Elastic Laminate Edge Reinforcement for Secure Ultrasonic Bonding
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Solution Overview
Problem
Existing elastic laminate assembly operations result in unstretched film portions that are bonded, leading to the use of high-basis-weight materials to secure these portions, which are costly and affect the aesthetic and tactile appearance of the laminate.
Innovation Solution
A method involving stretching central regions of elastic materials in the cross direction, positioning reinforcement layers between unstretched edge regions, and ultrasonically bonding these layers with substrates to form elastic laminates, allowing for low-basis-weight films and nonwovens while ensuring secure bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-basis-weight nonwovens and films are used to bond unstretched film portions, then bonding strength is improved, but manufacturing cost increases and aesthetic appearance deteriorates
Solution Approach 1:
The patent applies local quality by concentrating bonding reinforcement only at the edges where unstretched film portions occur, rather than using high-basis-weight materials throughout the entire laminate. The reinforcement layers are positioned specifically at edge regions to provide localized bonding strength where needed, allowing the use of lower-basis-weight materials in the central regions, thus reducing overall material cost while maintaining bonding strength at critical locations.
Solution Approach 2:
The patent segments the laminate into different functional zones: edge regions with reinforcement layers for bonding unstretched film portions, and central regions with lower-basis-weight materials for aesthetic and cost considerations. This segmentation allows each zone to be optimized independently - the edges provide structural integrity while the center provides aesthetic quality at lower cost.
2Strength
If high-basis-weight nonwovens and films are used to bond unstretched film portions, then bonding strength is improved, but aesthetic appearance and tactile impression deteriorate
Solution Approach 1:
By localizing the reinforcement layers to edge regions only, the patent preserves the aesthetic appearance and tactile impression of the central laminate regions. The lower-basis-weight materials used in the center provide better aesthetic quality and softer tactile properties, while the edge regions with reinforcement layers handle the bonding function invisibly at the periphery.
3Adaptability or versatility
If stretching is applied to elastic materials, then elasticity and functionality are improved, but unstretched edge regions require additional bonding reinforcement
Solution Approach 1:
The patent applies preliminary action by pre-positioning the reinforcement layers at the edge regions before the stretching process. This ensures that when the elastic material is stretched, the unstretched edge portions are already supported by the reinforcement layers, preventing bonding failures without requiring complex post-stretching reinforcement operations.
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 method enables the construction of elastic laminates with improved bonding strength in unstretched film portions, using lower-cost materials and maintaining aesthetic and tactile quality.
Implementation Method 1
forming an elastic laminate by ultrasonically bonding the reinforcement layer together with the edge regions of the elastic materials and the substrates
Data Source
AI summary
The present disclosure relates to elastic laminates and methods for assembling elastic laminates that may be used to make absorbent article components. Elastic laminates may include one or more reinforcement layers positioned between unstretched portions of elastic materials and substrates to which the elastic materials are bonded.