Elastic Laminate Deactivation via Segmented Cutting
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Solution Overview
Problem
The existing methods for manufacturing elastic belts in diapers often result in damaged laminates due to cutting, leading to poor aesthetic appearance and increased likelihood of tearing, along with handling difficulties and differential stretch characteristics.
Innovation Solution
A method involving the formation of an elastic laminate by intermittently bonding and severing elastic strands between substrate layers, which minimizes handling and enhances the aesthetic appearance by maintaining the integrity of the laminate during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If elastic strands are cut to deactivate them, then the elastic function is removed in required regions, but the laminate is damaged and aesthetic appearance deteriorates
Solution Approach 1:
The cutting operation is segmented into two distinct stages: first cutting through the elastic strands only, then subsequently cutting through the laminate layers. This segmentation allows selective deactivation of elastics without immediate damage to the laminate structure, preserving aesthetic appearance while achieving the required elastic deactivation.
Solution Approach 2:
The elastic strands are cut and deactivated before the final laminate cutting operation. This preliminary action removes the elastic function in required regions prior to completing the laminate structure, preventing elastic snap-back issues during subsequent handling while maintaining laminate integrity.
2Adaptability or versatility
If elastic strands are cut, then elasticity is removed in required regions, but cut ends snap back uncontrollably to undesired locations
Solution Approach 1:
Elastic strands are cut and deactivated before the laminate is fully assembled and before subsequent handling operations. By performing this deactivation preliminarily, the elastic strands are secured in their deactivated state within the laminate structure, preventing uncontrolled snap-back during later handling, conveying, and assembly operations.
Solution Approach 2:
The cutting operation is designed to preemptively counteract the potential harmful snap-back effect by removing elastic tension before handling difficulties can occur. This preliminary anti-action eliminates the risk of elastic ends moving to undesired locations during subsequent processing.
3Adaptability or versatility
If elastic strands are cut, then elasticity is deactivated, but the laminate is weakened and becomes more likely to tear
Solution Approach 1:
The cutting process is divided into two sequential operations: first cutting only the elastic strands, then subsequently cutting the laminate layers. This segmentation ensures that the laminate structure remains intact and strengthened by adhesive bonding during the elastic deactivation phase, preventing tears while achieving the required elastic deactivation.
Solution Approach 2:
Elastic strands are cut and deactivated before the final laminate cutting and separation operations. This preliminary deactivation allows the laminate to maintain its structural integrity during handling, while the subsequent cutting operations complete the laminate formation without compromising strength.
4Ease of manufacture
If extensive handling is performed after elastic deactivation, then assembly operations can be completed, but the laminate suffers damage and aesthetic appearance deteriorates
Solution Approach 1:
Elastic strand deactivation is performed as a preliminary operation before the laminate undergoes extensive handling and subsequent assembly operations. By completing the elastic deactivation early in the process, the laminate can be handled and assembled without the risk of elastic snap-back or structural damage, maintaining both manufacturability and aesthetic appearance.
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 reduces damage to the elastic laminate, improves its aesthetic appearance, and maintains structural integrity, addressing the issues of tearing and handling difficulties while ensuring consistent stretch characteristics.
Implementation Method 1
intermittently bonding elastic strands between a first substrate layer and a second substrate layer to form an elastic laminate
Implementation Method 2
cutting the elastic laminate to form a first continuous elastic laminate and a second continuous elastic laminate
Data Source
Figure 1
Figure 2A~3B
Figure 2B
AI summary
The present disclosure relates to methods and apparatuses for assembling absorbent articles, and more particularly, diapers, each including a chassis connected with front and back elastic belts. Opposing end regions of the chassis are connected with regions of the elastic belts where the elasticity of the elastic belts has been removed or deactivated. As discussed in more detail below, an elastic laminate is formed by intermittently bonding elastic strands between a first continuous substrate layer and a second continuous substrate layer. The elastic strands are then intermittently deactivated by severing the strands in the non bonded regions to form deactivated regions of the elastic laminate. A plurality of chassis may then be bonded with the elastic laminate, wherein the first or second end regions of each chassis may be bonded with deactivated regions of the continuous elastic laminate.