Elastomeric Laminate Bonding With Ultrasonic Strand Locking

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Solution Overview

Problem

Existing methods for manufacturing elastomeric laminates in absorbent articles face challenges such as severing of elastic strands during high-speed production, inconsistent bond quality, and the need for excessive adhesive use due to the spin finish on elastic strands, which complicates the assembly process and increases costs.

Innovation Solution

A method involving a pattern roll and an ultrasonic horn or energy transfer surface to bond elastic strands between substrates at high speeds without severing, using a frictional lock mechanism to secure the strands without nesting grooves, ensuring consistent bonding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hot melt adhesives are used to adhere stretched elastic strands to substrates, then bonding is achieved, but increased amounts of adhesive are required due to spin finish on the strands, which negatively impacts costs, functionality, and aesthetics

Engineering Contradiction:

Improvebonding effectivenessVSAvoidadhesive consumption

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent removes the spin finish coating from elastic strands using a corona treatment or plasma treatment before bonding. This extraction of the harmful coating allows standard adhesive amounts to bond effectively, eliminating the need for excessive adhesive application while maintaining bond reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the chemical bonding mechanism (adhesive) with a physical/chemical surface treatment (corona or plasma treatment) that modifies the elastic strand surface. This substitution eliminates the spin finish barrier without requiring additional adhesive, thereby reducing adhesive consumption while maintaining bonding effectiveness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If elastic strands are drawn from windings stacked on a beam, then close cross directional spacing is achieved, but the strands may be severed during high-speed production

Engineering Contradiction:

Improvecross directional spacingVSAvoidstrand integrity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent applies a preliminary surface treatment (corona or plasma treatment) to the elastic strands before they are drawn from the beam winding. This pre-treatment strengthens the strand surface and reduces the risk of severing during high-speed handling and bonding operations, while maintaining the close cross directional spacing achieved by beam drawing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies a protective surface coating or treatment to the elastic strands before they undergo high-speed processing. This cushioning layer protects the strands from mechanical damage and severing during handling, drawing, and bonding operations while preserving the close spacing configuration.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Productivity

If high-speed production is implemented, then productivity increases, but bond quality becomes inconsistent and strands may be severed

Engineering Contradiction:

Improveproduction speedVSAvoidbond quality consistency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent replaces mechanical bonding methods with a surface treatment-based bonding approach (corona or plasma treatment). This substitution enables consistent bond quality at high speeds by preparing the strand surface in advance, eliminating the need for precise mechanical alignment and pressure control that become difficult to maintain at high production speeds.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the surface parameters of the elastic strands through corona or plasma treatment, modifying the surface energy and chemistry to enable reliable bonding. This parameter change ensures consistent bond quality regardless of production speed variations, as the surface treatment creates a uniform bonding interface that is insensitive to speed fluctuations.

Inventive Principle:

Principle #35Parameter changes

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

Enables high-speed production of elastomeric laminates with secure bonding of elastic strands, reducing material waste and costs, and maintaining consistent bond quality without the need for complex groove guidance.

Implementation Method 1

A method involving a pattern roll and an ultrasonic horn or energy transfer surface to bond elastic strands between substrates at high speeds without severing

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

using a frictional lock mechanism to secure the strands

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS12599506B2Method for making elastomeric laminates

Publication Date: 2026.04.14 PROCTER & GAMBLE CO

AI summary

The present disclosure relates to methods for making elastomeric laminates that may be used as components of absorbent articles. Aspects of the methods for assembling elastomeric laminates may utilize elastic strands supplied from beams that may be joined with first and second substrates, and may be configured to carry out various types of operations, such as bonding and splicing operations.