Ultrasonic Bonding of Elastic Composite Structures for Sanitary Products
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Solution Overview
Problem
The use of adhesives in manufacturing elastic composite structures for absorbent sanitary products leads to increased costs, separation issues during the manufacturing process, and undesirable tactile properties in the end product.
Innovation Solution
A method and apparatus for forming elastic composite structures that eliminate the use of adhesives by using a bonding process involving rollers and bonding apparatuses with horns and anvils to create leg and cuff bonds without adhesive, securing elastic threads between foldover portions of web layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesives are used to attach elastic threads to web layers, then the elastic composite structure can be formed, but manufacturing costs increase and tactile properties deteriorate
Solution Approach 1:
The patent removes adhesives from the elastic composite structure by using a bonding apparatus that thermally bonds web layers directly to each other and to elastic threads, eliminating the harmful adhesive substance while maintaining structural integrity
Solution Approach 2:
The patent replaces the chemical bonding mechanism (adhesive) with a thermal bonding mechanism using a bonding apparatus that applies heat and pressure to create bonds between web layers and elastic threads
2Reliability
If adhesives are used to attach elastic threads, then the elastic composite structure can be formed, but separation issues occur during manufacturing
Solution Approach 1:
The patent combines the functions of attaching elastic threads and bonding web layers into a single thermal bonding operation performed by the bonding apparatus, eliminating the need for separate adhesive application and drying steps
Solution Approach 2:
The web layers and elastic threads bond to each other through the thermal bonding process without requiring external adhesive materials, making the system self-sufficient and reducing manufacturing complexity
3Reliability
If adhesives are used to attach elastic threads, then the elastic composite structure can be formed, but manufacturing costs increase
Solution Approach 1:
The patent extracts adhesives from the manufacturing process, relying instead on the inherent thermoplastic properties of the web layers and elastic threads to form bonds through heat and pressure application
Solution Approach 2:
The patent changes the bonding mechanism from chemical (adhesive-based) to physical (thermal bonding), utilizing temperature and pressure parameters to achieve strong bonds without consuming adhesive materials
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
Reduces manufacturing costs, minimizes separation issues, and improves the tactile properties of the end product by eliminating the need for adhesives while maintaining effective elastic functionality.
Implementation Method 1
a bonding apparatus having a horn and an anvil configured to bond the leg elastic portion to the leg foldover portion absent adhesive via a plurality of leg bonds and bond the cuff elastic portion to the cuff foldover portion absent adhesive via a plurality of cuff bonds
Data Source
AI summary
A machine and method for manufacturing an elastic composite structure for disposable sanitary products involves manufacturing the elastic composite structure with an elasticized leg and leg cuff region in a manner that minimizes or eliminates the use of consumable adhesives. The elastic composite structure includes pairs of leg bonds and cuff bonds that are formed without adhesive and anchor respective leg and cuff elastic threads in position relative to facing web layers. The leg bonds and cuff bonds are formed using one or more anvils that include discrete raised projections.