Elastic Composite Sheet Manufacturing via Temperature-Controlled Stretching
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Solution Overview
Problem
Conventional elastic composite sheet manufacturing devices are limited in producing elastic composite sheets with desired characteristics such as stretching stress, expansion and contraction ratios, texture, and air permeability, which vary by application and product type.
Innovation Solution
A method involving heating and melting a thermoplastic elastic resin, forming and extending an intermediate product, cooling and hardening it, stretching, and laminating it onto base material sheets, with optional variations in cooling and stretching processes to achieve desired properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional elastic composite sheet manufacturing device is used, then manufacturing process is simple, but characteristics of elastic composite sheet are limited and desired characteristics cannot be achieved
Solution Approach 1:
The manufacturing process is divided into six distinct steps: (i) heating and melting elastic resin material, (ii) forming film-shape or linear-shape intermediate product, (iii) extending intermediate product at high temperature, (iv) cooling and hardening to form elastic member, (v) stretching elastic member to prescribed ratio, and (vi) laminating and bonding to base material sheet. This segmentation allows precise control of each step to achieve desired characteristics.
Solution Approach 2:
The patent utilizes temperature parameter changes to control the elastic resin material's state transitions. The material is heated above its elastic deformation temperature region during forming, then cooled below this temperature region to achieve hardening. This parameter change enables precise control over the elastic composite sheet's final characteristics.
2Manufacturing precision
If elastic composite sheet characteristics are customized for different applications, then product quality improves, but manufacturing difficulty increases
Solution Approach 1:
The patent employs dynamic control of the stretching process where the elastic member is stretched to a prescribed stretching ratio in step (v) after being formed at high temperature and cooled. This dynamic adjustment of stretching ratio allows customization of elastic properties while maintaining ease of manufacture through a standardized six-step process framework.
Solution Approach 2:
By changing the stretching ratio parameter in step (v) and the extension degree in step (iii), the patent enables customization of elastic composite sheet characteristics such as stretching stress and expansion/contraction ratio for different applications while keeping the manufacturing process systematic and manageable.
3Manufacturing precision
If multiple processing steps are added to achieve desired characteristics, then product quality improves, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple functions into integrated processing steps. For example, step (iii) extends the intermediate product while maintaining it above the elastic deformation temperature, and step (iv) simultaneously cools and hardens the material. Step (vi) combines lamination and bonding operations. This merging reduces the need for separate equipment and operations, controlling manufacturing cost.
Solution Approach 2:
The manufacturing device is designed with multi-functional components that can perform multiple operations. The cooling unit serves both to cool the intermediate product and to harden it into an elastic member. The stretching unit can adjust stretching ratios to produce different characteristics. This universality allows a single device to produce various elastic composite sheet specifications, reducing overall manufacturing cost.
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 the easy manufacture of elastic composite sheets with tailored characteristics, reducing manufacturing costs and improving product quality.
Implementation Method 1
a first step of heating and melting an elastic resin material having a thermoplastic elastic resin as a main component
Implementation Method 2
a fourth step of forming a film-shape or a linear-shape elastic member by cooling the intermediate product to the temperature region at which the elastic resin material elastically deforms and hardening the intermediate product
Implementation Method 3
cooling the intermediate product to the temperature region at which the elastic resin material elastically deforms
Data Source
AI summary
An elastic resin material having a thermoplastic elastic resin as a main component is heated and melted, and the elastic resin material is discharged in a film or a linear shape from a discharge mechanism to form a film-shape or a linear-shape intermediate product. At a temperature above the temperature region at which the elastic resin material elastically deforms, extending is performed until the thickness or width of the film-shape intermediate product or the thickness of the linear-shape intermediate product assumes a prescribed value; with a cooling roller, the intermediate product is cooled to the temperature region at which the elastic resin material elastically deforms, and the intermediate product is hardened, forming a film-shape or linear-shape elastic member. The elastic member is stretched with a stretch roller to a prescribed stretching ratio, and the stretched elastic member is laminated on and bonded to a first base material sheet.