Multi-Directional Elastic Laminate via Perpendicular Stretching
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Solution Overview
Problem
Existing methods for producing elastic laminates, such as neck bonded and stretch bonded laminates, face challenges in achieving multi-directional stretch and recovery properties in personal care products, particularly in providing enhanced elastic performance in both machine and cross-machine directions while maintaining a single processing step and ensuring softness and drapability.
Innovation Solution
The method involves stretching pre-formed elastic laminate materials through intermeshing grooved rolls or disc arrangements to extend them in directions perpendicular to their original elasticity, enhancing their elastic performance by reducing percent set and increasing softness, thereby achieving multi-directional stretch capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If stretch bonded laminate process is used to provide high levels of stretch and recovery in machine direction, then machine direction elastic performance is improved, but cross-machine direction stretch and recovery properties are insufficient
Solution Approach 1:
The patent combines neck bonding and stretch bonding processes into a single integrated process. The laminate is bonded while the elastic material is stretched in the machine direction, and simultaneously stretched in the cross-machine direction through the necking action, achieving multi-directional elasticity in one operation.
Solution Approach 2:
The invention adds cross-machine direction stretch capability to the traditional machine direction stretch by introducing the necking dimension. The gatherable material is stretched in the cross-machine direction during bonding, creating elasticity perpendicular to the original stretch direction.
2Strength
If neck bonded laminate process is used to provide cross-machine direction stretch and recovery, then cross-machine direction elastic performance is improved, but machine direction stretch and recovery properties are insufficient
Solution Approach 1:
The patent merges neck bonding and stretch bonding into a unified process where the laminate undergoes both machine direction stretching and cross-machine direction necking simultaneously during bonding, achieving dual-directional elastic properties in one operation.
3Strength
If multiple processing steps are used to achieve multi-directional stretch and recovery, then elastic performance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The invention consolidates multiple stretching and bonding operations into a single integrated process. The laminate is bonded to the gatherable material while simultaneously being stretched in one direction and necked in the perpendicular direction, achieving multi-directional elasticity without requiring separate processing steps.
Solution Approach 2:
The bonding process serves multiple functions simultaneously: it bonds the elastic material to the gatherable material, stretches the laminate in the machine direction, and necks the gatherable material in the cross-machine direction, creating multi-directional elasticity in one universal operation.
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
This approach results in laminates with improved elastic performance, reduced percent set, and increased softness, enabling them to stretch in both machine and cross-machine directions, while maintaining a single processing step, which is beneficial for personal care products like diapers and adult incontinence devices.
Implementation Method 1
stretching the laminate material in a direction perpendicular to the single/original direction of elasticity
Implementation Method 2
stretches the laminate material in a direction perpendicular to the single/original direction of elasticity of the elastic laminate material
Implementation Method 3
enhancing their elastic performance by reducing percent set
Data Source
AI summary
A method for producing a machine direction and cross-machine direction elastic laminate includes the steps of providing a one direction elastic laminate material including at least one elastic layer and one facing layer and having a single direction of elasticity and coursing the one direction elastic laminate material through at least one stretching apparatus, such that the stretching apparatus stretches the laminate material in a direction perpendicular to the single direction of elasticity of the elastic laminate material, thereby producing a material that extends in a direction perpendicular to the direction of elasticity and also extends the elastic performance of the laminate in the single direction of elasticity.