Latent Elastic Laminate Handling via Controlled Polymer Bonding
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Solution Overview
Problem
Conventional elastic laminate materials are challenging to manipulate during trimming and incorporation into end products due to their low-density, highly porous nature, and high levels of meltblown adhesive can result in stiffness and increased costs, while latent elastic polymers often lack sufficient retraction forces.
Innovation Solution
The development of latent elastic laminate materials featuring a latent polymer applied to elastic members, which bonds them to substrates, allowing for controlled retraction when heated, enabling easy handling during converting processes without sacrificing elastomeric properties. This involves applying the latent polymer at a basis weight between 2 and 60 gsm, using smooth roll calendering, and incorporating it in forms like filaments or film, with optional adhesives to secure the laminate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional elastic laminate materials are used, then elastomeric properties are provided, but the materials are challenging to manipulate during trimming and incorporation due to low-density, highly porous nature
Solution Approach 1:
The patent applies a latent polymer coating to the elastic laminate before the trimming and incorporation steps. This preliminary application of adhesive material prepares the surface in advance, enabling easy manipulation during subsequent converting operations without requiring excessive vacuum pressure or mechanical restraint.
Solution Approach 2:
The latent polymer acts as an intermediary substance between the elastic laminate and the substrate or handling equipment. By applying this polymer coating, the patent creates a mediating layer that facilitates bonding and control during manufacturing operations, resolving the handling difficulties caused by the porous structure.
2Ease of operation
If high levels of meltblown adhesive are applied to the laminate, then vacuum control is improved, but the laminate becomes unduly stiff and costs increase
Solution Approach 1:
The patent changes the parameters of the adhesive application by using a latent polymer with specific glass transition temperature characteristics and applying it at controlled basis weights. This parameter optimization allows sufficient adhesive performance for vacuum control while preventing excessive stiffness that would result from high levels of conventional meltblown adhesive.
Solution Approach 2:
The latent polymer exhibits phase transition behavior based on temperature, remaining flexible at processing temperatures but providing adequate bonding. This thermal sensitivity allows the material to be manipulated easily during converting operations while still achieving sufficient adhesion, avoiding the stiffness problem associated with permanent high-adhesive formulations.
3Ease of operation
If latent elastic polymers are used to simplify material handling, then ease of manipulation is improved, but sufficient retraction forces are lacking
Solution Approach 1:
The patent applies a partial coating of latent polymer rather than attempting to use the elastic polymer itself for both handling and retraction functions. This partial application provides just enough adhesive force for easy manipulation during converting operations while preserving the full retraction capability of the underlying elastic members, avoiding the force loss that occurs when excessive polymer is applied.
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 latent elastic laminate materials can be easily controlled during manufacturing processes, maintaining elastomeric properties and allowing for activation into an elastic, gathered structure, simplifying production and enhancing product performance in personal care garments and other applications.
Implementation Method 1
The latent polymer may bond the elastic members to one or more substrates
Implementation Method 2
when the laminate is heated to a softening point of the latent polymer
Implementation Method 3
allow the laminate to retract into an elastic, gathered structure
Implementation Method 4
The bonding may be carried out using smooth roll calendering
Data Source
AI summary
A latent elastic laminate material, and methods of making latent elastic laminate materials. The laminate includes a latent polymer, which itself may or may not possess latent elasticity, that is applied to at least one elastic member while the elastic member is in a stretched configuration. The elastic member, at least partially covered with the latent polymer, is attached to at least one substrate. The amount of latent polymer applied to the elastic member may provide enough force to overcome a retractive force of the elastic member when the latent polymer is at a temperature below a softening point of the latent polymer, yet the amount of latent polymer may be small enough to allow the laminate to retract into an elastic, gathered structure when the laminate is heated to a softening point of the latent polymer. The laminate may be incorporated into a variety of articles including personal care garments and cleaning cloths.