Disposable Absorbent Article Bonding Pattern for Tear Resistance
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Solution Overview
Problem
Absorbent articles with low-cost web materials having weak cross-directional strength tend to tear during use due to conventional bonding patterns, which increases stiffness when more bonding points are added to prevent tearing.
Innovation Solution
A sanitary napkin design featuring a bonding pattern with discrete bonding points and optimized spacing between them, located in specific regions, to prevent tearing without increasing stiffness, using a first web with macroapertures and protruded extensions for improved strength and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of bonding points is increased to prevent tearing of weak web materials, then the strength and reliability of the article is improved, but the stiffness of the material increases making it less comfortable
Solution Approach 1:
The bonding pattern applies different bonding densities to different regions of the article. High bonding density is applied at the ends where tearing is most likely to occur, while the central region maintains lower bonding density to preserve flexibility and comfort. This localized differentiation resolves the contradiction by providing tear resistance only where structurally necessary.
Solution Approach 2:
The bonding pattern is segmented into discrete bonding points rather than continuous bonding. The spacing between bonding points (3-12 mm) creates distinct bonded regions that provide structural support while leaving unbounded material between them to maintain flexibility and comfort, thus resolving the stiffness-comfort contradiction.
2Ease of manufacture
If low-cost web materials with weak cross-directional strength are used, then the manufacturing cost is reduced, but the material becomes susceptible to tearing during use
Solution Approach 1:
Rather than uniformly strengthening the entire web material, the bonding pattern applies reinforcement locally at the ends where tearing is most likely to occur. This allows the use of low-cost weak web materials in the central region while providing targeted strength enhancement only where structurally critical, thus maintaining cost-effectiveness while improving reliability.
Solution Approach 2:
The bonding pattern pre-reinforces the web material at the ends before use, creating a preventive measure against tearing. By bonding the layers together at critical regions in advance, the structure is prepared to resist tearing forces that will occur during normal use, compensating for the inherent weakness of the low-cost material.
3Reliability
If continuous bonding is used to bond web materials together, then the strength and reliability is improved, but the flexibility and comfort of the article is reduced
Solution Approach 1:
The continuous bonding is segmented into discrete bonding points spaced 3-12 mm apart. This segmentation provides sufficient bond strength to prevent tearing while maintaining flexibility, as the unbounded material between bonding points can still deform and flex during use, resolving the contradiction between strength and flexibility.
Solution Approach 2:
Instead of applying full continuous bonding across the entire article, only partial bonding is applied at specific locations (the ends). This partial action provides sufficient bonding strength to prevent tearing at critical regions while leaving the central region unbounded to maintain flexibility and comfort.
Data Source
AI summary
In accordance with an embodiment of the disclosure, an article includes a first web and second web underlying the first web. The article further includes a bonding pattern. The bonding pattern includes a plurality of discrete bonding points and a sized spacing between each adjacent bonding point sufficient to have inscribed therein a circle having a diameter of about 1 mm to about 12 mm. The bonding pattern is located solely in one of the front end region or the back end region.