Stretch Laminate Beamed Elastics Gather Control
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Solution Overview
Problem
Current stretch laminates used in wearable absorbent articles face challenges in cost-effectiveness, breathability, and appearance due to the use of either expensive elastic films or bulky elastic strands, which also affect the integration of decorative elements.
Innovation Solution
The use of beamed elastics in stretch laminates, which involves closely spaced, low decitex elastic strands provided on a single spool, offers a cost-effective solution that enhances breathability and reduces the size and frequency of gathers, thereby improving the appearance and functionality of the laminates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elastic film is used in stretch laminates, then the laminate provides good stretchability and fit, but the cost increases and breathability decreases
Solution Approach 1:
The patent replaces expensive elastic film with inexpensive elastic strands that can be disposed of after providing their stretching function. The elastic strands are designed to be cost-effective while maintaining the necessary stretchability for the laminate structure.
Solution Approach 2:
The patent uses elastic strands instead of solid elastic film, creating a porous structure that allows air circulation and improves breathability. The spaces between the strands enable moisture vapor transmission while maintaining structural integrity and stretchability.
2Ease of manufacture
If elastic strands are used in stretch laminates, then cost decreases and breathability increases, but the laminate develops large ruffles that affect appearance
Solution Approach 1:
The patent modifies key parameters of the elastic strands including decitex (from high to low), spacing (from widely spaced to closely spaced), and pre-strain levels. These parameter changes reduce the formation of large ruffles while maintaining cost-effectiveness and breathability.
Solution Approach 2:
The patent applies different properties to different regions of the laminate by using closely spaced elastic strands in specific areas to control gather formation locally, while maintaining open structures in other areas for breathability. This localized optimization improves overall appearance.
3Object-generated harmful factors
If elastic strands are used in stretch laminates, then breathability improves, but decorative elements become folded and less recognizable
Solution Approach 1:
The patent reduces the decitex of elastic strands and increases their spacing to minimize gather size and frequency. This allows decorative elements printed on the laminate surface to remain visible and recognizable even when the laminate is stretched or contracted.
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
Beamed elastics in stretch laminates result in a more cost-competitive, breathable, and visually appealing product with reduced skin marking and increased wearer comfort, while allowing for better integration of decorative elements.
Implementation Method 1
the elastic material is pre-strained along a stretch direction during the manufacturing process, and sandwiched and affixed between the layers while in the pre-strained condition. Following completion of manufacture, the elastic material contracts toward its relaxed dimension(s), causing the sandwiching layers to gather along the stretch direction
Data Source
AI summary
A stretch laminate is disclosed. The stretch laminate may include a layer of nonwoven material that includes an accumulation of filaments and has an inner surface and an outer surface, the outer surface having an ordered arrangement of zones, each zone having an attenuated region adjacent to a build-up region wherein the attenuated region has a first basis weight and the build-up region has a second basis weight greater than the first basis weight, the difference in basis weights corresponding to disposition of the filaments according to the ordered arrangement. The stretch laminate may include a plurality of elastic strands space apart from each other in a crotch-stretch direction. In some examples the elastic strands may have an Average Strand Spacing no greater than 3 mm and/or an Average Decitex no greater than 300, and/or an Average Pre-Strain no greater than 250 percent.