Elastomeric Laminate Pre-SELFing Zero Strain Bonding
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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 method involves pre-SELFing a coverstock material to create a primary activation pattern with specific land areas, then joining it with an elastomeric layer at zero relative strain, allowing for targeted activation patterns and reduced stress on layers, thereby enhancing extensibility and texture customization without damaging the laminate during the activation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If mechanical straining process is used to activate all layers at once, then laminate extensibility is achieved, but layer damage and defects increase
Solution Approach 1:
The patent divides the activation process into separate stages for different layers. The coverstock layer is activated first through mechanical straining to create a patterned structure, then the elastomeric layer is bonded to this pre-activated coverstock. This segmentation allows each layer to be optimized independently and reduces the risk of damage to both layers during activation.
Solution Approach 2:
The coverstock layer undergoes preliminary activation through mechanical straining before bonding with the elastomeric layer. This pre-activation creates the desired extensibility pattern in the coverstock, and then the elastomeric layer is bonded in its unactivated state, protecting it from damage during the straining process.
2Strength
If expensive coverstock materials are used to ensure desired stretch, then laminate durability is improved, but manufacturing cost increases
Solution Approach 1:
The patent creates a composite laminate structure combining coverstock material and elastomeric material, each contributing different properties. The coverstock provides durability and structural integrity, while the elastomeric layer provides extensibility. This composite approach allows use of less expensive coverstock materials while achieving desired performance through the combined structure.
Solution Approach 2:
The patent changes the activation state parameter of different layers. The coverstock is activated (strained) while the elastomeric layer remains unactivated during bonding. This parameter differentiation allows each material to be used at its optimal state, reducing the need for expensive high-performance coverstock materials.
3Shape
If coverstock material is strained to greater extent than elastomeric material during lamination, then gathered laminate texture is created, but manufacturing complexity increases
Solution Approach 1:
The coverstock layer is pre-activated through mechanical straining to create the desired gathered texture pattern before bonding with the elastomeric layer. This preliminary texturing eliminates the need for complex post-lamination gathering processes, simplifying the overall manufacturing procedure while achieving the desired texture.
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 enables the creation of elastomeric laminates with improved extensibility, customizable textures, and reduced manufacturing costs by minimizing layer damage and stress, resulting in enhanced product performance and user comfort.
Implementation Method 1
an elastomeric layer (20) that has been activated prior to lamination... The laminate (10) comprises a total thickness, T... an activation thickness, TA, that is less than the total thickness, T
Implementation Method 2
SELFing the first coverstock material to create a pre-SELFed coverstock layer having a primary activation pattern comprising SELF-specific land areas
Data Source
Figure 1~2
Figure 3A~3C
Figure 4
AI summary
A method for forming an elastomeric laminate includes the steps of providing a first coverstock material; SELF'ing the first coverstock material to create a pre-SELFed coverstock layer having a primary activation pattern comprising SELF-specific land areas; providing an elastomeric layer; and joining the elastomeric layer to the pre-SELFed layer at zero relative strain, such that the elastomeric layer and pre-SELFed coverstock layer are joined at one or more bonding sites.