Elastic Laminate Bonding via Bicomponent Fiber Parameter Changes
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Solution Overview
Problem
Elastic laminates used in hygiene products face challenges with bonding polyethylene films and polypropylene fibers, resulting in lower laminate peel strengths, reduced tensile strengths, and poor abrasion performance, along with the formation of holes during bonding, which affect adhesion and performance.
Innovation Solution
A multilayer laminate comprising a film with a core layer of ethylene-based elastomer and outer layers, where the ethylene-based elastomer is an olefin block copolymer or random copolymer, and non-woven layers formed from bicomponent fibers with a polyethylene-based polymer and a polymer with a higher melting point, bonded using ultrasonic energy to enhance adhesion and prevent hole formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polyethylene films and polypropylene fibers are bonded using conventional methods, then the laminate can be formed, but the laminate peel strength is reduced and holes are produced
Solution Approach 1:
The patent changes the chemical parameters of the bonding surfaces by introducing polyethylene-based polymer coatings on the polypropylene fibers and using polyethylene-based elastomer in the film. This parameter change enables compatible bonding between polyethylene film and polypropylene nonwoven substrate, eliminating holes and improving peel strength through enhanced adhesion.
Solution Approach 2:
The patent creates a composite structure where polyethylene-based polymer is applied to polypropylene fibers, forming a bicomponent fiber system. This composite material approach allows the film and nonwoven substrate to bond effectively, resolving the adhesion issue between incompatible polymers.
2Strength
If conventional bonding methods are used to join film and nonwoven layers, then the laminate can be assembled, but tensile strength and abrasion resistance are reduced
Solution Approach 1:
The patent modifies the chemical composition parameters of the bonding interfaces by using polyethylene-based elastomer in the film and polyethylene-based polymer coating on the nonwoven substrate. This parameter change creates compatible bonding surfaces that maintain tensile strength and improve abrasion resistance through stronger interlayer adhesion.
3Ease of manufacture
If bonding is performed to join laminate layers, then the laminate structure is formed, but holes are produced which detrimentally affect performance
Solution Approach 1:
The patent changes the surface chemistry parameters by introducing polyethylene-based polymer coatings on polypropylene fibers. This parameter change enables hole-free bonding by creating chemically compatible surfaces that bond uniformly without creating voids or holes, thereby maintaining laminate performance.
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 improved adhesion, tensile strength, and abrasion resistance while maintaining elastic performance and preventing hole formation during bonding, resulting in a more effective and durable laminate.
Implementation Method 1
the film and at least one of the first non-woven layer or the second non-woven layer are joined at a plurality of ultrasonic bond sites
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
Disclosed herein is a multilayer laminate comprising a film comprising an ethylene-based elastomer; a first non-woven layer in contact with a first surface of the film; and a second non-woven layer in contact with a second surface of the film; wherein the second surface of the film is opposedly disposed to the first surface of the film; wherein at least one of the first non-woven layer or the second non-woven layer comprises a non-woven web; and wherein the non-woven web is formed from a bicomponent fiber having a first component comprising an polyethylene-based polymer and a second component comprising a polymer having a melting point that is higher than the polyethylene-based polymer, wherein at least a portion of a surface of the bicomponent fiber comprises the first component.