Elastomeric Film Laminates for Quiet Ultrasonic Bonding
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Solution Overview
Problem
Ultrasonically bonded laminates used in disposable absorbent products often exhibit low bond strength, high noise, and decreased drape ability, making them unsuitable for consumer products, while adhesive-based laminates are costly and have aesthetic issues.
Innovation Solution
The use of elastomeric films with a polymeric composition comprising at least 50% styrenic block copolymers and olefinic block copolymers, combined with nonwoven substrates of ribbon-shaped fibers, which are ultrasonically or thermally bonded to achieve high elongation break, peel force, and low noise levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ultrasonic bonding is used to bond laminates, then adhesive cost is reduced and manufacturing is simplified, but bond strength decreases and delamination occurs
Solution Approach 1:
The patent modifies the physical and chemical parameters of the elastomeric material, specifically using styrenic block copolymers with controlled glass transition temperatures and molecular weights. By adjusting these parameters, the material achieves optimal bonding characteristics for ultrasonic bonding, resolving the contradiction between manufacturing simplicity and bond strength.
Solution Approach 2:
The patent employs composite elastomeric materials combining styrenic block copolymers with other polymers to create a material system that simultaneously provides good ultrasonic bonding characteristics and high bond strength. This composite approach allows the laminate to achieve both ease of manufacture and strong bonding without delamination.
2Adaptability or versatility
If traditional elastomeric materials are used, then material availability is good, but noise during use increases and drape ability decreases
Solution Approach 1:
The patent changes the molecular structure parameters of the elastomeric material by using styrenic block copolymers with specific glass transition temperatures (Tg between -50°C to 0°C). This parameter modification reduces the material's tendency to generate noise during use while maintaining good material availability and processing characteristics.
3Shape
If elastomeric material is stretched at body temperature, then fit quality improves, but elasticity is lost and holes form
Solution Approach 1:
The patent carefully selects elastomeric materials with specific glass transition temperatures and molecular weight parameters that allow the material to be stretched at body temperature without losing elasticity or forming holes. The parameter optimization ensures the material maintains its integrity while achieving the desired fit quality.
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 resulting laminates demonstrate enhanced strength, quietness, softness, and drape ability, making them suitable for absorbent articles without the need for adhesives, while maintaining integrity and comfort.
Implementation Method 1
ultrasonically or thermally bonded
Implementation Method 2
ultrasonically or thermally bonded
Data Source
AI summary
Laminates comprising at least one film and a nonwoven substrate, wherein the film comprises a polymeric composition comprising at least about 50% of one or more styrenic block copolymers, olefinic block copolymers, or combinations thereof; wherein the nonwoven substrate comprises at least one layer of spunbond material comprising ribbon-shaped fibers, wherein the laminate comprises ultrasonic bonds, thermal bonds, or combinations thereof and which have advantageous properties relative to a comparative laminate in which the nonwoven comprises non-ribbon shaped fibers.