Cross-Directional Elastic Composite for Disposable Garments
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Solution Overview
Problem
Existing elastic composites for disposable absorbent garments face challenges in achieving cross-directional elasticity while maintaining cost-effectiveness and manufacturing efficiency, with limitations in design and construction impacting the fit, sealability, and overall quality of the garments.
Innovation Solution
A method and system for producing an elastic composite with cross-directional elasticity by integrating mutually spaced apart elastic elements between nonwoven carrier layers, allowing for the creation of a composite with a central elastic region and non-elastic regions, which can be easily processed and integrated into garment manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elastic members are incorporated into the garment to provide elasticity, then the fit and sealability are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The elastic composite is divided into distinct functional zones: a first elasticized region with elastic members for stretchability, a second non-elastic region without elastic members for stability, and connecting regions. This segmentation allows different parts to serve different purposes, improving overall fit and sealability while managing construction complexity through organized functional distribution.
Solution Approach 2:
Different regions of the elastic composite are赋予 different properties: the first elasticized region has elastic members for stretch and conformability, while the second non-elastic region provides structural stability. This local differentiation of material properties enables the garment to achieve both fit and sealability without requiring the entire structure to be complex.
2Reliability
If a multi-component elastic composite construction is used, then the elasticity and fit are improved, but the manufacturing process complexity and cost increase
Solution Approach 1:
The elastic members are pre-positioned and secured within the elastic composite structure before final garment assembly. The first and second substrates are prepared with specific regions designated for elastic member placement, allowing for streamlined integration during manufacturing while maintaining the multi-component construction's elastic properties.
Solution Approach 2:
The elastic composite structure serves multiple functions simultaneously: the first elasticized region provides stretchability, the second non-elastic region provides structural support, and the connecting regions provide transition and attachment. This multi-functionality reduces the need for separate components, simplifying manufacturing despite the enhanced elastic properties.
3Adaptability or versatility
If elastic members are positioned laterally throughout the waist regions, then the garment can accommodate variations in waist size, but the material cost and processing complexity increase
Solution Approach 1:
Elastic members are concentrated in the first elasticized region rather than distributed uniformly throughout the entire waist region. The second non-elastic region extends laterally without elastic members, providing waist size accommodation through the elastic properties of the first region while reducing overall material consumption and cost.
Solution Approach 2:
The elastic composite allows for variations in waist size through the elastic properties of the first elasticized region, while the second non-elastic region maintains structural integrity. This parameter-based approach (using elastic modulus variations) provides adaptability without requiring additional materials throughout the entire waist area.
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 enhanced cross-directional elasticity, improved manufacturing efficiency, and cost-effectiveness, enabling better fit and sealability of disposable absorbent garments while reducing material costs and processing complexities.
Implementation Method 1
a plurality of mutually spaced apart, cross-directional elastic elements extending generally laterally from the first carrier to the second carrier
Data Source
AI summary
A method of making an elastic composite is described that entails conveying a first sheet of material on a conveyor, and wrapping a section of elastic about the first sheet and the conveyor, thereby applying elastics cross directionally across the first sheets. A second sheet of material is applied onto the first sheet having elastics applied thereon, thereby creating a subcomposite including the first sheet, the second sheet, and elastics sandwiched therebetween, wherein a plurality of elastics extend outward from the one side of the subcomposite, about the conveyor, and return into an opposite side of the subcomposite. The sub-composite is cut through the first and second sheets and the elastics, thereby separating the sub-composite into a first carrier and a second carrier, each carrier including a first material layer and a second material layer, whereby a plurality of spaced apart elastic elements extend from the first carrier to the second carrier, the first and second carriers defining an exposed elastic region therebetween formed by the plurality of spaced apart elastic elements.