Elastomeric Laminate Pre-Activated Coverstock Defect Reduction
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Solution Overview
Problem
Existing elastomeric laminates face challenges in providing desirable tactile properties, textures, and cost efficiency, with limitations in manufacturing processes that can lead to defects and increased costs due to the need for expensive coverstock materials and complex mechanical straining processes, which affect product performance and user comfort.
Innovation Solution
The development of an elastomeric laminate with pre-SELFed coverstock layers and elastomeric layers, where the coverstock layers are pre-activated with specific activation patterns that extend in certain directions, allowing for differential properties and textures on both surfaces without full-thickness activation, reducing the risk of defects and enabling targeted extensibility and strength optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If mechanical straining process is used to activate zero strain laminates, then the laminate becomes elastically extensible, but defects and tears may occur in the laminate layers
Solution Approach 1:
The invention segments the activation process by applying it only to the coverstock layer separately from the elastomeric layer. The coverstock is activated to create land areas and activation thicknesses, while the elastomeric layer remains unactivated. This segmentation prevents defects from propagating through the entire laminate, as only the coverstock undergoes mechanical straining.
Solution Approach 2:
The invention applies local quality by creating specific activation patterns only in the coverstock layer, forming land areas with specific activation thicknesses less than the total laminate thickness. This localized activation provides the necessary elasticity in specific regions while maintaining integrity in other areas, reducing overall defect risk.
2Adaptability or versatility
If coverstock material is plastically deformed during activation, then the laminate achieves extensibility, but portions of the material may be completely destroyed
Solution Approach 1:
The invention applies partial action by activating only the coverstock layer to the extent necessary for creating land areas and activation thicknesses, rather than fully activating the entire laminate. The activation thickness is controlled to be less than the total laminate thickness, preventing complete material destruction while achieving sufficient extensibility.
3Stability of the object's composition
If all layers are activated simultaneously, then the laminate achieves uniform extensibility, but defects extend through the entire laminate
Solution Approach 1:
The invention segments the activation process by treating the coverstock and elastomeric layers differently. Only the coverstock undergoes activation to create land areas, while the elastomeric layer remains unactivated. This segmentation prevents defects from extending through the entire laminate thickness.
Solution Approach 2:
The invention creates local quality differences by applying activation only to the coverstock layer in specific patterns, forming land areas with controlled activation thicknesses. This localized approach allows uniform extensibility where needed while maintaining defect isolation in the elastomeric layer.
4Adaptability or versatility
If expensive coverstock materials are used to ensure desired stretch, then the laminate achieves sufficient extensibility, but manufacturing costs increase
Solution Approach 1:
The invention applies preliminary action by pre-activating the coverstock layer before lamination with the elastomeric layer. This preliminary activation creates the necessary land areas and activation thicknesses in advance, allowing the laminate to achieve desired stretch capability without requiring expensive coverstock materials with inherent high stretch properties.
Solution Approach 2:
The invention changes the parameter of activation thickness to be less than the total laminate thickness. By controlling the activation thickness of the coverstock, the laminate achieves sufficient stretch capability without requiring expensive materials, as the activation pattern itself provides the necessary mechanical properties.
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 enhances the laminate's extensibility, strength, and texture customization, reducing manufacturing costs and defects, while allowing for varied activation patterns that improve user comfort and product performance by avoiding full-thickness activation and enabling more complex textural designs.
Implementation Method 1
Zero strain laminates are activated by a mechanical straining process, which creates separations or deformations in the coverstock materials and renders the laminate elastically extensible
Implementation Method 2
the laminate may be in the form a gathered laminate, wherein the coverstock layer forms rugosities when the stretchable layer is relaxed
Data Source
AI summary
An elastomeric laminate is extensible in a first direction and has a first laminate surface; a second laminate surface substantially opposite the first laminate surface; and a laminate thickness, T, extending between the first and second laminate surfaces. A pre-SELFed coverstock layer forms the first laminate surface. The pre-SELF coverstock layer has a primary activation pattern, wherein the primary activation pattern includes SELF-specific land areas that extend in the first direction and one or more activation thicknesses. Each activation thickness is less than the laminate thickness, T. The elastomeric laminate also has an elastomeric layer joined to the pre-SELFed coverstock layer. The elastomeric layer forms the second laminate surface. The elastomeric laminate may be a zero strain laminate, a gathered laminate, or a hybrid gathered laminate.