Propylene Elastomer Polyalphaolefin Blend Elastic Film
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Solution Overview
Problem
Existing elastic laminates for applications like diaper waist bands and leg cuffs require adhesive tie layers for compatibility between elastic film and nonwoven fabric layers, increasing complexity and cost, while lacking the desired soft-stretch properties.
Innovation Solution
A blend composition comprising propylene-based elastomers and polyalphaolefins, where the propylene-based elastomer is a reactor blend with specific α-olefin content and properties, and the polyalphaolefin has defined kinematic viscosity, eliminating the need for adhesive tie layers and enhancing soft-stretch performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive tie layers are used to ensure compatibility between elastic film and nonwoven fabric layers, then bonding strength is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the adhesive tie layer from the laminate structure by developing an elastic film layer with inherent compatibility and bonding capability to propylene-based nonwoven fabrics, thereby simplifying the overall structure while maintaining bonding strength
Solution Approach 2:
The elastic film layer is designed to perform multiple functions simultaneously: providing elasticity, ensuring compatibility with propylene-based nonwoven fabrics, and enabling direct bonding without adhesive tie layers, thereby reducing structural complexity
2Reliability
If adhesive tie layers are added to ensure compatibility between layers, then bonding reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent eliminates the adhesive tie layer by incorporating compatibility agents directly into the elastic film layer composition, thereby reducing material costs and simplifying the manufacturing process while maintaining layer compatibility
Solution Approach 2:
The patent modifies the chemical composition parameters of the elastic film layer by incorporating specific propylene-based polymers and compatibility agents, enabling direct bonding to propylene-based nonwoven fabrics without additional adhesive layers
3Strength
If conventional elastic laminates are used, then structural integrity is maintained, but soft-stretch properties are insufficient
Solution Approach 1:
The patent optimizes the molecular weight distribution and composition ratios of propylene-based elastomers and polyalphaolefins in the elastic film layer to achieve both structural integrity and enhanced soft-stretch properties
Solution Approach 2:
The patent creates a composite elastic film layer by blending propylene-based elastomers with polyalphaolefins in specific ratios, combining the structural benefits of elastomers with the softness and stretchability of polyalphaolefins
Data Source
Figure 1
AI summary
Provided are blend compositions comprising a propylene-based elastomer and a polyalphaolefin. The blend compositions may be particularly useful in elastic film compositions, and especially useful as elastic film layers in nonwoven laminates. The film may comprise a blend of from about 0.5 to about 60 wt% of a polyalphaolefin and 40 to 99.5 wt% of a propylene-based elastomer. The film may comprise a blend of a propylene-base elastomer that comprises propylene and from 5 to 30 wt% of an a-olefin and a polyalphaolefin having a kinematic viscosity (KV) at 100 °C of from 3 to 3000 cSt.