Slit Web Elastic Arrangement for Wearable Articles
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Solution Overview
Problem
Conventional methods for manufacturing stretchable sheets with around-torso and around-leg elastic members require separate steps for arranging elastic members in straight and curved configurations, leading to increased material and equipment costs due to the need for multiple webs and complex welding processes.
Innovation Solution
A method involving slitting a single continuous web into wider and narrower divisions to sandwich and weld around-torso elastic members, and using the narrower division to bond around-leg elastic members in a curved pattern with an adhesive, reducing the number of material rolls and equipment costs while allowing for flexible elastic member arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If elastic members are arranged in a curved path, then the stretchable sheet can fit the torso and prevent leakage, but the conventional welding method cannot accommodate curved arrangements
Solution Approach 1:
The single continuous web is slitted into multiple divided webs (first divided web and second divided web) along the carrying direction. This segmentation allows different portions of the elastic members to be arranged in different configurations (straight in first divided web, curved in second divided web) while using a single source material, resolving the contradiction between curved arrangement capability and manufacturing complexity
Solution Approach 2:
The invention transitions from arranging all elastic members in a single-dimensional straight line to utilizing multiple dimensional paths by creating divided webs that can follow different trajectories. The first divided web carries elastic members in a straight path while the second divided web carries elastic members in a curved path, enabling both straight and curved arrangements simultaneously
2Adaptability or versatility
If separate steps are used for straight and curved elastic member arrangements, then both configurations can be achieved, but at least three webs are required increasing material and equipment costs
Solution Approach 1:
The invention merges the functions of multiple separate webs into a single continuous web that is subsequently slitted into divided webs. The single continuous web serves as the source for both the first divided web (carrying straight elastic members) and the second divided web (carrying curved elastic members), reducing material rolls from three or more to one while maintaining arrangement flexibility
Solution Approach 2:
The single continuous web performs multiple functions: it is the source material for both straight and curved elastic member arrangements, and it provides the base structure for both first and second divided webs. This multi-functionality eliminates the need for separate dedicated webs for each elastic member configuration, reducing both material quantity and equipment requirements
3Adaptability or versatility
If multiple rolls of material fabric are used for different web configurations, then straight and curved elastic members can be arranged separately, but material fabric cost and equipment cost increase
Solution Approach 1:
The single continuous web is segmented into first and second divided webs through slitting, allowing separate arrangement of straight and curved elastic members while using a single material source. This segmentation enables independent processing of different elastic member types without requiring multiple separate material handling systems, reducing equipment complexity and cost
Solution Approach 2:
The single continuous web serves as a universal source material for both straight and curved elastic member configurations. By making the single web universal for both purposes, the invention eliminates the need for multiple specialized material feeds and handling equipment, significantly reducing equipment investment while maintaining the capability for separate arrangement of different elastic members
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
This approach reduces material and equipment costs by using fewer rolls of fabric and enabling the arrangement of around-leg elastic members in a wave-like pattern, enhancing the flexibility and fit of the stretchable sheet without making it stiff.
Implementation Method 1
a welding step of welding together the first divided web W11, the second continuous web W2 and the around-torso elastic member FT intermittently in the carrying direction
Implementation Method 2
a bonding step of sandwiching an around-leg elastic member FL meandering relative to the carrying direction between the layered sheet S and the narrower second divided web W12, and attaching the around-leg elastic member FL to the layered sheet S and the second divided web W12 by an adhesive
Data Source
Figure 1(a)~1(c)
Figure 2(a)~2(k)
Figure 3(a)~3(c)
AI summary
A method including: a step of carrying first and second continuous webs in a predetermined carrying direction; a first slitting step of slitting the first continuous web along a virtual first cut-off line extending the carrying direction, thereby dividing the first continuous web into a wider first divided web and a narrower second divided web; a step of sandwiching an around-torso elastic member extending in a girth direction between the wider first divided web and the second continuous web; a welding step of welding together the first divided web, the second continuous web and the around-torso elastic member intermittently in the carrying direction, thereby producing a layered sheet; and a bonding step of sandwiching an around-leg elastic member meandering relative to the carrying direction between the layered sheet and the narrower second divided web, and attaching the around-leg elastic member thereto by an adhesive, thereby producing a stretchable continuous sheet.