Adhesive-Free Elastic Composite Structure for Absorbent Sanitary Products
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Solution Overview
Problem
The use of adhesives in manufacturing elastic composite structures for absorbent sanitary products leads to increased costs, separation issues during the manufacturing process, and undesirable tactile properties in the end product.
Innovation Solution
A method and apparatus for forming elastic composite structures that minimize or eliminate the use of adhesives by using ultrasonic welding or other bonding techniques to secure elastic threads within the web layers, creating elasticized regions without adhesive bonds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesives are used to attach elastic threads to web layers, then the elastic threads can be secured in position, but manufacturing costs increase and tactile properties deteriorate
Solution Approach 1:
The patent removes adhesives from the bonding process entirely, extracting the harmful element while maintaining the essential function of securing elastic threads through alternative mechanical bonding methods
Solution Approach 2:
The patent replaces the chemical bonding mechanism (adhesives) with a mechanical bonding mechanism (ultrasonic welding or thermal bonding), substituting one physical principle for another to eliminate harmful chemical residues
2Ease of manufacture
If adhesives are used to bond web layers, then the structure can be assembled, but manufacturing complexity increases due to separate attachment stages
Solution Approach 1:
The patent combines multiple separate operations (elastic thread attachment and web layer bonding) into a single integrated bonding step, where both functions are achieved simultaneously through ultrasonic or thermal bonding, thereby simplifying the manufacturing process
Solution Approach 2:
The bonding apparatus is designed to perform multiple functions: it simultaneously bonds web layers together and secures elastic threads within the web structure, making the equipment multi-functional and reducing overall manufacturing complexity
3Reliability
If adhesives are used for elastic thread attachment, then bonding can be achieved, but production efficiency decreases due to separation of attachment stages
Solution Approach 1:
The patent enables continuous bonding operations where web layers and elastic threads are bonded in a single uninterrupted process, eliminating the separation between attachment stages and maintaining continuous production flow, thereby improving manufacturing speed while preserving bond strength
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
Reduces manufacturing costs, minimizes separation issues, and improves the tactile properties of the end product by eliminating the need for adhesives.
Implementation Method 1
A first bonding apparatus having at least one horn and anvil configured to bond the cuff elastic portion to the cuff foldover portion absent adhesive
Implementation Method 2
using ultrasonic welding or other bonding techniques to secure elastic threads within the web layers
Data Source
Figure 1A~1D
Figure 2
Figure 3~7
AI summary
A machine and method for manufacturing an elastic composite structure for disposable sanitary products involves manufacturing the elastic composite structure with an elasticized leg and leg cuff region in a manner that minimizes or eliminates the use of consumable adhesives. The elastic composite structure includes pairs of leg bonds and cuff bonds that are formed without adhesive and anchor respective leg and cuff elastic threads in position relative to facing web layers. The leg bonds and cuff bonds are formed using one or more anvils that include discrete raised projections.