Stretchable sheets comprising a variety of layers and zones and methods to produce such products
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Solution Overview
Problem
Existing methods for producing stretchable and elastic products are limited in creating unified sheets with varying zones and properties, requiring multiple materials and processes, which increases complexity and cost.
Innovation Solution
A method involving controlled spraying of resilient elastomers onto a workpiece former to create sheets with multiple zones, each with distinct composite materials, thicknesses, and porosity levels, allowing for a seamless, unified sheet with different performance characteristics without the need for attaching separate materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate materials are attached together to create sheets with varying zones and properties, then the sheet can achieve different performance characteristics in different areas, but the process complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple materials with different properties into a single unified sheet structure. Different zones within the sheet contain different materials (e.g., absorbent particles, fibers, barriers) that are integrated during a single manufacturing process, eliminating the need to attach separate materials together and reducing process complexity while maintaining performance versatility
Solution Approach 2:
The patent creates sheets with spatially varying properties by distributing different materials to specific zones within the sheet. Each zone can be tailored with appropriate materials and concentrations to provide localized functionality (e.g., higher absorbency in certain areas, barrier properties in others) while maintaining a unified sheet structure
2Adaptability or versatility
If multiple separate materials are attached together to create sheets with varying zones and properties, then the sheet can achieve different performance characteristics in different areas, but the manufacturing cost increases
Solution Approach 1:
The patent combines multiple materials with different properties into a single unified sheet structure. Different zones within the sheet contain different materials (e.g., absorbent particles, fibers, barriers) that are integrated during a single manufacturing process, eliminating the need to attach separate materials together and reducing process complexity while maintaining performance versatility
Solution Approach 2:
The patent creates a unified sheet structure that serves multiple functions simultaneously. The same sheet provides absorbency, barrier protection, flexibility, and structural integrity through the integration of different materials in different zones, eliminating the need for multiple separate components and reducing manufacturing costs
3Device complexity
If traditional methods are used to create unified sheets with varying zones, then the sheet structure can be simplified, but the ability to produce thin, breathable sheets with varied properties is limited
Solution Approach 1:
The patent creates sheets with spatially varying properties by distributing different materials to specific zones within the sheet. Each zone can be tailored with appropriate materials and concentrations to provide localized functionality (e.g., higher absorbency in certain areas, barrier properties in others) while maintaining a unified sheet structure
Solution Approach 2:
The patent incorporates porous structures and breathable materials in specific zones of the sheet. The controlled distribution of porous absorbent materials and the creation of microporosity regions allow the sheet to provide breathability and fluid absorption capabilities while maintaining a simple unified structure
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 reduces process steps and costs, enabling the production of thin, stretchable, and breathable sheets with varied properties in a single unified product, enhancing utility and application across industries such as medical, food, and personal hygiene.
Implementation Method 1
using variety of controlled spraying units for spraying the principal material or materials onto a surface of a wall such as a workpiece former
Implementation Method 2
The resulting product is a sheet having at least two different zones unified within the sheet
Data Source
AI summary
The invention provides methods for producing flexible, stretchable, and/or elastic sheets and products having two or more zone having different material features and performance. The products can be comprised of material such as natural elastomers and other synthetic polymers. The method for producing stretchable products by spraying product material of different types over different zones of a workpiece former or conveyor belt.