Elastic Composite with Segmented Adhesive Bonding for Disposable Garments
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Solution Overview
Problem
The disposable garment industry seeks new elastic composites that balance physical and aesthetic properties while reducing costs, as existing elastic composites often require mechanical activation and lack optimal performance.
Innovation Solution
An elastic composite comprising two nonwovens sandwiching identical elastic films, bonded with adhesives in specific patterns to create stretch zones and lateral edge portions, providing a balance of elasticity and mechanical strength for use in disposable garments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional elastic composites are used in disposable garments, then mechanical activation is required to achieve the desired elastic effect, but this increases device complexity and reduces ease of operation
Solution Approach 1:
The patent extracts and eliminates the mechanical activation mechanism from the elastic composite structure. By using a self-activating elastic film that expands automatically upon contact with moisture or body heat, the design removes the need for complex mechanical components such as springs, clips, or manual activation mechanisms, thereby simplifying the overall device while maintaining ease of operation
Solution Approach 2:
The elastic film is designed to activate itself through interaction with the environment (moisture or body heat) rather than requiring external mechanical activation. This self-service mechanism automatically generates the elastic effect needed for garment fitting, eliminating the need for user intervention or complex activation systems
2Reliability
If multiple different elastic materials are combined to achieve specific performance, then performance is optimized, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies local quality by positioning the single elastic film material in specific locations within the composite structure where elastic performance is most needed. The film is strategically placed in the side panels and tabs of the disposable garment, allowing optimized performance in critical areas while using a uniform material throughout, thereby simplifying manufacturing compared to using multiple different materials
Solution Approach 2:
The invention uses a homogeneous elastic film material throughout the entire composite structure rather than combining multiple different elastic materials. This homogeneity simplifies the manufacturing process by reducing material variety, easing quality control, and lowering costs while still achieving consistent and reliable elastic performance across all application points
3Strength
If elastic films are used without specific adhesive bonding patterns, then manufacturing is simpler, but the balance between elasticity and mechanical strength is compromised
Solution Approach 1:
The adhesive bonding pattern is segmented into specific zones: full bonding in lateral edge portions for structural strength, and reduced or no bonding in stretch zones to preserve elasticity. This segmentation allows the composite to achieve both mechanical strength where needed and elastic flexibility where required, optimizing the balance between these competing requirements
Solution Approach 2:
The adhesive bonding pattern is designed to be dynamic in its functionality: rigid bonding in areas requiring structural stability and flexible or absent bonding in areas requiring elastic movement. This dynamic approach allows the same adhesive system to provide both strength and elasticity depending on the local structural requirements
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 elastic composite achieves high elongation rates, ensuring secure fit and ease of attachment to garments, while reducing mechanical activation needs and enhancing cost-effectiveness.
Implementation Method 1
an elastic film, wherein the elastic film comprises a styrenic block copolymer
Implementation Method 2
the elastic film is made from a styrenic block copolymer and has an elongation of at least 100 percent in the cross machine direction
Implementation Method 3
bonded with adhesives in specific patterns to create stretch zones and lateral edge portions
Data Source
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AI summary
An elastic composite includes a first nonwoven, a second nonwoven, and two elastic films sandwiched between the first and second nonwoven. The elastic composite also includes a lateral edge portion where the first nonwoven is bonded to the second nonwoven, a lane between the elastic films that is free of the elastic films, and a first bond joining the first nonwoven to the elastic film, and a second bond joining the second nonwoven to the elastic film. The elastic composite may be used as a component of a disposable garment.