Detectable marks in trim material

• US 6,352,497 B1
• Filed: 10/05/1999
• Issued: 03/05/2002
• Est. Priority Date: 04/02/1999
• Status: Expired due to Fees

• Current Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Original Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Inventors: Hensley, Robert Leo, Ungpiyakul, Tanakon
• Primary Examiner(s): Vo, Peter
• Assistant Examiner(s): TAWFIK, SAMEH
• Application Number:
  US09/412,255
• Time in Patent Office: 882 Days
• Field of Search: 493/8, 493/10, 493/11, 493/13, 493/19, 493/20, 493/22, 493/281, 493/373, 83/74, 83/764, 833/71, 156/64
• US Class Current: 493/22
• CPC Class Codes: A61F 13/15707 Mechanical treatment, e.g. notching, twisting, compressing, shaping
• CPC Class Codes: A61F 13/15772 Control

Abstract

This invention pertains to methods of checking for successful removal of trim material from trim areas disposed at periodic intervals along a web in a processing line. Marking material is marked, optionally as reference marks or reference images on the trim material pieces. Trim material is severed and removed to develop cut-outs at the trim areas. After removing the trim material, the method senses for the marking material at and adjacent the trim areas. The method thus detects marking material on trim material pieces which are not successfully removed from the web. In preferred embodiments, the web, outside the trim areas, is free from the specific marking material used for the reference marks or reference images. The marking material is preferably detectable, using a suitable sensor, independently of visible light emanating from, or reflected from, the marking material. Exemplary marking material can be detected using magnetic flux, energy in the ultraviolet spectrum, an olfactory sensor, color discrimination, energy in the infrared spectrum, and/or an optical brightener detectable through action of energy in the ultraviolet spectrum. The invention comprehends a web comprising corresponding trim areas, corresponding trim material, and corresponding marking material.

Claims

1. A method of checking for successful removal of trim material from trim areas disposed at periodic intervals along a web in a processing line fabricating discrete units of product from the web, thus to develop cut-outs in the units of product at the trim areas, the method comprising:

(a) utilizing marking material as reference marks on trim material pieces, said reference marks being disposed inside the trim areas; and

(b) severing and removing the trim material pieces from precursors of such units of product thus to develop the cut-outs at the trim areas of the web, and to correspondingly remove the reference marks from such precursors of such units of product; and

after removing the trim material pieces, sensing for the marking material utilizing at least one sensor at least at and adjacent the trim areas, thus to detect marking material on ones of the trim material pieces which have not been successfully removed from the web, the marking material as perceived by the at least one sensor being distinguishable from any indicator material used on the web outside the trim areas.

2. A method as in claim 1, the web, outside the trim areas, being free from the marking material, thus enhancing the at least one sensor'"'"'s capacity to distinguish marking material not successfully removed from the web, from other indicator material which may exist on the web.

3. A method as in claim 1, the marking material as applied being consistent with sufficient acuity and measurable intensity, and having suitable outline, that the reference marks thereof can readily be detected by a suitable such sensor having relatively low sensitivity and relatively low resolution capabilities.

4. A method as in claim 1, the marking material as applied being consistent with sufficient acuity and measurable intensity, and having suitable outline, that the reference marks thereof can readily be detected as reference images suitable for defining loci of respective reference image locations with respect to other areas on the web which are free of such reference images.

5. A method as in claim 4 wherein the reference marks have leading edges sufficiently sharply-defined as to be readily discerned by suitable such sensors having relatively low sensitivity and relatively low resolution capabilities, with sufficient resolution that the reference marks can serve as reference loci to which other web elements can be registered, the method further comprising applying the reference marks and a first set of web features periodically along the length of the web, using a common application device to force registration of the first set of web features to the reference marks.

6. A method as in claim 4 including, after sensing for a respective reference mark at a respective cut-out, severing the web and thereby creating a respective one of the discrete units of product containing the respective cut-out.

7. A method as in claim 4, including utilizing at least two separate and distinct reference marks each in given ones of the trim areas.

8. A method as in claim 4, the combination of the reference marks, the at least one sensor, and a controller operating in control of the fabrication line, having capacity to discern up to about 1000 of the reference marks per minute along a length of the web.

9. A method as in claim 4, including sensing for the reference marks off-line, independently of visible light from the reference marks, after fabrication of the units of product has been substantially completed.

10. A method as in claim 9, including using, in the reference marks, fragrance detectable by an olfactory sensor.

11. A method as in claim 9, including using, in the reference marks, magnetic ink detectable by bringing the ink into sensing proximity with a magnetic sensor.

12. A method as claim 4, the marking material as utilized at the trim areas being detectable using a suitable such sensor independently of visible light from the respective marking material images.

13. A method as in claim 4, including using a dark ink sufficiently dark that the ratio of opacity of the reference marks to opacity of the web around the reference marks is no more than about 0.67/1, and including detecting the marking material at the trim area utilizing an optical senor.

14. A method as in claim 4, including creating the reference marks using magnetic ink, passing the reference marks through a magnetic field, to magnetize the reference marks, and moving the magnetized reference marks past a sensor responsive to magnetic flux.

15. A method as in claim 14, including, after employing severing and removing apparatus to sever and remove the trim material, sensing for removal of the trim material, and passing the trim area through a sensing zone comprising one of a metal detector and a magnetic field detector as a back-up sensor for detecting any reference mark marking material not successfully removed from the web.

16. A method as in claim 4, including generating heat selectively in the reference marks, and detecting the heat using an infrared sensor.

17. A method as in claim 4, including using fragrance, detectible by an olfactory sensor, to create the reference marks.

18. A method as claim 1, including detecting the marking material at and adjacent the trim areas utilizing magnetic flux.

19. A method as in claim 1, including the marking material at and adjacent the trim areas utilizing energy in the ultraviolet spectrum.

20. A method as in claim 1, including detecting the marking material utilizing an olfactory sensor.

21. A method as in claim 1, including detecting the marking material at or adjacent the trim areas utilizing energy in the infrared spectrum.

22. A method as in claim 1, including distinguishing the reference marks on the basis of a difference between a first color of a respective reference mark and a second color of background material adjacent the reference mark.

23. A method as in claim 1, the processing line comprising a controller operating in control of the fabrication line, the method including culling units of product associated with trim areas wherein the at least one sensor detects a trim area reference mark downstream of the operation at which the trim material was to have been removed.

24. A method as in claim 1, including removing the entirety of the marking material from the web at the severing and removing step.

25. A method as in claim 1, the sensing for the marking material comprising sensing through a visually obstructive layer between the sensor and marking material on any trim areas still on the web at the respective location on the processing line.

26. A method as in claim 1, the units of product comprising absorbent personal care articles, each such absorbent personal care article having ones of the cut-outs, derived from opposing sides of the web, on opposing sides of the respective absorbent personal care article.

27. A method as in claim 1, including registering the reference marks to master references on respective work pieces in the web, and thereby indirectly registering the reference marks to the trim areas.

28. A method of checking for successful removal of trim material from trim areas disposed at periodic intervals along a web in a processing line fabricating discrete units of product from the web, thus to develop cut-outs in the units of product at the trim areas, the method comprising:

(a) utilizing marking material as reference marks on trim material pieces;

(b) registering the reference marks to master references on respective work pieces in the web, and thereby indirectly registering the reference marks to the trim areas;

(c) severing and removing the trim material pieces thus to develop the cut-outs at the trim areas; and

(d) after removing the trim material pieces, sensing for the marking material utilizing at least one sensor at least at or adjacent the trim areas, thus to detect marking material on ones of the trim material pieces which have not been successfully removed from the web;

the marking material as perceived by the at least one sensor being distinguishable from any indicator material used on the web outside the trim areas.

29. A method as in claim 28, the web, outside the trim areas, being free from the marking material, thus enhancing the at least one sensor'"'"'s capacity to distinguish marking material not successfully removed from the web, from other indicator material which may exist on the web.

30. A method as in claim 28, the marking material as applied being consistent with sufficient acuity and measurable intensity, and having suitable outline, that the reference marks thereof can readily be detected by a suitable such sensor having relatively low sensitivity and relatively low resolution capabilities.

31. A method as in claim 28, the marking material as applied being consistent with sufficient acuity and measurable intensity, and having suitable outline, that the reference marks thereof can readily be detected as reference images suitable for defining loci of respective reference image locations with respect to other areas on the web which are free of such reference images.

32. A method as in claim 31, the marking material as utilized at the trim areas being detectable using a suitable such sensor independently of visible light from the respective marking material images.

33. A method as in claim 31, including using a dark ink sufficiently dark that the ratio of opacity of the reference marks to opacity of the web around the reference marks is no more than about 0.67/1, and including detecting the marking material at the trim area utilizing an optical sensor.

34. A method as in claim 31, including creating the reference marks using magnetic ink, passing the reference marks through a magnetic field, to magnetize the reference marks, and moving the magnetized reference marks past a sensor responsive to magnetic flux.

35. A method as in claim 34, including, after employing severing and removing apparatus to sever and remove the trim material, and after sensing for removal of the trim material, passing the trim area through a sensing zone comprising one of a metal detector and a magnetic field detector as a back-up sensor for detecting any reference mark marking material not successfully removed from the web.

36. A method as in claim 31, including generating heat selectively in the reference marks, and detecting the heat using an infrared sensor.

37. A method as in claim 31, including using fragrance, detectible by an olfactory sensor, to create the reference marks.

38. A method as in claim 31, including sensing for the reference marks off-line, independently of visible light from the reference marks, after fabrication of the units of product has been substantially completed.

39. A method as in claim 38, including using, in the reference marks, magnetic ink detectable by bringing the ink into sensing proximity with a magnetic sensor.

40. A method as in claim 38, including using, in the reference marks, fragrance detectable by an olfactory sensor.

41. A method as in claim 31, the combination of the reference marks, the at least one sensor, and a controller operating in control of the fabrication line, having capacity to discern up to about 1000 of the reference marks per minute along a length of the web.

42. A method as in claim 31, including utilizing at least two separate and distinct reference marks each in given ones of the trim areas.

43. A method as in claim 31 including, after sensing for a respective reference mark at a respective cut-out, severing the web adjacent the respective cut-out and thereby creating a respective one of the discrete units of product containing the respective cut-out.

44. A method as in claim 31 wherein the reference marks have leading edges sufficiently sharply-defined as to be readily discerned by suitable such sensors having relatively low sensitivity and relatively low resolution capabilities, with sufficient resolution that the reference marks can serve as reference loci to which other web elements can be registered, the method further comprising applying the reference marks and a first set of web features periodically along the length of the web, using a common application device to force registration of the first set of web features to the reference marks.

45. A method as in claim 28, including detecting the marking material at and adjacent the trim areas utilizing magnetic flux.

46. A method as in claim 28, including detecting the marking material at and adjacent the trim areas utilizing energy in the ultraviolet spectrum.

47. A method as in claim 28, including detecting the marking material utilizing an olfactory sensor.

48. A method as in claim 28, including detecting the marking material at and adjacent the trim areas utilizing energy in the infrared spectrum.

49. A method as in claim 28, including distinguishing the reference marks on the basis of a difference between a first color of a respective reference mark and a second color of background material adjacent the reference mark.

50. A method as in claim 28, the processing line comprising a controller operating in control of the fabrication line, the method including culling units of product associated with trim areas wherein the at least one sensor detects a trim area reference mark downstream of the operation at which the trim material was to have been removed.

51. A method as in claim 28, including removing the entirety of the marking material from the web at the severing and removing step.

52. A method as in claim 28, the sensing for the marking material comprising sensing through a visually obstructive layer between the sensor and marking material on any trim areas still on the web at the respective location on the processing line.

53. A method as in claim 28, the units of product comprising absorbent personal care articles, each such absorbent personal care article having ones of the cut-outs, derived from opposing sides of the web, on opposing sides of the respective absorbent personal care article.

54. A method of checking for successful removal of trim material from trim areas disposed at periodic intervals along a web in a processing line fabricating discrete units of product from the web, thus to develop cut-outs in the units of product at the trim areas, the method comprising:

(a) utilizing marking material as reference marks on trim material pieces;

(b) severing and removing the trim material pieces thus to develop the cutouts at the trim areas; and

(c) after removing the trim material pieces, sensing for the marking material utilizing at least one sensor at least at and adjacent the trim areas, thus to detect marking material on ones of the trim material pieces which have not been successfully removed from the web,

the marking material as applied being consistent with sufficient acuity and measurable intensity, and having suitable outline, that the reference marks therof can readily be detected by the at least one sensor as reference images suitable for defining loci of respective reference image locations with respect to other areas on the web which are free of such reference images.

55. A method as in claim 54, the web, outside the trim areas, being free from the marking material, thus enhancing the at least one sensor'"'"'s capacity to distinguish marking material not successfully removed from the web, from other indicator material which may exist on the web.

56. A method as in claim 54, the marking material as applied being consistent with sufficient acuity and measurable intensity, and having suitable outline, that the reference marks thereof can readily be detected by a suitable such sensor having relatively low sensitivity and relatively low resolution capabilities.

57. A method as in claim 54, the marking material as utilized at the trim areas being detectable using a suitable such sensor independently of visible light from the respective marking material images.

58. A method as in claim 54, including detecting the marking material at and adjacent the trim areas utilizing magnetic flux.

59. A method as in claim 54, including detecting the marking material at and adjacent the trim areas utilizing energy in the ultraviolet spectrum.

60. A method as in claim 54, including detecting the marking material utilizing an olfactory sensor.

61. A method as in claim 54, including detecting the marking material at and adjacent the trim areas utilizing energy in the infrared spectrum.

62. A method as in claim 54, including using a dark ink sufficiently dark that the ratio of opacity of the reference marks to opacity of the web around the reference marks is no more than about 0.67/1, and including detecting the marking material at the trim area utilizing an optical sensor.

63. A method as in claim 54, including creating the reference marks using magnetic ink, passing the reference marks through a magnetic field, to magnetize the reference marks, and moving the magnetized reference marks past a sensor responsive to magnetic flux.

64. A method as in claim 63, including, after employing severing and removing apparatus to sever and remove the trim material, and after sensing for removal of the trim material, passing the trim area through a sensing zone comprising one of a metal detector and a magnetic field detector as a back-up sensor for detecting any reference mark marking material not successfully removed from the web.

65. A method as in claim 54, including generating heat selectively in the reference marks, and detecting the heat using an infrared sensor.

66. A method as in claim 54, including using fragrance, detectible by an olfactory sensor, to create the reference marks.

67. A method as in claim 54, including sensing for the reference marks off-line, independently of visible light from the reference marks, after fabrication of the units of product has been substantially completed.

68. A method as in claim 67, including using, in the reference marks, magnetic ink detectable by bringing the ink into sensing proximity with a magnetic sensor.

69. A method as in claim 67, including using, in the reference marks, fragrance detectable by an olfactory sensor.

70. A method as in claim 54, including distinguishing the reference marks on the basis of a difference between a first color of a respective reference mark and a second color of background material adjacent the reference mark.

71. A method as in claim 54, the combination of the reference marks, the at least one sensor, and a controller operating in control of the fabrication line, having capacity to discern up to about 1000 of the reference marks per minute along a length of the web.

72. A method as in claim 54, the processing line comprising a controller operating in control of the fabrication line, the method including culling units of product associated with trim areas wherein the at least one sensor detects a trim area reference mark downstream of the operation at which the trim material was to have been removed.

73. A method as in claim 54, including utilizing at least two separate and distinct reference marks each in given ones of the trim areas.

74. A method as in claim 54, including removing the entirety of the marking material from the web at the severing and removing step.

75. A method as in claim 54 including, after sensing for a respective reference mark at a respective cut-out, severing the web adjacent the respective cut-out and thereby creating a respective one of the discrete units of product containing the respective cut-out.

76. A method as in claim 54 wherein the reference marks have leading edges sufficiently sharply-defined as to be readily discerned by suitable such sensors having relatively low sensitivity and relatively low resolution capabilities, with sufficient resolution that the reference marks can serve as reference loci to which other web elements can be registered, the method further comprising applying the reference marks and a first set of web features periodically along the length of the web, using a common application device to force registration of the first set of web features to the reference marks.

77. A method as in claim 54, the sensing for the marking material comprising sensing through a visually obstructive layer between the sensor and marking material on any trim areas still on the web at the respective location on the processing line.

78. A method as in claim 54, the units of product comprising absorbent personal care articles, each such absorbent personal care article having ones of the cut-outs, derived from opposing sides of the web, on opposing sides of the respective absorbent personal care article.

79. A method as in claim 54, including registering the reference marks to master references on respective work pieces in the web, and thereby indirectly registering the reference marks to the trim areas.