Method and apparatus for constructing folded flats for housing absorbent articles

Patent metadata

Field	Value
Publication number	US-10576706-B2
Application number	US-201615139447-A
Country	US
Kind code	B2
Filing date	Apr 27, 2016
Priority date	May 19, 2015
Publication date	Mar 3, 2020
Grant date	Mar 3, 2020

Abstract

A method and apparatus for constructing a folded flat. The flat may include a first surface having a first panel and a second panel. Each of the first panel and the second panel include an inner edge. Further, the first panel may include a first score line that extends in the machine direction and a tab adjacent the first score line. The tab connects the first panel and the second panel. A folding apparatus may engage the first surface of the flat. The folding apparatus may include an engagement member and a fold assist member. The fold assist member may engage the area between the inner edge of the first panel and the inner edge of the second panel. The engaging member and the fold assist member cooperate fold the flat along the score line to form a folded flat.

First claim

What is claimed is:

1. A method for constructing a folded flat for housing absorbent articles, the method comprising the steps of:
providing a flat comprising a first surface and a second surface opposite the first surface, wherein the first surface comprises a first panel and a second panel, wherein each of the first panel and the second panel include an outer edge and an inner edge extending in a machine direction, and wherein the inner edge of the first panel and the inner edge of the second panel are separated by a first distance extending parallel to a cross direction, and wherein the first panel has a first panel length extending parallel to the cross direction and the second panel has a second panel length extending parallel to the cross direction, and wherein the first panel includes a first score line extending in the machine direction and a tab adjacent the first score line and connected to the second panel;
advancing the flat in a machine direction to a first location;
providing a fold apparatus;
determining at least one of the first distance, the first panel length, and the second panel length with a visual detection device positioned adjacent the fold apparatus at the first location;
adjusting the fold apparatus based on the first distance;
engaging the first surface of the flat with the fold apparatus;
adjusting one or more downstream processes based on the first panel length and the second panel length;

folding the flat along the first score line to construct a folded flat; and placing the folded flat in the second location;
wherein the fold apparatus comprises a first engagement member, a second engagement, and a fold assist member,
further comprising the steps of: comparing the first distance with a predetermined distance; engaging the fold assist member and the second engagement member when the first distance is greater than the predetermined distance, wherein the fold assist member is movably positioned between the inner edge of the first panel and the inner edge of the second panel;

and engaging the second engagement member when the first distance is less than the predetermined distance.

2. The method of claim 1 , wherein an illumination source is positioned adjacent the flat in the first location.

3. The method of claim 1 , wherein the second surface comprises a third panel and a fourth panel, wherein the third panel is separated by the second panel by a second score line, the fourth panel is separated from the third panel by a third score line, and the fourth panel is separated from the first panel by a fourth score line.

4. The method of claim 3 , further comprising the step of folding the flat along at least one of the second score line, the third score line, and the fourth score line to form the folded flat.

5. The method of claim 1 , wherein the first engagement member comprises one or more receiving members, and wherein each receiving member comprises a receiving surface configured to engage the first surface of the flat.

6. The method of claim 1 , wherein the second engagement member comprises an arcuate arm configured to traverse about an arcuate arm pathway, and wherein the arcuate arm has a proximal end portion and a distal end portion opposite the proximal end portion.

7. The method of claim 6 , wherein the arcuate arm comprises a press member adjacent the distal end portion, and wherein the press member has a press surface configured to engage the first surface of the flat.

8. The method of claim 1 , further comprising the step of supplying pressure to the fold assist member.

9. The method of claim 1 , wherein a portion the fold assist member comprises a proximal end portion, a distal end portion opposite the proximal end portion, and a central portion between the proximal end portion and the distal end portion, where the distal end portion comprises a fold fin and the central portion comprises a rigid member, and wherein the fold fin and the rigid member are configured to traverse along a longitudinal fin axis.

10. The method of claim 1 , wherein the predetermined distance is greater than about 2 mm.

11. The method of claim 1 , wherein the predetermined distance is greater than about 5 mm.

12. The method of claim 1 , wherein the fold apparatus is moveable in the machine direction and the cross direction.

13. The method of claim 1 , wherein the visual detection device is a camera.

14. The method of claim 1 , wherein a controller is operatively connected to the visual detection device.

15. A method for constructing a folded flat for housing absorbent articles, the method comprising the steps of:
providing a flat comprising a first surface and a second surface opposite the first surface, wherein the first surface comprises a first panel and a second panel, wherein each of the first panel and the second panel include an outer edge and an inner edge extending in a machine direction, and wherein the inner edge of the first panel and the inner edge of the second panel are separated by a first distance, and wherein the first panel includes a first score line extending in the machine direction and a tab adjacent the first score line and connected to the first panel;
providing a fold apparatus comprising a first engagement member, a second engagement member, and a fold assist member, wherein the first engagement member comprises a receiving surface and a plane of the receiving surface is parallel with a plane of the first surface of the flat, and wherein the second engagement member comprises a press surface and the press surface is configured to move from a first configuration to a second configuration;
advancing the flat in a machine direction to a first location;
evaluating the first surface of the flat using a visual detection device positioned adjacent the fold apparatus at the first location;
determining the first distance;
engaging a portion of the first panel and the press surface;
engaging a portion of the second panel and the receiving surface;
advancing the flat to a second location;
engaging the fold assist member when the first distance is greater than a predetermined distance, wherein the fold assist member is movably positioned between the inner edge of the first panel and the inner edge of the second panel;
engaging the second engagement member wherein the first distance is greater than, less than, or equal to the predetermined distance, wherein the second engagement member extends about an arcuate pathway; and
folding the flat along the first score line such that the first panel is substantially perpendicular to the second panel.

Assignees

• Procter & Gamble

Inventors

• Mahoney Iii William Paul
• Wilhelm Paul Allan
• Williams James J

Classifications

• B31B50/00 Primary

  Making rigid or semi-rigid containers, e.g. boxes or cartons · CPC title

• B31B2100/00

  Rigid or semi-rigid containers made by folding single-piece sheets, blanks or webs · CPC title

• B31B50/006

  Controlling; Regulating; Measuring; Improving safety · CPC title

• B31B50/80

  Pneumatically · CPC title

• B31B2120/30

  collapsible; temporarily collapsed during manufacturing · CPC title