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

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.

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.