Post-Bonded Grooved Elastic Laminate Fiber Pullout
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Solution Overview
Problem
Current methods for producing elastic laminates are costly and inefficient, particularly in achieving the desired level of softness and elasticity, especially when using meltblown or spunbond facings, which often result in fiber pullout and reduced durability in absorbent article applications.
Innovation Solution
A method involving the joining of an elastic film with a meltblown or spunbond nonwoven facing, where the laminate is grooved to decouple the facing from the elastic film, and then bonded using patterned rolls at controlled temperatures and pressures to enhance elasticity and prevent fiber pullout, achieving at least 200% elongation in the cross-machine direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a nonelastic component is joined to an elastic component while the elastic component is in a stretched condition (stretch bonding), then the resulting elastic laminate material is stretchable, but the manufacturing cost increases significantly
Solution Approach 1:
The elastic component is stretched and bonded to the nonelastic component before final use, preparing the laminate in advance with predetermined stretch properties. This preliminary stretching action allows the material to be pre-configured for its intended application, eliminating the need for expensive post-production stretching operations while ensuring consistent elastic performance.
2Adaptability or versatility
If a bonded carded web is used as nonwoven facing and grooved to decouple from elastic film, then cross-machine direction stretch is enabled, but the process becomes expensive and time consuming with increased fiber pull out
Solution Approach 1:
The patent employs a spunbond nonwoven facing with longer fibers that can be grooved without requiring expensive bonded carded web construction. The spunbond structure allows for cost-effective production while maintaining the necessary stretch properties, replacing the more complex and costly bonded carded web process with a simpler, more efficient alternative that produces similar functional results.
Solution Approach 2:
The patent changes the fiber length parameter from short (in bonded carded web) to long (in spunbond), which fundamentally alters how the material responds to grooving. Longer fibers in the spunbond structure allow for effective grooving that enables cross-machine direction stretch while avoiding the fiber pull-out problems associated with short fibers, and eliminating the need for expensive bonding processes.
3Ease of manufacture
If meltblown facing is used and grooved to provide elasticity, then the facing is easily grooved, but the loosely configured appearance and lack of integrity reduce durability and increase fiber pull out
Solution Approach 1:
The patent combines spunbond nonwoven facing with elastic film in a laminate structure, creating a composite material that leverages the strengths of both components. The spunbond provides a stable, durable base with good grooveability, while the elastic film contributes stretch properties. This composite approach eliminates the need for expensive bonded carded webs and avoids the durability problems of meltblown materials, achieving both ease of manufacture and high reliability.
4Object-generated harmful factors
If spunbond facing with longer fibers is used instead of bonded carded web, then fiber pull out is reduced, but the facing cannot be grooved easily to provide elastic laminates that stretch and recover
Solution Approach 1:
The patent changes the fiber length parameter from short (bonded carded web) to long (spunbond), which fundamentally alters the material's response to grooving. Longer fibers in the spunbond structure provide better grooveability while reducing fiber pull-out, contrary to conventional wisdom. The extended fiber length allows the material to accommodate grooving stresses without excessive fiber extraction, enabling successful elastic laminate production with minimal harmful fiber pull-out.
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 method produces elastic laminates that are soft, durable, and resistant to fiber pullout, suitable for reusable applications like absorbent articles, with improved elasticity and reduced manufacturing costs.
Implementation Method 1
bonding occurs at a temperature ranging from about 65° F. to about 300° F.
Implementation Method 2
bonding occurs at a pressure ranging from about 5 psi to about 100 psi
Implementation Method 3
the laminate is fed in between the two rolls with sufficient nip pressure to groove the nonwoven facing such that the grooving decouples the nonwoven facing from the elastic film
Implementation Method 4
the elastic film is in an unstretched state... the laminate can be stretched, and once the stretching force is removed, the material can retract and recover
Data Source
AI summary
An elastic nonwoven laminate that contains an elastic film laminated to one or more nonwoven facings is provided. The nonwoven facing contains a conventional polyolefin and can also contain a polyolefin-based plastomer. The laminate is activated by grooving to decouple the nonwoven facing from the elastic film. To reduce fiber-pull out that can result due to activation by grooving, the laminate can be post-bonded at room or elevated temperatures and a specific range of pressures to compact the fibers of the facing and minimize fiber pull-out/fuzziness while not sacrificing the softness, elasticity, and feel of the laminate.