3D-elastic laminates with printed ink structures
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Solution Overview
Problem
Elastic films used in absorbent and protective articles face challenges in achieving controlled stretch properties while maintaining aesthetic appeal and tactile comfort, as well as preventing blocking when wound into rolls, and require cost-effective production methods that do not rely on extensive adhesive and lamination processes.
Innovation Solution
A machine-direction and cross-machine-direction elastic film with three-dimensional ink structures printed in specific patterns on its surface, allowing for controlled stretch and tear properties, and optionally laminated with a nonwoven facing to enhance tactile properties without the need for extensive facing layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If nonwoven facings are attached to one or both sides of elastic films to improve drape and hand, then the tactile comfort and aesthetic appeal are improved, but the production cost and process complexity increase due to additional adhesive and lamination steps
Solution Approach 1:
The nonwoven facing is segmented into discrete islands rather than covering the entire film surface. These facing islands are strategically positioned in areas requiring tactile comfort (such as waist and leg regions), while leaving other areas exposed to maintain elasticity and reduce lamination complexity. This segmentation resolves the contradiction by providing targeted tactile enhancement without requiring complete surface coverage.
Solution Approach 2:
Different regions of the elastic film receive different treatments: some areas have nonwoven facing attached for tactile comfort, while other areas remain as bare elastic film for stretchability. This local differentiation allows the product to simultaneously achieve comfort where needed and elasticity where required, without the need for uniform lamination across the entire surface.
2Ease of operation
If nonwoven facings covering the entire film surface are used to improve drape and hand, then the aesthetic appeal is improved, but the production cost increases due to extensive adhesive and lamination steps
Solution Approach 1:
The facing material is applied in segmented islands rather than as a continuous layer. This segmentation dramatically reduces the amount of adhesive required and simplifies the lamination process, thereby reducing production costs while still providing aesthetic enhancement in critical visual areas.
Solution Approach 2:
Instead of applying facing material to the entire film surface (excessive action), the invention applies facing material only to specific regions where aesthetic appeal is most important (partial action). This partial application achieves the desired cosmetic effect while significantly reducing material costs, adhesive consumption, and processing time.
3Productivity
If elastic films are wound into rolls for storage, then the films are easy to store and transport, but the films block or become sticky and fuse/adhere to each other, making handling challenging during conversion
Solution Approach 1:
The outer surface of the elastic film is modified with a microtextured coating that creates localized asperities. This microtexturing is applied only to the surface layer, providing anti-blocking properties where films contact each other during rolling and storage, while the bulk film properties remain unchanged to maintain elasticity and stretch characteristics.
Solution Approach 2:
A thin, cost-effective microtextured coating is applied to the film surface to prevent blocking. This coating acts as a sacrificial layer that prevents adhesion between films during storage but does not compromise the long-term performance of the elastic film itself.
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 film achieves controlled stretch and tear resistance, prevents blocking when rolled, and maintains aesthetic appeal, all while reducing production costs by eliminating the need for extensive adhesive and lamination steps.
Implementation Method 1
The outer surface of the elastic film can be printed with a pattern... The pattern can comprise an individual line, groups of lines, groups of S-shapes, groups of discrete dots, groups of repeating geometric shapes, or combinations thereof
Implementation Method 2
an elastic film having a machine direction and a cross-machine direction... wherein the film is stretchable along the continuous gap in a direction that is generally perpendicular to the predominant direction in which the three-dimensional ink structures extend
Data Source
AI summary
An aesthetically pleasing elastic film with three-dimensional characteristics is provided. In one embodiment, a two-dimensional ink structure is printed onto an elastic film, which is then activated, for example, by heat, which transforms the two-dimensional ink structure into a three-dimensional ink structure on one or more outer surfaces of the film. The location and amount of ink applied can be selectively controlled so that the film has the desired hand feel without sacrificing the elastic properties of the film. Further the printing and activating of the ink can be controlled to increase the tear resistance of the film or to conversely allow the film to tear or rip at desired locations on demand. In another embodiment, the elastic film can be laminated to a facing to form a laminate, where the outer surface of the film that is not in contact with the facing contains the three-dimensional ink structures.