Three-Dimensional Substrate Tooling for Absorbent Articles
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Solution Overview
Problem
Three-dimensional substrates used in absorbent articles face compression and distortion issues during winding, unwinding, and packaging, leading to reduced three-dimensionality, necessitating reliable methods and tooling for production on an absorbent article manufacturing line that minimize feature compression and distortion.
Innovation Solution
The use of tooling with intermeshing rolls configured to create compressed regions or densified areas around aperture perimeters in three-dimensional substrates, stabilizing the apertures and maintaining three-dimensional features at line speed, and forming these substrates directly on the absorbent article manufacturing line to eliminate winding and shipping-related compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If three-dimensional substrates are tightly wound for shipping, then transportation efficiency is improved, but three-dimensional feature compression and distortion increase
Solution Approach 1:
The substrate is pre-formed with three-dimensional elements and apertures at the absorbent article manufacturing line before shipping. This preliminary formation ensures the substrate maintains its intended shape and functionality, eliminating the need for subsequent winding operations that would cause compression and distortion.
2Ease of manufacture
If three-dimensional substrates are unwound for manufacturing, then incorporation into absorbent articles is improved, but three-dimensional feature compression increases
Solution Approach 1:
The substrate is formed and integrated directly at the absorbent article manufacturing line, extracting it from the separate manufacturing and shipping process. This eliminates the winding and unwinding steps entirely, allowing the substrate to be incorporated into absorbent articles while maintaining its three-dimensional features without compression.
3Productivity
If compact packaging is used for absorbent articles, then shipping efficiency is improved, but three-dimensional substrate compression increases
Solution Approach 1:
The three-dimensional substrate is pre-formed with stabilized apertures and three-dimensional elements at the manufacturing line before packaging. This preliminary formation with built-in stability features allows the substrate to withstand subsequent compact packaging without compression or distortion of its critical features.
4Ease of manufacture
If three-dimensional substrates are manufactured at a separate location, then manufacturing specialization is improved, but winding and shipping complexity increases
Solution Approach 1:
The substrate formation process is merged with the absorbent article manufacturing process at a single location. This integration eliminates the separate manufacturing, winding, and shipping operations, reducing process complexity while maintaining manufacturing efficiency through in-line production.
Data Source
Figure 1
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Figure 3~3A
AI summary
Methods and tooling for making three-dimensional substrates and/or apertured substrates are provided. The three-dimensional substrates and/or apertured substrates may be used in absorbent articles, such as diapers and pants, for example. The methods and tooling may be used on an absorbent article manufacturing line.