Stretch Laminate Anchoring Zones for Absorbent Articles
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Solution Overview
Problem
The manufacturing of stretch laminates for absorbent articles is complex and costly, requiring extensive processes, and existing methods do not effectively balance fit and cost-effectiveness across various body types.
Innovation Solution
The development of a stretch laminate comprising a chassis with an elastomeric film and cover layers, featuring pre-activated elastomeric films with textured surfaces for enhanced bonding and extensibility, which includes anchoring and stretch zones with activation stripes for improved flexibility and fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional stretch laminates are used to achieve proper fit and containment, then the article can accommodate various body types, but the manufacturing process becomes complex and costly
Solution Approach 1:
The stretch laminate is divided into distinct functional zones: anchoring zones with high bonding strength to secure the laminate to the chassis, and stretch zones with enhanced extensibility to accommodate body movement and shape variation. This segmentation allows each zone to be optimized independently, achieving versatile fit without requiring complex overall manufacturing processes.
Solution Approach 2:
Different regions of the stretch laminate are given different properties: anchoring zones have increased adhesive bonding strength and skin layer density for secure attachment, while stretch zones have higher elastomeric content and optimized layer structure for maximum flexibility. This local differentiation enables the single laminate to serve multiple functions across various body types without complicating the base manufacturing process.
2Adaptability or versatility
If traditional stretch laminates are used to achieve proper fit and containment, then the article can accommodate various body types, but the manufacturing cost increases
Solution Approach 1:
The elastomeric film is pre-activated with a textured surface pattern before lamination, creating predetermined activation stripes that guide the stretching behavior. This preliminary action ensures consistent stretch zones are formed during manufacturing, eliminating the need for complex post-processing or precise real-time control during assembly, thereby reducing overall manufacturing costs while maintaining adaptability.
Solution Approach 2:
The skin layer of the elastomeric film is modified with specific surface energy characteristics and textured patterns that enhance adhesive bonding in anchoring zones while maintaining extensibility in stretch zones. By adjusting the skin layer properties (surface energy, texture, thickness) rather than changing the entire laminate structure, the manufacturing process remains simple and cost-effective.
3Ease of operation
If the elastomeric film is made more extensible to improve fit, then the article accommodates body movement better, but the bonding strength may be reduced
Solution Approach 1:
The laminate is segmented into anchoring zones and stretch zones. In anchoring zones, the skin layer has higher density and optimized adhesive properties to ensure strong bonding. In stretch zones, the elastomeric film has higher extensibility with slightly modified layer composition. This spatial segmentation allows the laminate to exhibit both strong bonding and high extensibility without compromise.
Solution Approach 2:
The stretch laminate is a composite structure combining the elastomeric film with skin layers and adhesive layers. The skin layers provide bonding interfaces while the elastomeric core provides extensibility. By optimizing the composite structure—specifically the thickness and properties of each layer—the laminate achieves simultaneous bonding strength and extensibility, with anchoring zones having stronger adhesive bonds and stretch zones having more flexible composite construction.
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 solution reduces manufacturing complexity and cost while providing better fit and containment across a range of body types, enhancing the performance and durability of absorbent articles by improving the bonding strength and extensibility of the stretch laminate.
Implementation Method 1
an elastomeric film disposed between the first cover layer and the second cover layer
Implementation Method 2
The stretch laminate includes a first cover layer, a second cover layer, and an elastomeric film disposed between the first cover layer and the second cover layer
Data Source
AI summary
An absorbent article includes a chassis comprising a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet, and at least one elastically elongatable panel joined to the chassis. The elastically elongatable panel includes a stretch laminate that has at least one cover layer and an elastomeric film attached to the cover layer, the elastomeric film having two surfaces and a skin on at least one of the surfaces. The stretch laminate has at least one anchoring zone and at least one stretch zone and the skin that is located in the anchoring zone has a plurality of activation stripes.