Elastomeric Laminate Manufacturing Process for Delamination Control
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Solution Overview
Problem
The manufacturing of elastomeric laminates that do not delaminate is challenging, requiring precise control over product quality attributes such as tensile strength, elongation, and dimensional characteristics, and existing methods often result in inconsistent properties.
Innovation Solution
A manufacturing process involving the lamination of an extruded elastomeric film with patterned adhesive nonwoven sheets, followed by partial activation using intermeshing rollers and heat application, and subsequent stretching on a rotating wheel to enhance elastic properties, ensuring consistent and improved laminate quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a two-step manufacturing process is used to make elastomeric laminates, then the process is manageable and follows a standard procedure, but the product quality attributes such as tensile strength, elongation, and dimensional characteristics are inconsistent and the laminate may delaminate
Solution Approach 1:
The patent segments the manufacturing process into distinct functional zones: a heating zone that applies heat to activate the adhesive, a stretching zone that applies tension to develop elastic properties, and a cooling zone that sets the final dimensions. This segmentation allows each zone to be independently controlled and optimized, resolving the contradiction between process manageability and product quality consistency.
Solution Approach 2:
The patent applies preliminary heating and stretching actions during the manufacturing process itself, rather than relying on subsequent processing steps. The laminate is heated to activate adhesive bonding before stretching, ensuring proper adhesion is established prior to mechanical deformation. This preliminary action prevents delamination and ensures consistent quality attributes.
2Strength
If heat is applied to activate the adhesive and stretch the laminate, then elastic properties are enhanced, but delamination may occur due to excessive heat or improper activation
Solution Approach 1:
The patent employs periodic action through the zoned heating system, where heat is applied in a controlled sequence: first in the heating zone to activate adhesive bonding, then continued through the stretching zone to maintain activation during elastic property development, and finally in the cooling zone to set the final structure. This periodic thermal action ensures reliable bonding while enhancing elastic properties.
Solution Approach 2:
The patent utilizes parameter changes by controlling temperature, tension, and time in each zone. The heating zone maintains a temperature sufficient for adhesive activation, the stretching zone applies controlled tension while maintaining thermal activation, and the cooling zone reduces temperature to set the final dimensions. These coordinated parameter changes achieve enhanced elastic properties without causing delamination.
3Strength
If the laminate is stretched to enhance elastic properties, then tensile strength and elongation are improved, but dimensional characteristics such as centerzone thickness become inconsistent
Solution Approach 1:
The patent segments the mechanical processing into distinct stretching and cooling zones. The stretching zone applies controlled tension to develop elastic properties and tensile strength, while the subsequent cooling zone maintains dimensional stability. This segmentation allows independent optimization of each function, achieving improved strength without compromising dimensional precision.
Solution Approach 2:
The patent maintains continuous useful action through the coordinated operation of heating, stretching, and cooling zones. The laminate continuously progresses through each zone with uninterrupted processing: heating activates adhesive and prepares the material for stretching, stretching develops elastic properties, and cooling sets the final dimensions. This continuous coordinated action ensures both enhanced strength and consistent dimensional characteristics.
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 process results in elastomeric laminates with superior elastic properties, reducing delamination issues and enhancing the production of articles like disposable absorbent products by achieving consistent tensile strength and dimensional stability.
Implementation Method 1
moving the laminate resulting from b) through a series of heaters so as to pre-activate the nonwoven sheets
Implementation Method 2
partially activating the laminate via intermeshing rollers
Implementation Method 3
passing the laminate through a series of contact heaters that apply heat to non-activated regions of the laminate
Implementation Method 4
the wheel has a wider separation between its outer edges at the base of the wheel as compared to the separation between its outer edges at the top of the wheel, so as to thereby stretch the laminate in a lateral direction and then relax the laminate to its original width
Implementation Method 5
a patterned adhesive that effects adhesion to the extruded elastomeric film when laminated thereto via the lamination nip
Data Source
AI summary
A process for making an elastomeric laminated product including the steps of laminating an elastomeric film between a first spunbond nonvowen layer and a second spunbond nonwoven layer so as to form a laminated web, transporting the laminated web through intermeshing rollers so as to strain portions of the laminated web to form activated regions in the laminated web, and transporting the activated laminated web to a first portion of a rotating wheel, the first portion of the wheel having a cross direction width that is smaller than a cross direction width at a second portion of the wheel, so that the laminated web follows rotation of the wheel and is stretched in the cross direction at the second portion of the wheel before separating from the wheel at the first portion in a relaxed state.