3D Nonwoven Structure for Compression-Resistant Absorbent Articles
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Solution Overview
Problem
Existing nonwovens used in absorbent articles often suffer from compression-induced thin appearance and reduced softness, which affects aesthetic appeal and performance, while three-dimensional nonwovens with capillary gradients are desirable for improved fluid handling and sensory feel but are costly and complex to produce.
Innovation Solution
A three-dimensional nonwoven structure with a protruded first area having a higher shape memory index than a second area, formed by bonding and deformation processes, creating a capillary gradient for enhanced fluid drainage and a recognizable three-dimensional perception.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If nonwovens are tightly wound on rolls for supply and storage, then storage efficiency and transport convenience are improved, but the nonwoven webs become compressed resulting in reduced caliper and thin appearance
Solution Approach 1:
The nonwoven web is pre-formed with a three-dimensional structure containing protruded areas and recessed areas before winding. This preliminary structural configuration allows the web to maintain its shape memory and resist compression during storage and transport, preventing the caliper reduction and thin appearance that would normally occur with tight winding.
2Shape
If heat is applied to nonwoven after unwinding from rolls to restore caliper, then the thin appearance and compressed structure are improved, but production time and energy consumption increase
Solution Approach 1:
The three-dimensional structure with varying shape memory indices is created during the nonwoven manufacturing process itself, before the web is wound onto rolls. This preliminary action eliminates the need for subsequent heat treatment to restore caliper, as the structure is inherently resistant to compression and maintains its shape without requiring additional time-consuming thermal processing steps.
3Reliability
If three-dimensional nonwoven structure with capillary gradient is created to improve fluid handling properties, then fluid drainage and sensory feel are improved, but manufacturing complexity and production cost increase
Solution Approach 1:
The nonwoven web features localized variations in shape memory index, with higher values in protruded areas and lower values in recessed areas. This local quality differentiation creates the three-dimensional structure and capillary gradient needed for improved fluid handling, while being achievable through standard manufacturing processes without requiring complex additional equipment or multi-step procedures.
Solution Approach 2:
The invention utilizes changes in the shape memory index parameter across different regions of the nonwoven web to achieve the desired three-dimensional structure and fluid handling properties. By controlling the shape memory index distribution during manufacturing, the capillary gradient is formed without requiring complex device modifications or additional processing steps.
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 cost-effective nonwoven with improved fluid handling and aesthetic appeal, maintaining a stable three-dimensional structure under compression, and enhancing the performance of absorbent articles.
Implementation Method 1
a shape memory index of the upper portion is higher than a shape memory index of the lower portion
Implementation Method 2
a nonwoven with a capillary gradient has been desirable as it can provide better fluid drainage from the surface of the topsheet to an adjacent layer
Data Source
AI summary
The present invention relates to a three-dimensional nonwoven comprising a first side, a second side, a protruded first area comprising an upper portion formed in the first side and a lower portion formed in the second side, and a second area comprising a plurality of deformations, wherein the upper portion has a shape memory index higher than a shape memory index of the lower portion, an absorbent article comprising the three-dimensional nonwoven, and a process for producing the three-dimensional nonwoven.