Non-stretch bonded elastic laminate cost reduction
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Solution Overview
Problem
Current elastic laminate technologies, such as stretch-bonded elastic laminates, are costly due to high usage of facing materials like spunbond and SMS nonwovens, which account for more than 50% of the total elastic laminate cost.
Innovation Solution
A composite nonwoven elastic web is formed by joining an elastic web with a core structure comprising an elastic core layer and a plastic core layer to a fibrous nonwoven web, using a non-stretch bonding process that involves stretching the elastic web to less than 100% and affixing the nonwoven web to the stretched elastic web, followed by relaxation and activation through processes like groove rolling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If stretch-bonded elastic laminate process is used with high usage of facing materials, then elastic laminate cost is reduced, but facing materials account for more than 50% of total elastic laminate cost
Solution Approach 1:
The patent changes the stretch ratio parameter from the conventional 300-500% to a reduced range of 50-150%, which fundamentally alters the bonding mechanism and reduces the quantity of facing materials needed while maintaining elastic laminate functionality
Solution Approach 2:
The patent uses composite materials by combining elastic web with thermoplastic polymers or adhesives to create effective bonding at lower stretch ratios, reducing reliance on large quantities of facing materials while achieving cost-effective elastic laminate production
2Reliability
If elastic web is stretched to 3-5 times its relaxed length, then bonding to facing materials is achieved, but cost of facing materials increases significantly
Solution Approach 1:
The patent changes the critical parameter of stretch ratio from 300-500% to 50-150%, which modifies the bonding mechanism to be more efficient and less material-intensive, thereby maintaining bonding effectiveness while reducing facing materials consumption
Solution Approach 2:
The patent introduces thermoplastic polymers or adhesives as intermediary bonding agents that enable effective bonding at lower stretch ratios, reducing the need for large quantities of facing materials while maintaining reliable attachment
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 the cost of elastic laminates by minimizing the usage of facing materials, while providing a soft, flexible, and cloth-like material with superior performance and consumer-preferred appearance, including desirable stretch-to-stop curves and breathability.
Implementation Method 1
stretching the elastic web to less than 100 percent stretch
Implementation Method 2
the plastic core layer reinforcing the core structure in the machine direction
Implementation Method 3
affixing a fibrous nonwoven web to the first surface of the stretched elastic web
Data Source
AI summary
A laminate includes a core structure having a first surface and a second surface, the core structure including an elastic core layer and a plastic core layer, wherein the elastic core layer is one of a film, a plurality of strands, and a plurality of strips, and wherein the plastic core layer is one of a film layer, a plurality of strands, and a plurality of strips, the plastic core structure reinforcing the core layer in the machine direction, and a nonwoven first facing layer affixed to the first surface.