Beamed Elastomeric Laminate for Disposable Absorbent Articles
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Solution Overview
Problem
Traditional stranded elastomeric laminates in disposable absorbent articles suffer from high strand pressure, modulus, and force requirements, leading to poor fit and skin marking, making them difficult to apply and wear.
Innovation Solution
The development of elastomeric laminates with closely spaced, fine elastic strands and densified bonds between nonwoven layers, which reduce strand pressure and modulus, facilitating easier application and a more comfortable fit by distributing force more evenly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional stranded elastomeric laminates use larger elastic strands with larger spaces between strands at higher pre-strains, then the laminate structure is simpler and easier to manufacture, but the strand pressure and modulus become too high resulting in poor sustained fit and skin marking
Solution Approach 1:
The patent applies parameter changes by transitioning from traditional large-diameter elastic strands (Average-Dtex greater than 400) to fine elastomeric strands (Average-Dtex less than 400), and from larger strand spacing (Average-Strand-Spacing greater than 4 mm) to closely spaced strands (Average-Strand-Spacing less than 4 mm). This parameter transformation fundamentally changes the mechanical properties of the laminate, reducing strand pressure below 1 psi and modulus below 10 gf/mm, thereby eliminating skin marking while maintaining ease of manufacture through consistent production processes
Solution Approach 2:
The patent implements local quality by creating multiple texture zones within the elastomeric laminate, where different sections have varying strand densities, spacing, or bonding characteristics. This allows specific zones to be optimized for different functions: some areas provide enhanced comfort and skin contact with lower strand pressure, while other zones maintain structural integrity and fit. The contoured fit is achieved through localized variations in laminate properties rather than uniform characteristics throughout
2Ease of operation
If traditional stranded elastomeric laminates use larger elastic strands with larger spaces between strands, then the application force required is reduced, but the sustained fit and comfort are compromised due to high strand pressure and modulus
Solution Approach 1:
The patent resolves this contradiction through parameter changes that simultaneously optimize both application ease and sustained fit. By using fine elastomeric strands (Average-Dtex less than 400) with closely spaced configuration (Average-Strand-Spacing less than 4 mm), the laminate achieves low strand pressure (Pressure-Under-Strand less than 1 psi) and low modulus (Section-Modulus less than 10 gf/mm). These parameter transformations enable the laminate to be easy to apply while maintaining reliable sustained fit throughout the wear period
Solution Approach 2:
The patent employs composite materials by combining fine elastomeric strands with nonwoven fabric layers to create a multi-component elastomeric laminate. This composite structure integrates the elasticity and recovery properties of the elastomeric strands with the comfort and breathability of the nonwoven materials. The composite construction allows the laminate to distribute forces evenly across the contact surface, reducing peak pressures while maintaining overall fit stability and comfort over time
3Object-affected harmful factors
If elastomeric laminates use closely spaced fine elastomeric strands, then strand pressure and modulus are reduced improving comfort, but the manufacturing complexity increases
Solution Approach 1:
The patent addresses manufacturing complexity through standardized parameter changes that can be implemented using existing production equipment. The specification of fine elastomeric strands with Average-Dtex less than 400 and closely spaced configuration with Average-Strand-Spacing less than 4 mm represents a parameter transformation that can be achieved through conventional web formation and bonding processes. The patent provides detailed guidance on bonding parameters, strand arrangement patterns, and laminate construction methods that enable manufacturers to produce these improved laminates using standard equipment, thereby minimizing the increase in manufacturing complexity
Solution Approach 2:
The patent applies segmentation by dividing the elastomeric laminate into distinct functional zones or sections with different strand configurations, bonding densities, or texture characteristics. This segmentation allows complex performance requirements to be met through modular design, where each zone can be optimized independently for specific functions such as comfort, fit, or breathability. The segmented approach simplifies manufacturing by allowing standardized sections to be produced and assembled, reducing overall manufacturing complexity despite the varied properties within the laminate
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
The new elastomeric laminates provide improved sustained fit, ease of application, and reduced skin marking, while maintaining performance across various textures and zones, enhancing the overall comfort and usability of disposable absorbent articles.
Implementation Method 1
The first and second nonwovens may be joined together via an adhesive, where the adhesive overlaps and at least partially surrounds a portion of the plurality of elastic strands
Data Source
AI summary
The present disclosure relates to stranded elastomeric laminates (including bi-laminates and tri-laminates) comprising beamed elastics and may have inventive Dtex-to-Nonwoven-Basis-Weight-Ratios, Dtex-to-Spacing-Ratios, and/or Void-Area-to-Strand-Area-Ratios. The stranded laminates of the present disclosure may be used for disposable absorbent article components (including pant belts) and may comprise inventive bonding arrangements that yield inventive textures and texture arrangements. When the inventive stranded elastomeric laminates are used for pant belts, the pants may have inventive Application-Forces, Sustained-Fit-Load-Forces, and Sustained-Fit-Unload-Forces. Further, when absorbent articles are packaged under compression at inventive In-Bag-Stack-Heights, the stranded elastomeric laminates of the present disclosure maintain their inventive properties and characteristics, including their inventive textures.