Stretch Laminate Without Mechanical Activation
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Solution Overview
Problem
The manufacturing of stretch laminates for absorbent articles, such as diapers, is complex and costly due to extensive pre-processing and post-processing steps, making it challenging to produce cost-effective products that fit a wide range of body types while maintaining leakage containment.
Innovation Solution
A stretch laminate comprising an elastomer film and a nonwoven material, where the tensile behavior in the transverse direction is within 2.5 N/cm at an engineering strain of 1.5, achieved without mechanical activation, and a method of attaching these layers using adhesives, eliminating the need for pre- and post-processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional stretch laminate fabrication methods are used with pre-processing and post-processing steps, then the tensile behavior and fit quality are improved, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The elastomer film is pre-stretched during the lamination process itself rather than requiring separate pre-processing steps. The film is stretched to a specific gauge length before bonding to the nonwoven layers, and this stretched state is maintained throughout the lamination process, eliminating the need for subsequent mechanical activation steps.
Solution Approach 2:
Multiple process steps are merged into a single lamination operation. The stretching, bonding, and finishing operations are combined into one continuous process where the elastomer film is stretched and bonded to nonwoven layers simultaneously, eliminating separate pre-processing and post-processing steps.
2Reliability
If extensive pre-processing and post-processing steps are implemented, then the fit quality and leakage containment are improved, but the production cost and time increase
Solution Approach 1:
The lamination process is designed as a continuous operation where the elastomer film is stretched, bonded to nonwoven layers, and finished in one uninterrupted sequence. This eliminates idle time between processing steps and maintains continuous production flow, reducing overall fabrication time while ensuring consistent quality.
3Manufacturing precision
If mechanical activation steps are added to achieve proper tensile behavior, then the fit accuracy is improved, but the manufacturing simplicity and cost-effectiveness deteriorate
Solution Approach 1:
The elastomer film's inherent elastic properties are utilized to provide the necessary tensile behavior without requiring external mechanical activation equipment. The film's natural recovery characteristics, combined with the stretching applied during lamination, self-regulate the fit properties of the final product.
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 solution simplifies the fabrication process, reduces costs, and maintains the necessary tensile properties for effective fit and leakage containment across various body types without requiring mechanical activation, resulting in a more affordable and efficient production method.
Implementation Method 1
a second layer comprising a nonwoven material, the second layer having a surface that is attached to the surface of the first layer
Data Source
AI summary
A stretch laminate includes a first layer including an elastomer film, the first layer having a surface, and a second layer including a nonwoven material, the second layer having a surface that is attached to the surface of the first layer. The tensile behavior in the transverse direction of the stretch laminate is within about 2.5 N/cm of the tensile behavior in the transverse direction of the film at an engineering strain of about 1.5, and exists independent of mechanical activation. A method of making the stretch laminate and an absorbent article having at least one region defined by the stretch laminate are also provided.