Patterned Stranded Elastic Laminate Embossing
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Solution Overview
Problem
Current elastic laminates used in personal care garments face challenges such as high production costs, complex processing methods, and reduced elasticity when exposed to elevated temperatures, due to the properties of elastomeric adhesive compositions and the need for high adhesive add-on, which results in bulky and costly products with poor adhesion and tension decay.
Innovation Solution
A patterned elastic laminate is created by placing an elastic layer between two facing layers made by meltblown or spunbond processes, with the elastic strands stretched and attached to the layers, then embossed using an anvil roll pattern, allowing for improved elasticity and adhesion while reducing raw material usage and processing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high adhesive add-on is used to bond elastic strands to facing sheets, then strand slippage is reduced, but the laminate becomes bulky and costly
Solution Approach 1:
The adhesive layer is segmented into discrete bonding zones rather than continuous coverage. The embossed pattern creates localized bonding areas at high-stress points, reducing overall adhesive quantity while maintaining slippage resistance where needed most.
Solution Approach 2:
The laminate structure transitions from uniform adhesive distribution to non-uniform local bonding. Embossed features concentrate adhesive and bonding strength at specific locations, providing enhanced slippage resistance at critical areas while reducing bulk in non-critical areas.
2Stability of the object's composition
If elastomeric adhesive compositions are stretched and bonded between nonwoven substrates, then elasticity is achieved, but adhesion is lost when aged at elevated temperatures
Solution Approach 1:
The bonding process uses elevated temperature and pressure parameters to activate adhesion, then allows cooling to preserve elasticity. The embossing step creates a bonding pattern that maintains adhesion through thermal history management, preserving both adhesion and elastic properties after aging.
Solution Approach 2:
The laminate combines elastomeric adhesive with thermoplastic nonwoven substrates in a composite structure. This composite approach allows the adhesive to provide elasticity while the thermoplastic components contribute to thermal stability and adhesion retention during aging.
3Reliability
If elastomeric adhesive compositions are formulated with certain polymers, tackifiers, and plasticizers, then adhesion is achieved, but tension and adhesion deteriorate when stretched and aged
Solution Approach 1:
The formulation parameters of the elastomeric adhesive are optimized to balance adhesion and tension retention. The embossing process parameters (temperature, pressure, dwell time) are controlled to create bonds that preserve the adhesive's elastic properties, preventing tension decay during stretching and aging.
4Reliability
If film lamination is used to bond facing materials, then bonding is achieved, but the process becomes complex and requires precise control to prevent film breakage
Solution Approach 1:
The continuous film bonding process is replaced with segmented discrete bonding through embossing. This segmentation simplifies process control by eliminating the need for precise continuous film handling and tension control, reducing complexity while maintaining bonding strength at critical locations.
5Reliability
If high adhesive output is required for film formation, then bonding coverage is improved, but on-line processing becomes difficult due to equipment output capacity limitations
Solution Approach 1:
Instead of requiring high adhesive output for complete coverage, the embossing process applies adhesive partially at strategic bonding locations. This partial action approach reduces the total adhesive quantity needed, enabling on-line processing within equipment output capacity while achieving sufficient bonding coverage for product performance.
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 an elastic laminate with enhanced elasticity and adhesion properties, lower adhesive output requirements, and reduced bulk, leading to cost savings and improved performance in personal care applications.
Implementation Method 1
an unstretched or stretched plurality of strands of an elastomeric construction adhesive composition that is self-adhered to at least a first nonwoven facing layer or a second nonwoven facing layer
Implementation Method 2
embossed by passing through the nip of an anvil set of rolls
Data Source
AI summary
The present disclosure provides for an apparatus for using a patterned stranded elastic laminate. The stranded elastic laminate is patterned by an anvil roll. The current disclosure also includes a process for making a patterned elastic laminate The patterned elastic laminate provides an aesthetic effect and is visible at least in both the stretched and unstretched states.