3D Nonwoven Topsheet Structure for Thin, Soft Diapers
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Solution Overview
Problem
Existing three-dimensional topsheets in absorbent sanitary articles are too thick due to their layered construction, which compromises the softness and fluffiness required to prevent a rough tactile feel against the skin, especially when using super absorbent polymers (SAP) as absorbent cores.
Innovation Solution
A three-dimensional topsheet with a continuous mesh pattern of bonded nonwoven material, featuring protruding features and a monolayer or dual-layer construction, is manufactured using a specialized apparatus with synchronized drums to create a softer, thinner structure that provides fluid channels and cushioning without increasing thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a layered construction is used to create a three-dimensional topsheet, then the softness and fluffiness are improved, but the thickness increases
Solution Approach 1:
The patent applies dimensionality change by transforming a two-dimensional nonwoven fabric into a three-dimensional structure through localized protrusions. The topsheet features a continuous mesh pattern with protruding features that create depth and softness without requiring multiple layers, thus reducing overall thickness while maintaining the cushioning effect against the skin.
Solution Approach 2:
The invention implements local quality by creating protruding features at specific locations within the continuous mesh pattern. These protrusions provide localized softness and fluffiness where needed for skin comfort, while the base layer remains thinner. This selective three-dimensional structure allows the topsheet to be soft where it contacts the skin without uniformly increasing thickness across the entire structure.
2Length of stationary object
If super absorbent polymers (SAP) are used as absorbent core, then the thickness is reduced, but the texture becomes grainy and rough
Solution Approach 1:
The continuous mesh pattern with protruding features acts as an intermediary layer between the SAP absorbent core and the skin. This mesh structure provides a soft, fluffy interface that cushions the grainy texture of the SAP particles, preventing direct skin contact with the rough polymer beads while maintaining the thickness advantages of SAP technology.
Solution Approach 2:
The patent employs a thin, flexible nonwoven fabric structured into a continuous mesh pattern that serves as a protective interface. This single-layer flexible film with three-dimensional protrusions provides the necessary cushioning between the rigid SAP particles and the skin, eliminating the need for thicker layered constructions while maintaining comfort.
3Length of stationary object
If a smooth sheet is used as topsheet, then the thickness is reduced, but the softness and fluffiness are insufficient to cushion the absorbent core
Solution Approach 1:
The patent resolves this contradiction by introducing three-dimensional protruding features into a single-layer nonwoven fabric. This creates localized thickness and softness at the surface level without requiring multiple layers, thus maintaining overall thinness while providing sufficient cushioning between the absorbent core and the skin.
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 results in a softer, thinner topsheet that maintains fluffiness and prevents a rough tactile feel, while accommodating SAP cores, reducing manufacturing logistics and environmental impact.
Implementation Method 1
wherein the bonding unit is a thermal bonding unit or an ultrasonic bonding unit
Implementation Method 2
wherein the bonding unit is a thermal bonding unit or an ultrasonic bonding unit
Implementation Method 3
a thermal conditioning unit upstream of the meshing location M that is configured to thermally condition the layer L1
Data Source
Figure 1
Figure 1A
Figure 1B
AI summary
Disclosed herein is a three dimensional tape (1) that may be used as a top sheet and a backsheet for a sanitary product, particularly a baby diaper or a sanitary pad. The three dimensional tape of the invention allows manufacturing of comparatively thinner, fluffless sanitary products with an improved comfort for the user. Manfacturing of the tape (1) may be accomplished in-line, thereby dispensing with all of the logistics burden from outsourced products, and all of the environmental impact the logistics comes with.