Elastomeric Laminate Fusion Bonding for Personal Care Articles
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Solution Overview
Problem
Conventional methods for providing elastic properties in disposable personal care articles require adhesive bonding of elastic strands to polymeric substrates, increasing manufacturing costs and complexity, and hindering recycling due to the mixed composition of waste materials.
Innovation Solution
A method of forming an elastomeric laminate with targeted elastic properties by sandwiching an elastomeric core layer and film ribbon web between nonwoven webs and bonding them using fusion techniques without adhesives, reducing material and equipment costs and enhancing recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive bonding is used to attach elastic strands to polymeric substrates, then elastic properties are achieved, but manufacturing cost and process complexity increase
Solution Approach 1:
The invention extracts and eliminates the adhesive component from the conventional elasticization process. Instead of using adhesive bonding to attach elastic strands to the substrate, the patent uses elastic films that are directly laminated to the polymeric substrate, removing the need for separate adhesive layers and simplifying the manufacturing process while maintaining the desired elastic properties
Solution Approach 2:
The invention changes the bonding mechanism parameter from adhesive-based chemical bonding to heat-based physical bonding. By using heat to laminate the elastic film directly to the substrate, the process eliminates adhesive materials while achieving reliable attachment, thereby reducing process complexity and manufacturing cost
2Reliability
If adhesive bonding is used to attach elastic strands to polymeric substrates, then elastic properties are achieved, but manufacturing cost increases
Solution Approach 1:
The invention extracts and eliminates the adhesive component from the conventional elasticization process. Instead of using adhesive bonding to attach elastic strands to the substrate, the patent uses elastic films that are directly laminated to the polymeric substrate, removing the need for separate adhesive layers and simplifying the manufacturing process while maintaining the desired elastic properties
Solution Approach 2:
The invention replaces expensive adhesive materials and bonding equipment with a simpler, more cost-effective direct lamination process using heat. The elastic films themselves serve as the bonding interface, eliminating the need for additional adhesive materials and reducing overall manufacturing cost
3Reliability
If adhesive bonding is used to attach elastic strands to polymeric substrates, then elastic properties are achieved, but recyclability of waste materials is hindered
Solution Approach 1:
The invention extracts and eliminates the adhesive component from the conventional elasticization process. Instead of using adhesive bonding to attach elastic strands to the substrate, the patent uses elastic films that are directly laminated to the polymeric substrate, removing the need for separate adhesive layers and simplifying the manufacturing process while maintaining the desired elastic properties
Solution Approach 2:
The invention creates a homogeneous structure where the elastic film and substrate are directly bonded without adhesive intermediaries. This homogeneity allows waste materials to be more easily sorted and recycled, as the laminate consists of compatible polymeric materials that can be processed together rather than as a mixed composition of substrate, elastic strands, and adhesive
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 eliminates the need for adhesives in the laminating process, lowering costs and simplifying the manufacturing process while improving the recyclability of waste materials by using fusion bonding to create elastomeric laminates with targeted elastic properties for personal care articles.
Implementation Method 1
bonding the elastomeric film ribbon web to the first and second nonwoven webs by fusing the elastomeric film ribbon web to the first and second nonwoven webs
Implementation Method 2
bonding the core layer of elastomeric material to at least one of the first and second nonwoven webs comprises fusing the elastomeric film web core layer to the at least one of the first and second nonwoven webs
Implementation Method 3
Upon release of the tensioning force, the elastic strands gather the substrate, providing the desired functional properties, such as, for example, providing a snug fit around the leg or waist opening of a disposable garment
Data Source
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AI summary
A method of forming an elastomeric laminate having targeted elastic properties for use in personal care articles is disclosed. In particular embodiments, the method comprises providing first and second nonwoven webs; providing a core layer of elastomeric material under tension; sandwiching the core layer between the first and second nonwoven webs; bonding the core layer to at least one of the first and second nonwoven webs; providing an elastomeric film ribbon web under tension; sandwiching the elastomeric film ribbon web between the first and second nonwoven webs; and fusing the elastomeric film ribbon web to the first and second nonwoven webs. In particular embodiments, the core layer of elastomeric material is an elastomeric film web core layer. In particular embodiments, the elastomeric film ribbon web, the core layer, or both is/are bonded to the first and second nonwoven webs solely by fusing, without the use of adhesive.