Absorbent Article Nonwoven Topsheet Stiffness Softness
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Solution Overview
Problem
Current disposable absorbent articles, such as diapers and incontinence guards, often lack comfort, fit, and a cloth-like feel, leading to skin chafing and fluid leakage issues due to inadequate material properties.
Innovation Solution
The development of an absorbent article featuring a topsheet and standing gathers made from nonwoven materials with polypropylene-containing fibers, which have specific stiffness, softness, and smoothness characteristics, along with a breathable backsheet, to provide a soft, cloth-like sensation and improved fit, reducing skin irritation and fluid leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional materials are used for topsheet and standing gathers, then the article structure is simple and easy to manufacture, but the article lacks comfort, cloth-like feel, and causes skin chafing
Solution Approach 1:
The patent applies parameter changes by modifying the physical properties of the nonwoven material through specific stiffness (2.3-20 mm/N), softness (TS7 ≤ 4.5 dB V^2 rms), and smoothness (TS750 ≤ 4.0 dB V^2 rms) values. These parameter specifications transform conventional rough nonwoven material into a ultra-soft material that provides comfort while maintaining ease of manufacture through standardized production processes.
Solution Approach 2:
The patent employs composite materials by combining polypropylene-containing fibers with specific bonding patterns (5-30% bonded area) and slip agents to create a nonwoven material that integrates multiple functions: structural integrity, ultra-soft feel, and anti-chafing properties. This composite approach resolves the contradiction by achieving comfort enhancement without significantly complicating the manufacturing process.
2Device complexity
If conventional materials are used for topsheet and standing gathers, then the material structure is simple, but the article lacks softness, smoothness, and cloth-like appearance
Solution Approach 1:
The patent transforms the material appearance by changing key parameters: reducing bonded area to 5-30% to create a more open, cloth-like structure, and specifying softness (TS7 ≤ 4.5 dB V^2 rms) and smoothness (TS750 ≤ 4.0 dB V^2 rms) values that give the material a fabric-like hand feel while maintaining structural simplicity.
Solution Approach 2:
The patent applies local quality by creating alternating bonded and non-bonded areas in the nonwoven material. The non-bonded areas (70-95% of surface) provide softness and cloth-like appearance, while the bonded areas (5-30% of surface) maintain structural integrity, achieving aesthetic enhancement without excessive complexity.
3Object-affected harmful factors
If the topsheet and standing gathers are made soft and smooth, then comfort and cloth-like feel are improved, but the material may lose structural integrity and gripability
Solution Approach 1:
The patent resolves this contradiction by optimizing the bonded area parameter to 5-30% of the total surface area. This parameter range provides sufficient bonding for structural integrity while leaving enough non-bonded area (70-95%) to maintain softness and comfort. The stiffness parameter (D = 2.3-20 mm/N) is also controlled to ensure adequate structural support.
Solution Approach 2:
The patent applies local quality by creating distinct bonded and non-bonded regions within the same material. The bonded areas provide localized strength and structural support, while the non-bonded areas provide localized softness and comfort, allowing both requirements to coexist within the same material structure.
4Object-affected harmful factors
If standing gathers are made with soft material, then comfort is improved, but the barrier function against fluid leakage may be compromised
Solution Approach 1:
The patent resolves this contradiction by specifying a stiffness range (D = 2.0-20 mm/N) for the standing gather material that balances softness with barrier function. The controlled bonded area (5-30%) provides sufficient structural support for the standing gather to maintain its barrier shape while the non-bonded areas (70-95%) provide comfort against the skin.
Data Source
Figure 1
Figure 2
AI summary
An absorbent article (1) having a topsheet (11), a backsheet (12) arranged on the garment-facing side (10), an absorbent core (13) enclosed between the topsheet (11) and the backsheet (12), and a pair of standing gathers (14,15). The topsheet (11) and the standing gathers (14,15) comprise sheet materials with specified stiffness, softness and smoothness properties.