Stretchable Laminate Ultrasonic Welding Delamination Prevention

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Solution Overview

Problem

Conventional stretchable laminates with elastomer and non-woven fabric layers face issues of delamination, odor from adhesives, inhibited air permeability, and increased costs due to the use of adhesives or pressure-sensitive adhesives for bonding.

Innovation Solution

A stretchable laminate with multiple layers, including an elastomer layer and non-woven fabric layers directly bonded using ultrasonic welding, eliminating the need for adhesives and preventing delamination, odor, and air permeability inhibition, while reducing production costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If adhesive or pressure-sensitive adhesive is used to bond elastomer layer and non-woven fabric layer, then bonding strength is improved, but delamination occurs between layers

Engineering Contradiction:

Improvebonding strengthVSAvoiddelamination resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent removes the adhesive layer from the laminate structure, directly bonding the elastomer layer to the non-woven fabric layers through thermal or ultrasonic welding. This extraction of the adhesive component eliminates the source of delamination while maintaining bonding strength through direct material-to-material bonding.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces a thermal bonding agent or ultrasonic energy as an intermediary mechanism to bond the elastomer layer and non-woven fabric layers without using adhesive. The thermal or mechanical energy acts as a mediator to create strong bonds between the layers, eliminating delamination issues associated with adhesive bonding.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If adhesive or pressure-sensitive adhesive is used for bonding, then bonding strength is improved, but unique odor from adhesive occurs

Engineering Contradiction:

Improvebonding strengthVSAvoidadhesive odor

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent removes the adhesive component entirely from the laminate structure, replacing it with direct thermal or ultrasonic bonding between the elastomer layer and non-woven fabric layers. This extraction eliminates the source of adhesive odor while maintaining bonding strength through alternative bonding mechanisms.

Inventive Principle:

Principle #2Taking out (Extraction)

3Strength

If adhesive or pressure-sensitive adhesive is used for bonding, then bonding strength is improved, but air permeability is inhibited

Engineering Contradiction:

Improvebonding strengthVSAvoidair permeability inhibition

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent removes the adhesive layer that blocks air passages, allowing direct bonding between the elastomer layer and non-woven fabric layers. This extraction restores air permeability while maintaining bonding strength through thermal or ultrasonic welding, enabling breathability in the laminate structure.

Inventive Principle:

Principle #2Taking out (Extraction)

4Strength

If adhesive or pressure-sensitive adhesive is used for bonding, then bonding strength is improved, but production cost increases

Engineering Contradiction:

Improvebonding strengthVSAvoidproduction cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent removes the adhesive component from the laminate structure, eliminating the need for adhesive application, curing, and related processing steps. This extraction reduces material costs and simplifies the manufacturing process while maintaining bonding strength through direct thermal or ultrasonic bonding methods.

Inventive Principle:

Principle #2Taking out (Extraction)

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 effectively prevents delamination, suppresses adhesive-related odors, maintains air permeability, and lowers production costs by directly bonding elastomer and non-woven fabric layers using ultrasonic welding.

Implementation Method 1

the welding bonding comprises ultrasonic welding bonding, and wherein the through-holes in the region C are formed by feeding an ultrasonic wave from a horn so that vibration energy is more intensively applied to sites where the through-holes are to be formed at the time of bonding in the region C

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Data Source

PatentEP3284595B1Expanding/contracting laminate and product including same

Publication Date: 2024.02.21 NITTO DENKO CORP

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AI summary

Provided is a stretchable laminate formed of two or more layers including an elastomer layer, the stretchable laminate having the following features : delaminat ion hardly occurs between the elastomer layer and a layer adjacent thereto; the occurrence of a unique odor derived from an adhesive or a pressure-sensitive adhesive is suppressed; the inhibition of air permeability due to the bonding of the elastomer layer and the layer adjacent thereto can be prevented; and the laminate can be produced at lower cost than ever before. Also provided is an article including such stretchable laminate. The stretchable laminate of the present invention includes two or more layers including an elastomer layer, in which the elastomer layer and a layer adjacent thereto are directly laminated.