Absorbent Article Bonding via Convexo-Concave Nonwoven Shaping
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Solution Overview
Problem
Existing absorbent articles face challenges in maintaining high bonding strength between the absorbent structure and the waist panel without excessive adhesive application, which can lead to adhesive oozing and deterioration of the nonwoven fabric's touch and softness.
Innovation Solution
A manufacturing method that involves forming convexo-concave portions on a nonwoven fabric in the crotch region, applying adhesive to these areas for bonding with the waistline sheet, and using surfaces with varying fiber densities to enhance bonding strength while maintaining fabric softness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a large amount of adhesive is applied to increase bonding strength, then the bonding strength between the absorbent structure and waist panel is improved, but the adhesive may ooze out from the nonwoven fabric and the touch of the sheet deteriorates
Solution Approach 1:
The patent applies adhesive selectively to specific regions (leg opening portions and front/back waistline portions) rather than uniformly across the entire absorbent structure. This localized adhesive application ensures bonding strength is concentrated where mechanical stress occurs during wear, while avoiding adhesive oozing and touch deterioration in other areas. The adhesive amount is controlled to 1-5 mm² in specific regions, preventing excessive adhesive from compromising fabric quality.
Solution Approach 2:
The bonding structure is divided into multiple discrete adhesive application regions: leg opening portions and front/back waistline portions. This segmentation allows precise control of adhesive placement and quantity in each high-stress zone, ensuring adequate bonding strength where needed while maintaining fabric integrity and softness in non-adhesive areas.
2Reliability
If the bonding strength is increased to withstand loads from waist panel lifting and absorbent structure weight, then the reliability of the bonded portion is improved, but the amount of adhesive required increases excessively
Solution Approach 1:
Adhesive is applied locally to the leg opening portions and front/back waistline portions where mechanical loads are concentrated during wear. This targeted approach ensures bonding reliability in high-stress regions without requiring excessive adhesive throughout the entire structure, thus maintaining bonding reliability under load while controlling adhesive quantity.
Solution Approach 2:
The adhesive is applied in advance to specific regions before the absorbent structure is assembled with the waist panel. This preliminary positioning ensures that bonding occurs precisely where mechanical stress will occur during use, providing reliable bonding under load from the start while minimizing overall adhesive consumption.
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
This method increases bonding strength between the crotch and waistline regions without excessive adhesive, preventing adhesive oozing and maintaining the softness of the nonwoven fabric.
Implementation Method 1
an adhesion step of bonding the first sheet to a waistline sheet disposed in the waistline region with a first adhesive after the shaping step
Data Source
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AI summary
A method of manufacturing an absorbent article that can increase the bonding strength of the bonded portion between the absorbent structure and the waist panel without excessively increasing the amount of adhesive to be applied, is provided. A method of manufacturing an absorbent article (10) is a method of manufacturing an absorbent article including a waistline region (14, 15), a crotch region (16), and an absorber (11) disposed at least in the crotch region. The method of manufacturing comprises: a shaping step (S1) of forming a convexo-concave portion (57a) on a first sheet (51) composed of a nonwoven fabric disposed in the crotch region; an absorber disposing step (S6) of disposing the absorber on the first sheet; and an adhesion step (S8) of bonding the first sheet to a waistline sheet (18, 19) disposed in the waistline region with a first adhesive (28, 29) after the shaping step. The adhesion step includes applying at least part of the first adhesive to a region which overlaps with the convexo-concave portion and does not overlap with the absorber in at least one of the first sheet and the waistline sheet.