Elastomeric Strand Bonding via Segmented Adhesive Zones
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Solution Overview
Problem
Current manufacturing processes for elasticized absorbent articles, such as diapers and adult pants, face challenges in reducing costs, increasing production rates, and minimizing waste, particularly in the application of elastic strands during cross-direction manufacturing.
Innovation Solution
The method involves forming elasticated waist panels by advancing continuous substrate materials and elastomeric strands in a machine direction, applying different adhesives intermittently to the strands and substrates to create non-overlapping adhesive regions, which helps maintain elastic strands' position and prevent web de-lamination, thereby optimizing adhesive usage and reducing redundancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is applied continuously to elastic strands and substrate materials, then bonding strength is improved, but adhesive waste increases and costs rise
Solution Approach 1:
The adhesive application is segmented into distinct zones: a first adhesive is applied intermittently to elastic strands in a first region, while a second adhesive is applied intermittently to substrate materials in a second region. This segmentation allows each adhesive to be used only where specifically needed, reducing overall adhesive consumption while maintaining bonding strength.
Solution Approach 2:
Different adhesive properties and application patterns are applied to different regions of the waist panel. The first adhesive targets elastic strand bonding areas while the second adhesive targets substrate bonding areas. This local differentiation ensures optimal adhesive usage in each region, preventing both over-application and under-application.
2Reliability
If multiple adhesives are applied to the same region, then bonding reliability is improved, but process complexity and cost increase
Solution Approach 1:
The bonding process is divided into two separate adhesive application systems operating in different spatial regions. The first adhesive applicator serves the first region with elastic strands, while the second adhesive applicator serves the second region with substrate materials. This eliminates the need for complex multi-adhesive application to the same area while maintaining reliable bonding through region-specific optimization.
Solution Approach 2:
The redundant application of multiple adhesives to the same region is extracted and eliminated. Instead, the patent applies different adhesives to different regions, removing the unnecessary complexity of overlapping adhesive applications while preserving bonding reliability through targeted adhesive placement.
3Reliability
If adhesive is applied to all regions of the waist panel, then bonding coverage is improved, but manufacturing cost and waste increase
Solution Approach 1:
The adhesive application strategy transitions from uniform coverage to localized quality-based application. The first adhesive is applied only where elastic strands require bonding, and the second adhesive is applied only where substrate materials require bonding. This ensures adequate bonding coverage in each specific region while minimizing overall adhesive consumption.
Solution Approach 2:
Instead of applying adhesive excessively to all regions, the patent applies adhesive partially and selectively to specific regions where it is actually needed. The intermittent application pattern ensures sufficient bonding coverage in critical areas while avoiding unnecessary adhesive application in other areas, reducing waste.
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 efficiency of adhesive application, reduces waste, and lowers production costs by ensuring that only necessary adhesives are used in specific regions, improving the overall manufacturing process for elasticized absorbent articles.
Implementation Method 1
applying a first adhesive intermittently to at least one of the plurality of elastomeric strands, applying a second adhesive intermittently to at least one of the lower surface of the first continuous substrate material and the upper surface of the second continuous substrate material
Data Source
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AI summary
Absorbent articles and methods of manufacturing absorbent articles are disclosed. In one embodiment, an absorbent article may comprise a chassis comprising an elasticated front waist panel, and elasticated rear waist panel material, and an absorbent insert coupled to the front and rear waist panels. The front waist panel may comprise a garment facing web, a body facing web, and a plurality of elastomeric strands disposed between the garment facing web and the body facing web. The front waist panel may further comprise a first front panel adhesive region comprising a first adhesive but not a second adhesive and a second front panel adhesive region comprising the second adhesive but not the first adhesive. The rear waist panel may comprise the same components and adhesive regions as the front waist panel. An absorbent insert may also be coupled to the front waist panel and the rear waist panel.