Apertured Segmented Films for Breathable Personal Care
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Solution Overview
Problem
Existing methods face challenges in creating low-cost, breathable, and elastic films or film laminates with segmented structures that provide both body conformance and high vapor permeability, particularly in microporous filled-films, due to difficulties in aligning aperturing equipment across multiple segments and varying segment widths for different applications.
Innovation Solution
A multi-segmented film with a pattern of surface embossments on one segment and apertures through another, where the embossments do not extend through the first segment, and both segments are continuous in the machine-direction, allowing for uniform thickness and specific polymer compositions like thermoplastic polymers and elastic polymers to achieve desired properties, which can be laminated with nonwoven webs for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If aperturing is applied to elastic segments to improve breathability, then vapor permeability is improved, but alignment difficulty increases due to multiple segments and varying widths
Solution Approach 1:
The patent applies preliminary action by pre-forming embossments in the first film segment before aperturing the second film segment. The embossment pattern serves as a registration guide that enables accurate alignment of the aperturing equipment with the elastic segments, thereby solving the alignment difficulty while maintaining high vapor permeability through proper aperture placement
Solution Approach 2:
The patent applies local quality by creating different surface characteristics in different segments of the multi-segmented film. The first film segment receives embossments that provide a textured surface for registration, while the second film segment receives apertures for breathability. This localized differentiation allows each segment to serve its specific function while maintaining overall film integrity
2Ease of operation
If polymer composition is optimized for stretch and recovery to improve body conformance, then elasticity is improved, but pore structure stability deteriorates
Solution Approach 1:
The patent applies segmentation by dividing the film into multiple segments with different polymer compositions and functions. The first film segment can be optimized for pore structure stability using polymers with good dimensional stability, while the second film segment can be optimized for elasticity using elastomeric polymers. This segmentation allows each segment to independently fulfill its specific functional requirement without compromising the other
Solution Approach 2:
The patent applies composite materials by combining different polymer materials in the multi-segmented film structure. The first film segment may use polymers such as polyethylene or polypropylene for stability, while the second film segment uses elastomeric polymers for stretch and recovery. The lamination of these composite segments creates a unified structure that exhibits both stable pore architecture and excellent body conformance
3Adaptability or versatility
If segmented film structure is used to provide different properties in different areas, then functional versatility is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies merging by combining multiple manufacturing operations into a single integrated process. The embossing and aperturing operations are performed simultaneously on different segments of the film in one pass through the processing equipment. This merging of operations reduces manufacturing complexity despite the functional versatility achieved through the multi-segmented structure
Data Source
AI summary
Unitary films and laminates thereof are provided having at least first and second film segments which extend adjacent one another and are permanently joined together. The multi-segment films include a pattern of surface embossments on a surface of the first film segment and a pattern of apertures extending through the second film segment. The first and second segments have different compositions whereby the unitary film includes distinct segments having varied physical properties such as, for example, varied levels of breathability and/or elasticity. The unitary films and laminates thereof are well suited, for example, for use as outer covers in personal care articles.