Methods and Apparatuses for Transferring Absorbent Articles and Rejecting Defective Absorbent Articles

Abstract

The present disclosure relates to methods and apparatuses for rejecting defective absorbent articles from a converting line. At a downstream portion of a converting process, a continuous length of absorbent articles may be subjected to a final knife and cut to create discrete absorbent articles advancing on a first carrier. From the first carrier, the discrete absorbent articles may be transferred to a transfer apparatus, which in turn, transfers the discrete absorbent articles to a second carrier. The transfer apparatus may include carrier members that orbit around an axis of rotation and may be adapted to receive the absorbent articles from the first carrier and transfer the absorbent articles to the second carrier. Defective absorbent articles may be detected by an inspection system, which may be operably connected with the transfer apparatus and/or the first carrier to remove the defective absorbent articles from the converting process.

What is claimed is: 
     
         1 . A method for rejecting defective absorbent articles from a web converting manufacturing process, the method comprising the steps of:
 converting a substrate and component parts into a continuous length of absorbent articles;   inspecting the substrate or component parts with a sensor;   communicating inspection parameters from the sensor to a controller;   cutting the continuous length of absorbent articles into discrete absorbent articles;   identifying defective discrete absorbent articles based on the inspection parameters;   advancing the discrete absorbent articles in a machine direction on a first carrier;   orbiting the carrier members about a first axis of rotation;   transferring discrete absorbent articles in a first orientation from the first carrier onto the carrier members;   applying a vacuum pressure to the carrier members to hold the discrete absorbent articles on the carrier members;   rotating the carrier members about a second axis of rotation to place the discrete absorbent articles in a second orientation; and   transferring discrete absorbent articles from the carrier members to the second carrier in the second orientation; and   rejecting defective discrete absorbent articles before the defective absorbent articles are placed in the second orientation.   
     
     
         2 . The method of  claim 1 , wherein each carrier member comprises a carrier surface and an aperture in the carrier surface, and wherein the step of applying a vacuum pressure further comprises placing the aperture in fluid communication with a vacuum system. 
     
     
         3 . The method of  claim 2 , wherein the step of rejecting defective discrete absorbent articles further comprises interrupting the fluid communication between the aperture and the vacuum system. 
     
     
         4 . The method of  claim 3 , wherein the step of rejecting defective discrete absorbent articles further comprises placing the aperture in fluid communication with a positive pressure system. 
     
     
         5 . The method of  claim 4 , wherein the step of rejecting defective absorbent articles further comprises removing one defective absorbent article from one carrier member. 
     
     
         6 . The method of  claim 4 , wherein the step of rejecting defective absorbent articles further comprises preventing one defective absorbent article from being transferred from the first carrier to one carrier member. 
     
     
         7 . A system for rejecting defective absorbent articles, the system comprising:
 a stator member including an arc shaped manifold, a first port, and a second port;   an arc shaped insert positioned inside the manifold and movably connected with the manifold, wherein a portion of the manifold housing the insert defines a first zone, and a remaining portion of the manifold defines a second zone;   an actuator connected with the insert and adapted to move the insert to a first position and a second position, wherein the first zone of the manifold is in fluid communication with the first port when insert is in the first position, and the first zone of the manifold is in fluid communication with the second port when the insert is in the second position;   a support member extending radially outward from a first axis of rotation and adapted to rotate about the first axis of rotation; and   a carrier member connected with the support member, the carrier member including an apertured carrier surface, the aperture carrier surface being in intermittent fluid communication with the manifold as the support member rotates about the first axis of rotation.   
     
     
         8 . The system of  claim 7 , wherein the second zone of the manifold is in continuous fluid communication with the second port. 
     
     
         9 . The system of  claim 8 , further comprising:
 a positive air pressure system fluidly connected with the first port; and   a vacuum air system fluidly connected with the second port.   
     
     
         10 . The system of  claim 9 , further comprising:
 an inspection sensor;   a controller operably connected with the inspection sensor and the actuator, the controller configured to receive an inspection parameter from the inspection sensor to generate a reject command based on the inspection parameter; and   wherein the actuator moves the insert to the first position in response to a reject command.   
     
     
         11 . The system of  claim 10 , wherein the carrier member is pivotally connected with the support arm, and wherein the carrier member is adapted to pick-up an absorbent article in a first orientation and pivot with respect to the support member to place the absorbent article in a second orientation.