACHINE 3,580,198 /1971 Teed 112/155 X 7,64 68 24 [75] Inventor Charles Bmcklehurst Honea 947,605 111310 1 12 Path, S.C. 3,489,113 1/1970 Flanagan 112/203 X [73] Assignee: Riegel Textile Corporation, Ware 52 22;: all. 12 2:836:135 5 1952 Briggs 112 214 22' i May 6, 1971 2,619,057 11/1952 Ellis, Sr 112/203 3,345,965 10/1967 Gore 112/10 X [21] Appl. No.: 140,783

Primary Examiner-James R. Boler [52] 11.5. CI. 112/121.11, 112/214 AtwmeyePennie. Edmonds, MortomTaylm & ams [51] Int. Cl D05b 19/00 [58] Field 01 Search 112/2, 121.11, 121.12, 57 TR T 1 i 9 1 9 7 u o I 3 33 3 A d1aper machine havmg folding, sewlng, cuttmg, conveyor, and hemming sections which incorporates novel [56] References Cited means for centering during folding, for regulating the overall width during sewing of a center fold and for UNITED STATES PATENTS conveying diaper segments in a novel manner while 3,273,522, 9/1966 Gore et a1 112 10 x hemming 3,013,513 12/1961 Jude1son..... 3,043,532 7/1962 Seiden 242/57.1 12 Claims, 10 Drawing Figures 1 1 *0 600 J9. 1? :1 2.5 3 51 03- 7 i I a? i 11 57 '11, I09 I 5 59 1l2 M122 1 I: l

Pmmmm 3.745941 sum: 0F 7 INVENTOR. CHARLES E. BROCKLEHURST BY $1 LZ /I ATTORNEYS Pmm'tn m samsori FIG. 4

- HARLES E. BROCKLEHURST /Zm, 4%42 4 a l w ATTORNEYS minnow 3.145.947

' "SHEET? or 7 FIG. '9

INVENTOR.

CHA ESE. BRoc LEHURST ,ZMZ;

ATTORNEYS DIAPER MACHINE BACKGROUND OF THE INVENTION Conventional folded diaper manufacture requires the formation of a center panel having one or more folds to provide increased absorbency with related sewing of the center panel. Cutting of the diaper to length and hemming of the cut sides are accomplished to complete the finished diaper. Diaper machines which perform these steps are known,; however, obtaining a folded diaper of the described construction within desired dimensional limits and at high production rates has been difficult. For example, centering of the folded panel has not been readily obtained nor has the desired width of the diaper been easily obtained within satisfactory limits. After cutting of diapers to length, it has been diffi' cult to achieve satisfactory hemmed edges due to certain limitations in prior techniques of conveying diaper segments throughout the hemming operation.

It is the purpose of the present invention to provide an improved diaper machine which obviates the afore mentioned difficulties.

SUMMARY OF THE INVENTION In accordance with the present invention a diaper machine is constructed having sequential operationally positioned supply, folding, sewing, scray, length cutting, conveying, and hemming sections; each section being preferably under the control of a multi-cam programmer. During folding of a center panel, means are provided for centering such panel; during sewing, means are provided for adjusting the width of the diaper by making slight variations in the width of the center panel. During hemming, the diaper is held securely upon a conveyor drum which eliminates much of the jamming and waste which has accompanied previous conveying techniques.

These and other aspects of the invention will become apparent upon examination of the following detailed specification and of the accompanying drawing.

BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a side elevation showing an apparatus constructed according to the principles of the invention;

FIG. 2 is a plan view of the apparatus of FIG. 1;

FIGS. 3-5 are respectively sections taken in the direction of arrows 3-3, 4-4, and 5-5 of FIG. 1;

FIG. 6 is a sectional view taken in the direction of arrows 6-6 of FIG. 2;

FIG. 7 is an enlarged detail view of an edge trimming apparatus included in the machine of the present invention;

FIG. 8 is a sectional view taken in the direction of arrows 8-8 of FIG. 7;

FIG. 9 is a side elevation showing a multi-cam programmer for controlling the several parts of apparatus of FIGS. 1 and 2; and I FIG. 10 is a sectional view taken in the direction of arrows 10-10 of FIG. 9.

DESCRIPTION OF PREFERRED EMBODIMENT Referring now to the drawing and initially to FIGS. 1 and 2 thereof, a diaper machine constructed according to the principles of the present invention has been illustrated. The diaper machine may be characterized as having a supply section 10, folder section 11, center panel sewing section 12, scray 13, cutting section 14,

conveyor section 16, and an edge hemming and trimming section 17. The various sections cooperate to manufacture and produce a completed diaper having a central folded panel, as will be described.

Beginning with the supply section 10, a roll 18 of web material suitable for the manufacture of diapers is mounted at one end of the machine upon arms 20 connected to plates 21. As seen in FIGS. 1 and 2, the roll 18 is held in position by arms 22 mounted to a cross bar which rests across the top of roll 18. Arms 21 have ends 21a which are slidable laterally upon an upper rod 25 secured to frame members 26. The lower ends 21a are secured to longitudinal and transverse rods 27a, 27b, the latter being reciprocable by a cylinder 27c secured to frame 29. Cylinder 270 can be actuated therefore to slide the roll 18 laterally.

The web 19 passes between three freely rotating guide rolls designated generally be reference numeral 24.

Fold plates

30, 31 are connected to two side frame members 32 by a cross rod 33 and as shown in FIG. 4, converge toward each other as the web 19 proceeds upwardly from the guide rolls 24. Switch assembly 35 having sensor elements 350 which contact the edge of web 19 will cause actuation of cylinder 27c to maintain the proper edge positioning of web 19.

A large diameter roll 34 is freely rotatable on a shaft 36 supported at each end in frame members 32. The web 19 passes thereover and downwardly about two converging

fold plates

37, 38 to pass around a second large diameter roll 39.

Intermediate the two

rolls

34 and 39 along the side edges of web 19 are positioned two switches, 40 and 41, whose sensor elements 40a and 41a contact the opposite edges of web 19. Switches 40, 41 together control the actuation of a cylinder 42 whose actuating rod 43 is connected to a crank 44. The latter is connected to parallel actuating

links

46, 47, which are connected to rod 48.

Links

46 and 47 control the angularity of opposing pairs of

rollers

49, 50 which receive edge portions of web 19 therebetween and which are angularly rotatable about a vertical plane in mounting brackets 51, 52.

When the edges of web 19 track evenly between

switches

40 and 41 according to sensor elements 40a and 41a, no actuation of cylinder 42 will take place. When, however, either of the sensor elements 40a or 41a detect an unbalanced condtion, wherein the edge of web 19 is increasing or decreasing, the cylinder 42 will be actuated to tilt or swingrollei s 50 and 49 to cause correctinglateral movement of web 19. If the web 19 should increase or decrease in width evenly, no signal would be sent to cylinder 42, since the resultant signal produced by both switches 40 and would be zero.'l-lowever, should either one or both the

switches

40, 41 sense non-centering of the web 19 to the left or right as viewed in FIG. 4, a resultant signal would be produced which would cause

rollers

49 and 50 to correct the position of the web.

After passing beneath roll 39, web 19 proceeds to the center panel sewing section 12. As seen in FIGS. 1, 2 and 5, the sweing section includes horizontal

transverse support members

55, 56 and 57 which are bolted to the main

longitudinal frame members

58 and 59.

Sewing machines

60 and 61 are attached to carriages 60a and 61a which rest upon and are moveable parallel to sup port members 55-57,. Such movement is caused by and is under the control of motor 63, whose shaft 64 is attached to bell crank 66 and in turn to

links

67, 68. Thus, rotation of shaft 64 will cause movement of

sewing machines

60 and 61 toward or away from a center line between the machines. Machine 60 carries a plate 69 and machine 61 carries plate 70 which overlap at the center to receive the center fold 19a after passing beneath roller 39.

Machines

60 and 61 will sew along edge portions of the folded center panel.

Sensor elements

71 and 72 are biased resiliantly by spring elements 71a and 72a toward the center of the web 19.

Elements

71 and 72 are connected by a rod to a switch 75 which controls the operation of the motor 63.

The purpose and function of

sensor elements

71 and 72 in combination with lateral movements of

machines

60, 61 and

plates

69, 70 are as follows:

Since the web 19 has previously been centered by

rollers

49 and 50, the positioning of the center panel or fold 19a along the center of the diaper web 19 is assured. However, the width of the diaper may still vary, that is to say, the diaper may be too narrow or too wide. Accordingly,

sensor elements

71 and 72 will detect increases or decreases in the overall width of the diaper and in accordance with such increases or decreases will actuate switch 75 to move

machines

60 and 61 toward or away from each other. In this process,

plates

69 and 70 will also be shifted toward or away from each other and will cause the width of the center panel 19a to vary somewhat to correct for variations in the overall width of the web 19. Thus, the overall width of the web 19 can be maintained within some finite limits, such as for example, between a width of 14 A to inches, by small shifts laterally in the positioning of

machines

60 and 61, automatically increasing or decreasing the width of the center fold 19a.

Machines

60 and 61 are conventionally driven by belts 76 which connect with drive gears 77, 78. Gears 77 are of a sufficient width to accommodate the lateral movement of the

machines

60 and 61 and are mounted upon drive shaft 79, having pulleys 80 thereon, which are driven by motor 81 through the agency of gear box 82.

After leaving sewing section 12, the web 19 passes between rollers 84 which draw the web 19 through sections 11 and 12. Rollers 84 are driven as shown in FIG. 1 by belt drive 85 from gear box 82. The web 19 passes into a scray whose function is to permit a sufficient quantity of web 19 to accumulate in a relaxed condition prior to the remaining operations. Scray 13 is essentially a bin 13a between frame members 58, supported upon a shaft 86 which is pivotable with respect to frame

members

58 and 59. A counter-weight 87 is connected to the opposite side of the bin 13a and is arranged in such manner as to actuate a switch controlling the motor 81 when the bin 13 has been filled to a pro-determined weight. Thus, a second function of the scray 13 is to interrupt the flow of diaper web 19 between section 12 and the remaining sections 14-17.

The cutting section 14 includes rails, 89, 90 upon which a carriage assembly 91 is slidably mounted. The carriage assembly 91 includes a cross member 92 which mounts a base 93 connected to jaws 94. Carriage assembly 91 is reciprocally moved along

rails

89, 90 by an arm 96 actuated by a rotary cylinder 97. Jaws 94 are actuated by cylinder 98.

A conventional shear type cutting mechanism 99 is a'ctuated by cylinder 100 to cut across the width of web 19. Thus separating segments of diaper 101. Prior to each cut, the carriage 91 will move to a position where jaws 94 can engage the edge of diaper web 19. Upon return of carriage 91 to the position of FIG. 2, cutting mechanism 99 will be actuated to sever the diaper segment which will thereupon be released by jaws 94.

After cutting, each diaper segment 10] will be transported at right angles upon a conveyor 102 to the hemming section 17. As best seen in FIG. 6, section 17 includes a drum 103 mounted for rotation upon shaft 103a. Drum 103 is rotated by circumferential belts 104 which pass around the major circumference of the drum 103 and around a series of pulleys 106-111. The diaper segments 101 are held at all times securely against the drum by the belts 104 during the hemming operation. Tension is induced in the belts 104 by arm 112 biased by spring 113 connected to pulley 109. Belt 104 is driven by motor 114 connected by belt 115 to pulley 116 which drives pulley 110 through the agency of belt 117. Motor 114 also is connected by belt 118 to intermediate pulley 119 connected by belt 120 to drive pulleys 121 of sewing machines 122.

As seen in FIGS. 7 and 8, each diaper segment 101 after hemming is connected by a thread section 101a formed by the continuous operation of the machines 122 bridging the gap between each segment 101. As shown in FIGS. 8 and 9, a finger will track along each edge of diaper segments 101 until the finger drops into the gap 1011: between such segments. Finger 120 is connected to switch 121 which is actuated by movement of finger 120 to cause cutter blade 122 to be driven downwardly by air cylinder 123. Cutter blade 122 will be driven downwardly to sever and disconnect threaded sections 101a in the first instance, when tinger 120 first drops into gap 121 and in the second instance when finger 122 returns again to ride upon the upper surface of a diaper segment 101. Conduit 124 provides a vacuum to remove each section 101a.

It will be understood that the aforementioned sequence of operations is preferably under the control of a multi-cam programmer 126 such as has been shown in FIGS. 10 and 11. The programmer 126 such comprises an electric motor 127 which drives shaft 129 through reduction gearing 128. Shaft 129 is journalled at one end in a bearing 130. Mounted upon shaft 129 are a series of cams 131 which as shown in FIG. 11 are appropriately contoured with respect to followers 132 to actuate various switches 133. Thus the machine of the invention has each of its different operations under the control of a respective cam 131 and each operation is, therefore, timed precisely with respect to other op erations. The various switches 133 directly or indirectly actuate motors or valves controlling the essential functions of the machine.

In accordance with the present invention, therefore, improved manufacture of diapers having a folded center panel is accomplished. The center section is folded more accurately than heretofore, and is maintained in centered relation to the edges of the diaper while the edges are adjusted to the proper width. Positive cutting of each diaper segment to length is provided. After cutting the diaper segments are transported with precision and held in an improved manner during hemming and trimming. It will be understood that the foregoing description has been of a preferred embodiment of the invention and is, therefore representative. In order to appreciate the scope of the invention, reference should be made to the appended claims.

I claim: 1

1. An apparatus for producing a web of textile material having a prefolded and secured center panel from a continuous flat web of textile material comprising:

a. a supply section having means for introducing a continuous web of textile material;

b. a folding section disposed adjacent to the supply section including means to fold the web of material in a manner toprovide a substantially centered sfold panel;

c. means including an edge sensing device adapted to cooperate with an actuating device for shifting said supply means laterally in response to variations of at least one edge of said web with respect to said folding means;

d. means cooperating with said folding means for shifting. said web laterally during passage through said folding section in accordance with the positioning of both sides of said web to effect centering of said web in said folding section;

e. a securing section disposed adjacent to said folding section and adapted to secure said folded center panel to said web; and

f. means cooperating with said securing section to adjust the width of said web while simultaneously varying the width of the folded center panel so as to maintain the width of the folded web within predetermined limits, thereby providing a panelled web having a substantially consistent width and a substantially centered panel.

2. An apparatus for producing a web of textile material having a prefolded and secured center panel from a continuous fiat web of textile material comprising:

a. a supply section having means for introducing a continuous flat web stock of textile material; b. a folding section disposed adjacent to the supply section including means to fold the web of material in a manner to provide a substantially centered s-fold triple panel having three layers of material;

c. means including an edge sensing device adapted to cooperate with an actuating device for shifting said supply means laterally in response to variations of at least one edge of said web with respect to said folding means; and I d. means cooperating with said folding means for shifting said web laterally during passage through said folding section in accordance with the positioning of both sides of said web to effect centering of said web;

e. a sewingsection for sewing said folded center panel to said web by applying longitudinal stitches near each edge of said center panel, said sewing section including two oppositely disposed sewing machines positioned such that at least a portion of each side of the folded center panel passes through the sewing section of an associated machine after emerging from the folding section;

f. plate members connected to each sewing machine with one of said plates overlying the other and having members adapted to guide the web into the sewing section while being adapted to adjust the width of the center fold;

g. web edge sensing means to detect widening and narrowing of said web; and

h. means responsive to said sensing means to shift said sewing machines toward and away from each other while shifting said plate members connected to said sewing machines so as to maintain the width of said web within predetermined limits while varying the width of said center panel to facilitate ad justment of the width of said web thereby providing a web which is substantially uniform in overall width and a folded center panel which is substantially centered with respect to said web throughout the length of said web.

3. The apparatus according to claim 2 wherein said means cooperating with said folding means for shifting said supply means laterally in response to variations of at least one edge of said web with respect to said folding means comprises: a web edge sensing device positioned in said folding section; and means in said supply section to shift said supply means laterally in response to said web sensing means to maintain the supply means substantially centered with respect to said folding section.

4. The apparatus according to claim 3 wherein said means cooperating with said folding means for shifting said web laterally during passage through said folding section comprises: web edge sensing means within said folding section adapted to detect lateral variations of each edge of the web; two pairs of pinch roller means positioned such that each edge portion of the web passes through a respective pair of rollers; and means responsive to the web edge sensing means to shift the pinch rollers respectively to maintain the web in a substantially centered position as it passes through the web folding section.

5. The machine of claim 4 wherein transverse rail members are provided, said machines are slidable upon said rail members, a rotary actuator, a crank rotatable by said actuator and a transverse link connecting each machine to said crank whereby rotation of said actuator will cause simultaneous inward and outward movements of said machines toward and away from each other.

6. The apparatus according to claim 5 further comprising: a scray section which is positioned and adapted for receiving said .web after sewing; of said center panel to permit a quantity of said web to accumulate in a relaxed condition; driven roller means for drawing said web from said supply roll through said center panel folding and sewing sections; and means responsive to the weight of material in said scray section to control the operation of said roller means and said sewing machines supplying said folded web to said scray.

7. The apparatus according to claim 6 further comprising means for cutting said folded web into sections having a predetermined length suitable for use as diapers, said means comprising: longitudinal rails; a carriage slidably mounted on said rails; means for reciprocatingly moving said carriage along said rails; a base support member carried by said carriage; web engaging jaws mounted on said base support member; a transverse cutting device for separating segments of the center panelled web as it leaves said scray, said carriage and web engaging jaws being adapted to reciprocate in one direction to draw an incremental length of said web past said cutter for separation of each segment from said web, said carriage reciprocating in an opposite direction after cutting to again engage said web.

8. The apparatus according to claim 7 wherein said web segments are released by said jaws and deposited. upon a conveyor moving in a direction perpendicular to said reciprocating movement of said carriage.

9. The apparatus according to claim 8 further comprising: a rotatably driven drum positioned adjacent to said conveyor for receiving said folded panel web segments upon its circumference; belt means in contact with the outer surface of said drum to temporarily secure said segments while hemming and for rotatably driving said drum; sewing means for hemming said segments along at least two sides thereof; and means for driving said belt means to move said segments past said sewing means.

10. The apparatus according to claim 9 wherein: said hem sewing means is continuous and interconnects adjacent folded panel diaper segments along their edges with a thread section; means is provided for sensing the beginning and end of each thread segment; and trim cutting means is provided to separate each thread section from said diaper segments.

11. The apparatus according to claim 10 wherein each operation other than automatic center panel centering and width controls in controlled by a multi-cam programmer having appropriately contoured cams and associated cam followers adapted to actuate a series of switches in timed sequence so as to coordinate the controlled operational steps of the apparatus.

12. An apparatus for hemming textile web material segments comprising: a conveyor drum for receiving said web materials upon the outer circumferential surface thereof; belt means circumferentially contacting said drum in a secure manner for securing said web materials against said drum; means for rotatably driving said belt means to rotate said drum; a first stationary hem sewing means positioned adjacent an upper portion of said drum and adapted for hemming at least one edge of said web material segments while said segments are carried through the sewing section of said hem sewing means during rotation of said drum, said first hem sewing means adapted to connect edge portions of adjacent segments with a thread section; a second stationary hem sewing means positioned adjacent a lower portion of said drum and adapted for hemming a second edge of said web material segments while said segments are carried through the sewing section of the second hem sewing means during rotation of said drum, said second hem sewing means adapted to connect edge portions of adjacent segments with a thread section; and means for separating and removing said connecting thread sections, whereby the secure positioning of said web segments provided during hemming and cutting of thread sections provides substantially accurately hemmed web segments.

Claims

1. An apparatus for producing a web of textile material having a prefolded and secured center panel from a continuous flat web of textile material comprising: a. a supply section having means for introducing a continuous web of textile material; b. a folding section disposed adjacent to the supply section including means to fold the web of material in a manner to provide a substantially centered s-fold panel; c. means including an edge sensing device adapted to cooperate with an actuating device for shifting said supply means laterally in response to variations of at least one edge of said web with respect to said folding means; d. means cooperating with said folding means for shifting said web laterally during passage through said folding section in accordance with the positioning of both sides of said web to effect centering of said web in said folding section; e. a securing section disposed adjacent to said folding section and adapted to secure said folded center panel to said web; and f. means cooperating with said securing section to adjust the width of said web while simuLtaneously varying the width of the folded center panel so as to maintain the width of the folded web within predetermined limits, thereby providing a panelled web having a substantially consistent width and a substantially centered panel.

2. An apparatus for producing a web of textile material having a prefolded and secured center panel from a continuous flat web of textile material comprising: a. a supply section having means for introducing a continuous flat web stock of textile material; b. a folding section disposed adjacent to the supply section including means to fold the web of material in a manner to provide a substantially centered s-fold triple panel having three layers of material; c. means including an edge sensing device adapted to cooperate with an actuating device for shifting said supply means laterally in response to variations of at least one edge of said web with respect to said folding means; and d. means cooperating with said folding means for shifting said web laterally during passage through said folding section in accordance with the positioning of both sides of said web to effect centering of said web; e. a sewing section for sewing said folded center panel to said web by applying longitudinal stitches near each edge of said center panel, said sewing section including two oppositely disposed sewing machines positioned such that at least a portion of each side of the folded center panel passes through the sewing section of an associated machine after emerging from the folding section; f. plate members connected to each sewing machine with one of said plates overlying the other and having members adapted to guide the web into the sewing section while being adapted to adjust the width of the center fold; g. web edge sensing means to detect widening and narrowing of said web; and h. means responsive to said sensing means to shift said sewing machines toward and away from each other while shifting said plate members connected to said sewing machines so as to maintain the width of said web within predetermined limits while varying the width of said center panel to facilitate adjustment of the width of said web thereby providing a web which is substantially uniform in overall width and a folded center panel which is substantially centered with respect to said web throughout the length of said web.

6. The apparatus according to claim 5 further comprising: a scray section which is positioned and adapted for receiving said web after sewing of said centEr panel to permit a quantity of said web to accumulate in a relaxed condition; driven roller means for drawing said web from said supply roll through said center panel folding and sewing sections; and means responsive to the weight of material in said scray section to control the operation of said roller means and said sewing machines supplying said folded web to said scray.

8. The apparatus according to claim 7 wherein said web segments are released by said jaws and deposited upon a conveyor moving in a direction perpendicular to said reciprocating movement of said carriage.