Unidirectionally Stretchable Substrate with Local Bonding
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Solution Overview
Problem
Existing unidirectionally stretchable substrates face issues with poor thermal fusion bonding strength between styrene-based elastomer and olefin materials, leading to separation and reduced shape retention, while increasing density to improve bonding results in higher material usage, weight, and decreased air permeability and flexibility.
Innovation Solution
A unidirectionally stretchable substrate is created by bonding a meshed material with elastomeric linear members and a non-woven fabric made of thermoplastic resin filaments, where the filaments are drafted and linearly arranged in one direction to enhance bonding and limit stretchability in that direction, minimizing weight increase and maintaining flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the density of lateral and longitudinal strands is increased to improve thermal fusion bonding strength, then bonding strength is improved, but material usage increases, weight increases, and air permeability and flexibility deteriorate
Solution Approach 1:
The patent applies local quality by concentrating the bonding function at specific locations (intersections of lateral and longitudinal strands) rather than uniformly increasing strand density throughout the entire net structure. This allows thermal fusion bonding to occur effectively at critical points while maintaining lower overall material usage and preserving air permeability and flexibility in non-bonding regions.
Solution Approach 2:
The patent uses composite materials by combining styrene-based elastomer for lateral strands with olefin material for longitudinal strands. This material combination enables effective thermal fusion bonding at intersections while allowing the overall structure to maintain low weight and high flexibility, as each material contributes its advantageous properties to the composite structure.
2Reliability
If the density of lateral and longitudinal strands is increased to prevent separation, then reliability is improved, but material usage increases and cost increases
Solution Approach 1:
The patent applies local quality by concentrating the bonding function at specific locations (intersections of lateral and longitudinal strands) rather than uniformly increasing strand density throughout the entire net structure. This allows thermal fusion bonding to occur effectively at critical points while maintaining lower overall material usage and preserving air permeability and flexibility in non-bonding regions.
Solution Approach 2:
The patent uses thermal fusion bonding as an intermediary mechanism that chemically/physically connects lateral and longitudinal strands at intersections. This bonding mechanism acts as a mediator that prevents separation between strands without requiring increased strand density, thereby maintaining reliability while controlling material usage.
3Adaptability or versatility
If olefin material is used for longitudinal strands with styrene-based elastomer for lateral strands, then limited stretchability is achieved, but thermal fusion bonding strength deteriorates
Solution Approach 1:
The patent applies parameter changes by optimizing the thermal fusion bonding conditions (temperature, pressure, time) to enable effective bonding between styrene-based elastomer and olefin material. By adjusting these parameters, the patent achieves both limited stretchability from the olefin material and sufficient bonding strength at intersections.
Solution Approach 2:
The patent uses composite materials by combining styrene-based elastomer for lateral strands with olefin material for longitudinal strands. This material combination enables effective thermal fusion bonding at intersections while allowing the overall structure to maintain low weight and high flexibility, as each material contributes its advantageous properties to the composite structure.
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 provides a substrate with improved shape retention and reduced weight, allowing for efficient production with increased feed speed and minimal impact on air permeability, suitable for applications requiring limited stretchability in one direction.
Implementation Method 1
the filaments have been drafted in one direction and are linearly arranged only in that direction
Implementation Method 2
there is a problem of poor thermal fusion bonding strength of the intersections when styrene-based elastomer and an olefin material are used for the longitudinal and lateral strands, respectively, and integrated into a net
Data Source
AI summary
A unidirectionally stretchable substrate which has good shape retaining characteristics and whose weight can be easily reduced is provided. Unidirectionally 1 stretchable substrate has meshed material 2 that has a plurality of elastomeric linear members 3 arranged orthogonal to each other, the linear members having stretchability and thermoplasticity; and non-woven fabric 4 that is formed of a plurality of filaments 5, the filaments being made of a thermoplastic resin. Filaments 5 of non-woven fabric 4 have been drafted in one direction and are linearly arranged only in that direction. Non-woven fabric 4 is bonded to meshed material 2 such that direction y in which filaments 5 of the non-woven fabric 4 are arranged is parallel with one of directions y in which linear members 3 of meshed material 2 extend.