Stretchable Elastic Member Manufacturing for Disposable Diapers
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Solution Overview
Problem
Existing methods for manufacturing stretchable elastic members for disposable diapers result in non-uniform appearance due to free movement of cut elastic members and excessive adhesive usage, leading to cost and air permeability issues.
Innovation Solution
A method involving the application of first and second adhesives at predetermined intervals on sheets, with specific non-application regions to control the cutting of elongated resilient and elastic members, ensuring they contract uniformly and reducing adhesive usage, using a cutting unit with a cutting roller and smoothing roller to maintain alignment and prevent wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is applied continuously to fix elongated resilient and elastic members, then the members are firmly fixed, but the manufacturing cost increases and flexibility is deteriorated
Solution Approach 1:
The adhesive application is segmented into intermittent patterns rather than continuous application. The patent applies adhesive at specific intervals along the sheet, creating discrete bonding zones that provide sufficient fixing strength while reducing overall adhesive consumption and manufacturing cost.
Solution Approach 2:
The patent implements different adhesive application characteristics in different regions. By varying the adhesive application pattern (intermittent vs. continuous) in different zones, the solution provides localized fixing strength where needed while maintaining flexibility and reducing cost in other areas.
2Strength
If adhesive is applied continuously to fix elongated resilient and elastic members, then the members are firmly fixed, but air permeability is significantly lowered
Solution Approach 1:
The adhesive application is divided into discrete intermittent segments rather than continuous coverage. This segmentation reduces the total quantity of adhesive applied while maintaining sufficient fixing strength at the bonded locations, thereby preserving air permeability through the sheet.
Solution Approach 2:
The patent applies adhesive partially rather than excessively. By using intermittent adhesive application, the solution provides just enough bonding strength required for the application, avoiding excessive adhesive that would block air permeability pathways.
3Ease of manufacture
If cut elongated resilient and elastic members are allowed to contract freely, then the cutting process is simple, but the members become bent or folded resulting in deterioration of appearance
Solution Approach 1:
The patent applies adhesive to the sheet before cutting the elongated resilient and elastic members. This preliminary adhesive application ensures that when the members are cut and contract, they remain properly positioned and aligned, preventing bending or folding that would deteriorate appearance.
Solution Approach 2:
The adhesive acts as an intermediary substance between the sheet and the elongated resilient and elastic members. It provides a bonding interface that controls the contraction behavior of cut members, maintaining their alignment and preventing unwanted bending or folding.
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 method enhances the appearance and cost-effectiveness of stretchable elastic members by preventing openings and wrinkles, while maintaining air permeability and ensuring uniform contraction of cut portions, thus improving the overall performance of disposable diapers.
Implementation Method 1
applying an adhesive to between two layers of sheets and arranging and fixing elongated resilient and elastic members
Implementation Method 2
cutting the elongated resilient and elastic members located in the non-application regions of the adhesive
Implementation Method 3
when the cut elongated resilient and elastic members contract, end portions of the cut elongated resilient and elastic members freely move
Data Source
AI summary
Provided is a method for manufacturing a stretchable elastic member excellent in appearance and reduced in manufacturing cost by applying a first adhesive to an inner surface of a sheet at one side at predetermined intervals, applying a second adhesive to elongated resilient and elastic members at predetermined intervals, forming first application regions in which the first adhesive is applied and first non-application regions between the first application regions and the adjacent first application regions, forming second application regions in which the second adhesive is applied over a large number of the first application regions and second non-application regions between the second application regions and the adjacent second application regions, fixedly installing, on an inner surface of the sheet at the one side, the elongated resilient and elastic members and a sheet at the other side at the outer side of the elongated resilient and elastic members, and cutting the elongated resilient and elastic members in sections in which the first non-application regions and the second application regions oppose each other when seen from the above.