Composite Stretchable Material Uniform Pleat Formation
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Solution Overview
Problem
Existing composite stretchable members used in disposable diapers and similar applications face challenges in achieving high flexibility, low heat retention, uniform pleat formation, and reduced thickness, while maintaining bond integrity between nonwoven sheets, due to issues with pleat formation and adhesive distribution.
Innovation Solution
A composite stretchable member comprising a first and second nonwoven sheet superposed with elastic members in the stretch direction, joined by adhesive applied to the elastic members, with specific thickness, root mean square height, and coefficient of variation of profile curve elements to ensure flexibility and uniform pleat formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the first nonwoven sheet and the second nonwoven sheet are joined at joined parts provided discontinuously in the first direction and second direction, then the composite stretchable member can be formed with pleats, but the flexibility is reduced and the pleats are not uniform
Solution Approach 1:
The joined parts are segmented into discrete locations only in the second direction, rather than forming a grid pattern in both directions. This segmentation allows the nonwoven sheets to move more freely in the first direction, improving flexibility while still maintaining pleat formation through the joined parts.
Solution Approach 2:
The joined parts are strategically positioned only at specific locations in the second direction, creating local bonding zones that allow pleat formation while leaving other areas free to move. This local quality approach maintains flexibility in regions without joined parts while achieving the desired pleat shape at the joined locations.
2Temperature
If the pleats are formed by the first nonwoven sheet and the second nonwoven sheet, then the heat retaining function is increased, but the thickness is increased and sweating is liable to occur
Solution Approach 1:
The excessive heat retention caused by thick pleats is eliminated by reducing the pleat height through optimized joined part configuration. The joined parts are positioned and sized to create smaller, more uniform pleats that reduce the air layer thickness, thereby extracting the harmful heat retention effect while preserving the beneficial flexibility and comfort.
Solution Approach 2:
The parameters of the joined parts (size, spacing, distribution) are optimized to control pleat formation. By adjusting these parameters, the pleat height is reduced, which directly reduces the thickness and the associated heat retention, preventing sweating while maintaining structural integrity.
3Shape
If multiple pleats are formed by the nonwoven sheet between joined parts, then the uniformity of flexibility is reduced, but the pleat formation is more complex
Solution Approach 1:
The joined parts are segmented into discrete, evenly spaced locations only in the second direction, creating uniform intervals that promote consistent pleat formation. This segmentation prevents irregular multiple pleats from forming between joined parts, ensuring uniform flexibility across the composite stretchable member.
Solution Approach 2:
The joined parts are designed with uniform size, shape, and spacing in the second direction, creating homogeneous bonding conditions throughout the structure. This homogeneity ensures that pleats form uniformly across the entire surface, maintaining consistent flexibility and eliminating the variability caused by irregular pleat formation.
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 solution provides a composite stretchable member with improved flexibility, reduced thickness, and uniform pleat formation, while maintaining bond integrity and minimizing heat retention, thus enhancing wearer comfort and product performance.
Implementation Method 1
the first nonwoven sheet part and the second nonwoven sheet part joined with each other by an adhesive which is applied to the elastic members
Implementation Method 2
a plurality of elastic members which are arranged between the first nonwoven sheet part and the second nonwoven sheet part, the elastic members extending in the first direction
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
Provided is a composite stretchable member with a smaller thickness and more uniform pleats. The composite stretchable member is stretchable in a first direction (D1) and is provided with a first nonwoven fabric sheet part (2A) and a second nonwoven fabric sheet part (2B) which are superposed on each other, and a plurality of elastic members (3) which are arranged between the first nonwoven fabric sheet part (2A) and the second nonwoven fabric sheet part (2B). The elastic members (3) extend in the first direction (D1) while being separated from each other in a second direction (D2) perpendicular to the first direction (D1), and the first nonwoven fabric sheet part (2A) and the second nonwoven fabric sheet part (2B) are joined with each other by an adhesive which is applied to the elastic members (3).