Disposable Absorbent Article Nonwoven Segmentation for Printability

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Solution Overview

Problem

Wearable disposable absorbent articles face challenges in providing a soft, pliable, and cost-efficient design with large printable areas while maintaining leakage protection, as existing nonwoven cloths obscure printed regions and result in significant material losses.

Innovation Solution

A wearable disposable absorbent article with a crotch panel featuring a laminate structure comprising a liquid barrier sheet and a nonwoven layer, where the nonwoven layer is positioned on the outer side and partially overlaps the front and back panels, minimizing material loss and allowing for clear prints without cutting, and is made of thermoplastic polymer fibers or filaments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the nonwoven cloth extends along the entire length of the crotch panel, then the outer surface becomes soft and comfortable, but the printable areas on the front and back panels are obscured and material losses increase

Engineering Contradiction:

Improvecomfort of outer surfaceVSAvoidmaterial loss from cutting nonwoven cloth

Core Design Contradiction:

Ease of operationVSLoss of substance

Solution Approach 1:

The nonwoven layer is segmented into distinct sections: a first section on the front panel, a second section on the back panel, and a third section in the crotch panel. This segmentation allows the nonwoven material to be strategically placed only where comfort is needed, while leaving printable areas on the front and back panels clear and intact, thereby reducing material waste from cutting.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different sections of the absorbent article have different nonwoven layer configurations. The front and back panels have nonwoven layers optimized for comfort and printability, while the crotch panel has a continuous nonwoven layer for comfort and leakage protection. This local differentiation resolves the contradiction by applying nonwoven material only where it serves its primary function without compromising printability elsewhere.

Inventive Principle:

Principle #3Local quality

2Ease of operation

If the nonwoven cloth extends over large areas of the front and back panels, then the outer surface feels soft and pliable, but the printable areas become obscured and visibility decreases

Engineering Contradiction:

Improvesoftness and pliability of outer surfaceVSAvoidprintable area on front and back panels

Core Design Contradiction:

Ease of operationVSArea of stationary object

Solution Approach 1:

The nonwoven layer is divided into separate sections for the front panel, back panel, and crotch panel. This segmentation ensures that printable areas on the front and back panels remain unobscured while the crotch panel maintains continuous nonwoven coverage for comfort and leakage protection.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The nonwoven layer configuration is optimized locally for each panel. The front and back panels have nonwoven sections that provide comfort while preserving printability, whereas the crotch panel has extensive nonwoven coverage for comfort and protection, resolving the contradiction between softness and printable area visibility.

Inventive Principle:

Principle #3Local quality

3Reliability

If the nonwoven layer covers the entire crotch panel and extends over front and back panels, then leakage protection is improved, but production costs increase due to material losses

Engineering Contradiction:

Improveleakage protectionVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The nonwoven layer is segmented into three sections corresponding to the front panel, back panel, and crotch panel. This segmentation allows the liquid barrier sheet to extend continuously for leakage protection while the nonwoven material is applied only where needed, reducing material waste and production costs.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The nonwoven layer is strategically positioned to provide leakage protection in the crotch panel while minimizing material usage on the front and back panels. This local optimization maintains reliability for leakage protection while reducing production costs by eliminating unnecessary material and cutting operations.

Inventive Principle:

Principle #3Local quality

4Area of stationary object

If portions of the nonwoven cloth are cut out to provide printable areas, then printability is improved, but significant material losses occur

Engineering Contradiction:

Improveprintable areaVSAvoidmaterial loss from cutting

Core Design Contradiction:

Area of stationary objectVSLoss of substance

Solution Approach 1:

The nonwoven layer is segmented into separate sections for the front panel, back panel, and crotch panel from the beginning of the design, eliminating the need for cutting operations. This segmentation maintains large printable areas on the front and back panels while preserving material integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The nonwoven layer configuration is designed locally for each panel to provide adequate comfort and protection without requiring cutting. The front and back panels have nonwoven sections that allow for printable areas, while the crotch panel has continuous coverage, resolving the contradiction between printability and material loss.

Inventive Principle:

Principle #3Local quality

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 design provides a comfortable, cost-efficient absorbent article with large printable areas and high leakage protection by minimizing nonwoven material usage, ensuring softness and pliability while maintaining effective liquid barrier functionality.

Implementation Method 1

The backsheet has a laminate structure comprising a liquid barrier sheet and a nonwoven layer arranged on top of each other

Methodology Applied

Scientific EffectLiquid barrier:

Implementation Method 2

The nonwoven layer is arranged at an outer side of the crotch panel, facing away from a wearer of the absorbent article when worn. Such a nonwoven layer gives the outer surface of the absorbent article a comfortable, cloth-like feel.

Methodology Applied

Scientific EffectNonwoven fabric texture:

Implementation Method 3

The crotch panel comprises a topsheet, a backsheet, and an absorbent core provided between the topsheet and the backsheet

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Data Source

PatentEP3454808B1Wearable disposable absorbent article

Publication Date: 2020.04.01 ESSITY HYGIENE & HEALTH AB

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AI summary

The invention relates to a wearable disposable absorbent article (10) comprising a front panel (12), a back panel (14), and a crotch panel (16) bridging and at least partially overlapping the front and back panels (12, 14). The backsheet (20) of the crotch panel has a laminate structure comprising a liquid barrier sheet (24) and a nonwoven layer (26) arranged on top of each other. The liquid barrier sheet (24) extends over the entire length of the crotch panel and further over at least a portion of each of the front and back panels (12, 14). The nonwoven layer (26) extends at least over the entire length of the crotch panel but not over a length of more than 40 mm over each of the front and back panels (12, 14). The width of the nonwoven layer (26) is smaller than the width of the liquid barrier sheet (24).