Elastic Laminate Stretching Layout for Precise Film Alignment
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Solution Overview
Problem
Existing methods for producing elastic laminates face challenges such as precise spacing issues between elastic films, large manufacturing line dimensions, and limited flexibility in producing different types of products, leading to inefficiencies and increased costs.
Innovation Solution
A method and apparatus utilizing a stretching unit with dual stretching devices, each driven by a single motor on one side, and adjustable mechanisms for precise alignment, combined with an anvil wheel and fastening device to ensure accurate positioning and flexibility in producing various elastic laminates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two stretching units are arranged in two distinct areas with angular offset, then elastic films can be stretched and applied to nonwoven web, but positioning precision between elastic films and nonwoven web deteriorates and manufacturing line dimensions increase
Solution Approach 1:
The patent merges the two stretching units into a single integrated stretching device where both elastic films are stretched simultaneously in the same spatial area. The stretching members are arranged side-by-side with their axes parallel to each other, allowing both films to be stretched and applied to the nonwoven web in close proximity, thereby maintaining precise positioning while avoiding the angular offset problem of prior art.
Solution Approach 2:
The patent changes the spatial arrangement from angular offset in different areas to parallel arrangement in the same area. The stretching members are positioned side-by-side with parallel axes, utilizing horizontal spacing rather than angular separation. This dimensional reorganization allows both stretching operations to occur in the same plane, improving positioning precision while controlling manufacturing line dimensions.
2Adaptability or versatility
If two stretching units are arranged in two distinct areas, then elastic films can be processed, but manufacturing line dimensions become large
Solution Approach 1:
The patent combines two stretching units into a single integrated device where stretching members are positioned side-by-side. This merging reduces the overall footprint by eliminating the need for separate stretching areas and angular offsets, thereby processing multiple elastic films within a compact space that controls manufacturing line dimensions.
3Ease of manufacture
If stretching members have axes inclined with respect to each other, then stretching can be performed, but setting and adjustment operations become complex and time-consuming
Solution Approach 1:
The patent employs asymmetric positioning of the stretching members relative to the web path, with both members having parallel axes that are inclined with respect to the web direction. This asymmetric parallel arrangement simplifies the adjustment mechanism compared to mutually inclined axes, as both members can be adjusted independently along parallel reference lines, reducing the complexity of setting and adjustment operations.
4Productivity
If existing stretching units are used, then single type of elastic laminates can be produced, but flexibility to produce different types of products is limited
Solution Approach 1:
The patent incorporates adjustable mechanisms that allow dynamic reconfiguration of the stretching parameters. The stretching members can be independently adjusted in position, speed, and tension, enabling the production of different types of elastic laminates by varying the stretching conditions for each film. This dynamic adjustability provides flexibility to produce multiple product types on a single production line.
Solution Approach 2:
The integrated stretching device with parallel-axis members is designed to handle different types of elastic films and nonwoven webs through adjustable parameters. The universal design allows the same apparatus to produce various elastic laminate types by modifying stretching conditions, eliminating the need for dedicated production lines for each product type.
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
Enables precise and flexible production of elastic laminates with improved positioning accuracy and reduced manufacturing space requirements, allowing for a broader range of products without the need for multiple manufacturing lines.
Implementation Method 1
first and second elastic films (84, 86) stretched in a transverse direction (Y) by first and second stretching members (16, 18)
Implementation Method 2
The outer cylindrical surface of the anvil wheel (90) is provided with suction holes pneumatically connected to a source of sub-atmospheric pressure (91)
Implementation Method 3
the first and second nonwoven webs are welded together ultrasonically through the first and second elastic films
Data Source
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AI summary
A method for producing elastic laminates, comprising: - gripping first and second continuous elastic films (84, 86) in respective gripping zones (68) by respective first and second stretching members (16, 18), - transversely stretching the first and second continuous elastic films (84, 86) by rotating said first and second stretching members (16, 18) about respective first and second axes of rotation 20, 22) inclined with respect to each other, and - releasing the transversely stretched first and second continuous elastic films (84, 86) from the respective first and second stretching members (16, 18) in respective release zones (70) aligned along a common transverse release line (72).