Absorbent Article Waist Laminate with Angled Stretch-Zone Cuts
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Solution Overview
Problem
Existing methods struggle to consistently cut low decitex elastic strands in absorbent article laminates without damaging the nonwoven webs, leading to poor aesthetic appearance and handling difficulties due to uncontrolled cutting and weakened laminate structure.
Innovation Solution
The absorbent article features high-stretch zones separated by low-stretch zones with cut lines oriented at an offset angle greater than 0 degrees and less than 45 degrees, which prevent the cut lines from opening under lateral forces and mask the cut lines, ensuring precise cutting of elastic strands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a knife blade with smooth/radiused edge is used to cut elastic strands, then the elastic strands can be cut without cutting through the nonwoven webs, but the cutting process becomes inconsistent and difficult to control for low decitex elastic strands
Solution Approach 1:
The elastic laminate is divided into discrete elastic strand segments through cutting, allowing each segment to be independently controlled and positioned. This segmentation enables precise cutting of low decitex elastic strands while maintaining nonwoven web integrity, as the cuts are made at specific intervals rather than continuously through the entire web.
Solution Approach 2:
The cutting process transitions from a single-plane approach to a multi-dimensional control system that accounts for elastic strand positioning, web thickness, and blade angle. By introducing additional control dimensions (blade angle, cutting speed, web tension), consistent cutting of low decitex elastic strands becomes achievable without damaging the nonwoven webs.
2Adaptability or versatility
If elastic strands are cut to create low-stretch zones, then the laminate structure is modified to provide stretch control, but the cut elastic strand ends snap back in uncontrolled fashion to undesired locations
Solution Approach 1:
The elastic laminate is pre-configured with adhesive bonds at strategic locations that counteract the snap-back force of cut elastic strands. This preliminary anti-action prevents the uncontrolled movement of cut elastic strand ends to undesired locations, while still allowing the laminate to provide necessary stretch control in designated areas.
Solution Approach 2:
Adhesive bonds serve as an intermediary force between the cut elastic strands and the nonwoven web. This intermediary prevents the elastic strands from snapping back uncontrollably while maintaining the integrity of the laminate structure and preserving the stretch control functionality.
3Ease of manufacture
If nonwoven webs are cut while deactivating elastics, then the elastic strands can be separated, but the laminate becomes weakened and more prone to tearing
Solution Approach 1:
The laminate is designed with non-uniform adhesive distribution, concentrating bonding strength in specific regions while allowing elastic strand separation in other areas. This local quality approach enables easy separation of elastic strands during manufacturing while maintaining overall laminate integrity and resistance to tearing in critical areas.
Solution Approach 2:
Adhesive bonds are pre-positioned at strategic locations before the cutting process. This preliminary action ensures that when elastic strands are cut and separated, the laminate structure already has reinforced areas that prevent weakening and tearing, allowing manufacturing to proceed without compromising overall strength.
4Shape
If cut lines are oriented at offset angles greater than 0 degrees and less than 45 degrees relative to the lateral axis, then cut lines are masked and aesthetic appearance is improved, but the geometry becomes more complex
Solution Approach 1:
The cut lines are deliberately oriented at asymmetric angles (greater than 0 degrees and less than 45 degrees) relative to the lateral axis rather than being perfectly horizontal or vertical. This asymmetric geometry masks the cut lines from view, improving aesthetic appearance. The asymmetry is controlled and deliberate, not random, allowing for visual concealment while maintaining manufacturing feasibility.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces web control and handling difficulties while enhancing the aesthetic appearance of the laminate by preventing cut line opening and maintaining laminate integrity.
Implementation Method 1
an elastic material positioned between and connected with a first substrate and a second substrate; a first high-stretch zone and a second high-stretch zone separated laterally by a low-stretch zone, wherein the first and second high-stretch zones are elasticated by the elastic material
Implementation Method 2
each cut line is oriented to define an offset angle relative to the lateral axis that is greater than 0 degrees and less than 45 degrees
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
The present disclosure relates to absorbent articles having elastic laminates in front and/or back waist regions with high-stretch zones and low-stretch zones.