Absorbent articles and methods for manufacturing same
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Solution Overview
Problem
Increasing absorbency in tissue products like facial tissue, bath tissue, and paper towels without the complexity and cost of manufacturing multi-ply sheets.
Innovation Solution
A one-ply, multi-layer absorbent article with controlled delamination between layers, allowing for increased absorbency by creating voids during use, achieved through loose bonding of layers using nonwoven materials and foam formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multi-ply sheets are manufactured to increase absorbency, then absorbency is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent divides a single ply into multiple sub-layers (first nonwoven layer, second nonwoven layer, third nonwoven layer) that are loosely bonded together. This segmentation allows each layer to contribute to absorbency while maintaining a single-ply structure that is simpler to manufacture than traditional multi-ply sheets.
Solution Approach 2:
The patent changes the bonding parameter between layers from strong bonding (traditional multi-ply) to loose bonding. This parameter change enables the layers to remain attached during manufacturing and packaging but separate during use, providing multi-ply absorbency with single-ply manufacturing simplicity.
2Quantity of substance
If multi-ply sheets are manufactured to increase absorbency, then absorbency is improved, but manufacturing cost increases
Solution Approach 1:
The patent segments the absorbent structure into multiple loosely-bonded nonwoven layers within a single ply, achieving multi-ply absorbency without the need for complex multi-ply manufacturing processes, thereby reducing manufacturing cost.
Solution Approach 2:
The patent uses disposable nonwoven layers that are inexpensive to produce and can be loosely bonded together. These layers provide cost-effective absorbency enhancement without requiring expensive multi-ply manufacturing equipment or processes.
3Volume of stationary object
If one-ply structure is used to reduce shipping volume, then shipping efficiency is improved, but absorbency is reduced
Solution Approach 1:
The patent segments the one-ply structure into multiple sub-layers that can delaminate during use. This segmentation allows the product to ship compact as a single ply while providing multi-ply absorbency when the layers separate during application.
Solution Approach 2:
The patent introduces dynamic delamination between layers that transitions the structure from a compact single-ply state during shipping to an expanded multi-layer state during use. This dynamic behavior resolves the contradiction between shipping efficiency and absorbency.
4Quantity of substance
If layers are loosely bonded to enable delamination, then absorbency is improved through void creation, but structural integrity deteriorates
Solution Approach 1:
The patent applies different bonding qualities to different regions of the layers. The layers are loosely bonded in areas where delamination is desired for absorbency, while maintaining sufficient bonding in other areas to preserve structural integrity during handling and application.
Solution Approach 2:
The bonding strength is designed to be dynamic - sufficiently strong to maintain structural integrity during manufacturing and handling, but sufficiently weak to allow controlled delamination during use. This dynamic bonding characteristic resolves the contradiction between structural integrity and absorbency.
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 absorbent article achieves absorbency comparable to or exceeding that of two-ply products while maintaining ease of manufacturing and packaging, with a 34% increase in absorbency upon delamination.
Implementation Method 1
engineered a controlled measured of delamination between given layers of the one-ply products
Implementation Method 2
the one-ply absorbent article has a first absorbency measure at a first delamination state and a second absorbency measure at a second delamination state
Data Source
AI summary
A one-ply absorbent article comprising a nonwoven first layer; a non-woven third layer; a nonwoven second layer between the first layer and the third layer; and wherein the one-ply absorbent article has a first absorbency measure at a first delamination state and a second absorbency measure at a second delamination state, wherein the first absorbency measure is less than the second absorbency measure and the first delamination state is less than the second delamination state.