Segmented Film Overlap Design for Interface Strength
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Solution Overview
Problem
Segmented films used in various applications often exhibit weakness at the interface between different segments due to lack of cohesiveness, leading to potential tearing issues.
Innovation Solution
A segmented film design where one segment overlaps the other significantly at the interface, with a feed block allowing early contact of the segments before extrusion, and subsequent stretching to enhance cohesion and breathability, using polymers like polyolefins and elastomers to create a strong and breathable film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If segmented films are used to provide different properties to different areas, then functional versatility is improved, but interface strength deteriorates due to lack of cohesiveness between segments
Solution Approach 1:
The feed block is designed to allow early contact between segments from different extruders before the film is fully formed. This preliminary interaction at the feed block enables better bonding and cohesiveness between segments, preventing interface weakness while maintaining functional versatility
Solution Approach 2:
The invention uses composite material structures where segments from different extruders are combined in a controlled manner. The feed block facilitates integration of these different materials, creating a composite film structure that maintains both functional diversity and interface strength
2Stability of the object's composition
If segments are joined at the interface, then structural continuity is improved, but breathability deteriorates due to reduced porosity at the seam
Solution Approach 1:
The invention maintains porous structure at the segment interfaces by controlling the extrusion and forming process. The feed block design allows segments to bond while preserving porosity, ensuring that breathability is maintained even at the seams where structural continuity is achieved
Data Source
Figure 1A~1
Figure 2~3
AI summary
Unitary films and laminates thereof are provided having at least first and second film segments which extend adjacent one another and are permanently joined together. The first and second film segments are joined at an interface, wherein at the interface a tip of the second segment overlaps the first segment in the cross-direction of the film. The film has a thickness "T" at the tip of the second segment, and the second segment has a thickness "t" at a distance T in the cross direction from the tip of the second segment. The ratio T/t is suitably greater than about 3. The unitary films and laminates thereof are well suited, for example, for use as outer covers in personal care articles.