Split-Layer Elastomeric Films for Tear Resistance
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Solution Overview
Problem
Elastomeric films used in disposable hygiene products are prone to tearing and have high activation defects, leading to leakage issues, and current cost-effective solutions for improving tear resistance and elastic properties are limited.
Innovation Solution
The development of co-extruded split-layer elastomeric films with a structure A-(B-C)n-B-A, where B is an elastic layer and A and C are inelastic layers, with the C-layers not exceeding 5% of the total thickness, enhancing tear strength and elastic properties while reducing activation defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If relatively thick elastomeric films are used to reduce activation defects, then reliability is improved, but device complexity and material consumption increase
Solution Approach 1:
The patent applies composite materials by creating a multilayer film structure combining elastomeric layers (B) with inelastic layers (A and C). This composite structure achieves superior tear resistance and reduced activation defects without requiring increased overall film thickness, as the layered configuration provides enhanced mechanical properties through material synergy rather than simple thickness accumulation.
Solution Approach 2:
The patent segments the elastomeric film into multiple functional layers with the structure A-(B-C)n-B-A. The elastomeric layers (B) are divided and separated by inelastic layers (A and C), creating a segmented architecture that prevents defect propagation and enhances tear resistance. This segmentation allows the film to maintain reliability while using thinner overall material.
2Productivity
If elastomeric films are made thinner to reduce material consumption, then productivity is improved, but strength deteriorates
Solution Approach 1:
The composite multilayer structure provides enhanced strength-to-thickness ratio by combining elastomeric and inelastic materials in specific configurations. The inelastic layers (A and C) act as reinforcement that prevents tear propagation through the elastomeric layers (B), enabling thin-film applications with adequate tear strength for hygiene products.
Solution Approach 2:
The patent applies local quality by assigning different functional properties to different layers: elastomeric layers (B) provide stretchability and comfort, while inelastic layers (A and C) provide tear resistance and structural stability. This localized functional differentiation allows the thin film to achieve both material efficiency and adequate strength through optimized layer-specific properties.
3Ease of manufacture
If conventional multi-layer films are used without thickness control of inner layers, then ease of manufacture is maintained, but tear strength deteriorates
Solution Approach 1:
The patent applies parameter changes by establishing a specific thickness constraint for the inelastic inner layers (C), limiting them to 5% or less of the total film thickness. This quantitative parameter specification transforms the manufacturing process from conventional multi-layer film production into a controlled coextrusion process that achieves superior tear strength while maintaining ease of manufacture through standardized parameter ranges.
Solution Approach 2:
The patent applies local quality by controlling the thickness of specific inner layers (C) relative to the total film structure. This localized thickness control of the inelastic separator layers optimizes their function in preventing tear propagation while maintaining overall film flexibility and manufacturability through coextrusion processing.
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 films exhibit significantly improved tear resistance, superior elastic properties, and cost-effectiveness, with increased stretchability and reduced activation defects, making them suitable for disposable hygiene products.
Implementation Method 1
when the C-layers each are not allowed to exceed 5% of the total thickness of the film, the films exhibit surprisingly superior tear strength relative to a comparative film
Implementation Method 2
the films exhibit surprisingly superior tear strength relative to a comparative film
Implementation Method 3
B is an elastic layer comprising polymeric composition B
Implementation Method 4
A and C are inelastic layers each having a thickness and each comprising individually at least one of polymeric compositions A and C
Data Source
AI summary
Split-layer thermoplastic films having the structure A-(B-C)n-B-A, wherein A and C are inelastic layers each having a thickness and each comprising individually at least one of polymeric compositions A and C; B is an elastic layer comprising polymeric composition B, n≥1, and wherein the layers comprising (B-C)n-B have a combined thickness x, polymeric compositions A and C comprise an inelastic polymer; polymeric composition B comprises an elastomeric polymer; and the thickness of C comprises 5% or less of the total thickness of the film; and further wherein the film has a notched Elmendorf tear strength of at least twice the notched Elmendorf tear strength of a comparative thermoplastic film having the structure A-B-A, wherein A and B comprise substantially the same polymeric compositions A and B as the thermoplastic film, and wherein the B-layer of the comparative thermoplastic film has a thickness y which is substantially equal to x.