3D Absorbent Laminates With Compressed Regions
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Solution Overview
Problem
Three-dimensional substrates used in absorbent articles face issues with compression and tension during winding, unwinding, and packaging, leading to reduced three-dimensionality, and there is a challenge in joining substrates without delamination, which affects product quality.
Innovation Solution
The method involves creating three-dimensional substrates or laminates on an absorbent article manufacturing line, using tooling to form compressed regions and densified areas, and applying welds such as thermo-mechanical welds to reduce compression and delamination between substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If three-dimensional substrates are tightly wound and shipped to a different location, then transportation and storage are enabled, but the three-dimensionality of the substrates is reduced due to compression and tension
Solution Approach 1:
The patent applies preliminary action by forming compressed regions and densified areas in the three-dimensional substrate before shipping and handling operations. These pre-formed compressed regions act as structural reinforcements that enable the substrate to withstand subsequent compression and tension during winding, transportation, and storage without losing its three-dimensionality.
2Productivity
If three-dimensional substrates are unwound and fed into manufacturing lines, then production is enabled, but the three-dimensionality is further reduced due to compression and tension
Solution Approach 1:
The patent forms compressed regions and densified areas in advance before the substrate enters the manufacturing line. These pre-formed regions provide structural support that allows the substrate to be unwound and fed through manufacturing processes while maintaining its three-dimensional characteristics, thus enabling productivity without sacrificing shape.
3Adaptability or versatility
If substrates are joined to form laminates, then product functionality is enhanced, but delamination occurs affecting product quality
Solution Approach 1:
The patent applies local quality by creating densified areas at specific locations where substrates are joined to form laminates. These localized densified regions act as bonding zones that enhance the adhesion between layers, preventing delamination while maintaining the overall functionality of the laminate structure.
Solution Approach 2:
The patent creates composite structures by joining multiple substrates into laminates, where each substrate contributes different functional properties. The densified areas formed during the joining process create a composite material structure with enhanced interlayer bonding, ensuring reliability while achieving enhanced product functionality through the combination of different substrate properties.
4Volume of stationary object
If compact packaging is used for absorbent articles, then storage efficiency is improved, but three-dimensionality is reduced further
Solution Approach 1:
The patent forms compressed regions and densified areas before packaging operations. These pre-formed regions create a more rigid and compression-resistant structure that can be packaged compactly without collapsing or losing its three-dimensional characteristics, thus achieving both storage efficiency and shape retention.
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
This approach allows for the production of substrates that resist compression and delamination, maintaining three-dimensional elements even during packaging and enhancing consumer perception of product quality by ensuring better stability and integrity of the laminates.
Implementation Method 1
applying welds such as thermo-mechanical welds to reduce compression and delamination between substrates
Data Source
AI summary
Three-dimensional laminates and methods for making the same are provided. The three-dimensional laminates may be apertured and may have welds between various substrates. The three-dimensional laminates may be used in absorbent articles, such as diapers and pants, for example, as topsheets, as topsheets and acquisition layers, or as outer cover materials, for example. The three-dimensional laminates may be produced on an absorbent article manufacturing line.