Low-Bulk Disposable Pant Belt Using Pre-Strained Elastic Film Laminate
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Solution Overview
Problem
Current disposable absorbent pants with a belt configuration have a bulky appearance due to ruffles or gathers caused by pre-strained elastic strands, which may be perceived negatively by consumers, especially older children who prefer a more underwear-like design.
Innovation Solution
The use of a laminate structure with a laterally pre-strained elastic film member between nonwoven layers, which forms gathers that are small and dense, giving a thin, cloth-like appearance, and the addition of supplemental elastic members to ensure a snug fit and reduce bulkiness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pre-strained elastic strands are used in the belt structure, then elastic stretch and contraction are provided to facilitate donning and provide snug fit, but ruffles or gathers are formed that create a bulky appearance
Solution Approach 1:
The patent changes the physical state and distribution of elastic elements by using a continuous elastic film with controlled pre-strain rather than discrete elastic strands. This parameter change in elastic element configuration reduces the formation of large ruffles while maintaining the necessary stretch and contraction properties for easy donning and snug fit.
Solution Approach 2:
The patent employs a composite belt structure consisting of a stretch laminate formed by bonding a nonwoven fabric to an elastic film. This composite material combination allows the belt to provide elastic functionality while the nonwoven fabric layer controls and distributes the gathers, reducing bulkiness and creating a smoother appearance that resembles underwear rather than traditional diapers.
2Adaptability or versatility
If an encircling elastic belt structure is used, then considerable elastic stretch and contraction are provided about the wearer's waist, but the belt occupies volume and contributes to bulky appearance
Solution Approach 1:
The patent replaces traditional discrete elastic strands with a thin, continuous elastic film that is bonded to a nonwoven fabric. This thin film structure provides the necessary elastic adaptability and stretch while occupying minimal volume, thereby reducing the bulky appearance of the belt region while maintaining functional performance.
3Ease of operation
If ruffles or gathers are formed in the belt structure, then softness and breathability are imparted to the belt, but a ruffled or frilly appearance is created that may be perceived negatively
Solution Approach 1:
The patent applies local quality by using a nonwoven fabric layer in the belt structure that provides softness and breathability at the contact points with the wearer's skin, while the overall belt structure maintains a smooth, flat appearance. The nonwoven fabric's inherent properties provide comfort locally without creating unwanted ruffles or gathers that would affect the overall aesthetic appearance.
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 results in a pant with a reduced bulky appearance and improved fit, addressing consumer preferences for a more underwear-like design while maintaining necessary elasticity and comfort.
Implementation Method 1
the elastic strands contract toward their unstrained lengths and draw the nonwoven web layers along with them, causing the nonwoven web layers to form ruffles or gathers of material along the lateral length of the belt structure
Data Source
AI summary
A low-bulk disposable absorbent pant for a child is disclosed. The pant may have a belt structure formed of a stretch laminate of a pre-strained elastic film between two nonwoven layers. The belt may have a relaxed lateral size and a stretched lateral size that is at least 150% of the relaxed lateral size, the relaxed lateral size being no more than 400 mm. The pant may include one or more of waistband, leg band and supplemental elastic members.