Carrier Material Layer Segmentation for Conveying and Easy Separation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing composite materials used in manufacturing processes lack sufficient tensile strength and flexibility, leading to challenges in conveying and handling during product encasement and manufacturing processes.

Innovation Solution

A composite material comprising an elastic layer and a support layer with a tensile strength of greater than or equal to 98 kgf/m in the machine direction, where the support layer is adhered to the elastic layer and features regions with perforations or cuts to facilitate separation and minimize interference during manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a support layer with high tensile strength is used to maintain structural integrity during conveying, then the composite material can be handled efficiently, but the flexibility and ease of separation during manufacturing processes is reduced

Engineering Contradiction:

Improvetensile strengthVSAvoidflexibility and ease of separation

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The support layer is divided into multiple regions with different functions: a first region that is separable from the elastic layer to facilitate easy removal after manufacturing, and a second region that remains adhered to provide continuous structural support and tensile strength during conveying and handling operations

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the support layer have different properties: the first region has low adhesion to the elastic layer allowing easy separation, while the second region has high adhesion providing structural integrity. This local differentiation resolves the contradiction between ease of separation and maintenance of tensile strength

Inventive Principle:

Principle #3Local quality

2Strength

If the support layer extends across the entire surface of the elastic layer, then maximum structural support is provided, but interference with manufacturing processes and product encasement is increased

Engineering Contradiction:

Improvestructural supportVSAvoidinterference during manufacturing

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The support layer is segmented into a first region that is removed after providing initial structural support during manufacturing, and a second region that remains to provide ongoing support. This segmentation allows the support layer to fulfill its structural function while minimizing interference with subsequent manufacturing steps and product encasement

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first region of the support layer is extracted or removed from the composite material after serving its purpose of providing structural support during conveying and manufacturing. This extraction eliminates the harmful interference of the support layer with final product encasement while maintaining the benefits of its presence during critical manufacturing phases

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS20250326215A1Carrier material layer

Publication Date: 2025.10.23 ALTRIA CLIENT SERVICES LLC

AI summary

At least one example embodiment relates to a composite material. In at least one example embodiment, the composite material includes an elastic layer and a support layer. The support layer is adhered to at least a portion of the elastic layer. The support layer extends across at least apportion of a surface of the elastic layer.