Elastomeric Laminates Using Low Decitex Elastics for Comfort
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional elastomeric laminates in absorbent articles face issues such as high skin pressure, reduced breathability, and increased modulus, leading to discomfort and skin marking, while also requiring significant raw material usage and high investment costs. Additionally, there is a need for sustainable packaging and improved coordination between product characteristics and raw material usage.
Innovation Solution
The development of absorbent articles featuring elastomeric laminates with elastics of low decitex and increased strand spacing, incorporating recycled polymers to maintain performance without the need for a complete redesign of the laminate structure. These laminates include a first and second elastomeric laminate with specific decitex, strand spacing, and pre-strain values, and utilize recycled polymers to optimize comfort, breathability, and raw material efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If traditional elastomeric laminates use high decitex elastics with close strand spacing, then adequate force for fit is achieved, but skin pressure increases leading to discomfort and marking
Solution Approach 1:
The elastic laminate is segmented into multiple individual elastic strands distributed across the laminate structure. By using many low decitex elastics (Average-Dtex < 600) spaced more than 4 mm apart, the total elastic force is distributed across numerous contact points rather than concentrated in fewer high-decitex strands, reducing peak skin pressure while maintaining overall fit force
Solution Approach 2:
The patent changes key parameters of the elastic strands: reducing decitex from traditional high values to below 600, increasing strand spacing to more than 4 mm, and applying pre-strain between 50%-400%. These parameter changes collectively reduce skin pressure while maintaining adequate fit force through the combined effect of multiple strands
2Strength
If elastic film laminates are used to provide occlusive effect, then fit is improved, but breathability decreases leading to skin hydration and discomfort
Solution Approach 1:
The elastomeric laminate uses porous nonwoven substrate layers that allow air permeability while providing structural support. The substrate layers contain interconnected voids and channels that enable breathability, preventing skin hydration while maintaining the occlusive fit effect through the elastic strands embedded within the porous structure
Solution Approach 2:
The laminate combines elastic strands with porous nonwoven substrate materials to create a composite structure. This composite approach allows the elastic components to provide fit while the porous substrate components maintain breathability, resolving the contradiction between occlusive fit and air permeability
3Force
If high decitex elastics are used to provide adequate force, then fit is maintained, but raw material usage and costs increase
Solution Approach 1:
The patent uses low decitex elastics that require less raw material per strand. By employing many thin elastics instead of fewer thick ones, the total polymer consumption is reduced while achieving the same overall elastic force through distributed strain across multiple strands
Solution Approach 2:
Changing the decitex parameter to lower values (< 600) and adjusting strand spacing (> 4 mm) allows reduction in material usage. The pre-strain parameter (50%-400%) is optimized to ensure adequate force generation from the thinner elastics, maintaining fit performance with reduced material input
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 solution provides improved comfort, breathability, and fit while reducing raw material usage and costs, ensuring adequate force and elasticity without the necessity of high decitex elastics, thus addressing the challenges of traditional laminates and aligning with sustainability goals.
Implementation Method 1
the first elastomeric laminate comprises a first plurality of elastics disposed between a first substrate layer and a second substrate layer and wherein the first plurality of elastics comprises an Average-Dtex of less than 600, an Average-Strand-Spacing of more than 4 mm and an Average-Pre-Strain of from 50% to about 400%
Data Source
Figure 1
Figure 2
AI summary
An absorbent article comprising an absorbent chassis comprising a topsheet, a backsheet and an absorbent core disposed between the topsheet and the backsheet. The absorbent article comprises a first elastomeric laminate forming at least a portion of a belt, a side panel, or an ear panel in a front waist region and a second elastomeric laminate forming at least a portion of a belt, a side panel, or an ear panel in a back waist region. The first elastomeric laminate comprises a first plurality of elastics disposed between a first substrate and a second substrate and having an Average-Dtex of less than 600, an Average-Strand-Spacing of more than 4 mm and an Average-Pre-Strain of from 50% to about 400%. The second elastomeric laminate comprises a second plurality of elastics disposed between a first substrate and a second substrate and having an Average-Dtex of less than 600, an Average-Strand-Spacing of more than 4 mm and an Average-Pre-Strain of from 50% to about 400%. The first and/or second plurality of elastics comprise from about 0,1% to about 99,9%wt of recycled polymers by total weight of polymers, preferably from about 10% to about 90%wt of recycled polymers by total weight of polymers.