Absorbent Article Shell Elastic Tension Control for Curl Reduction
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Solution Overview
Problem
Body adhering absorbent articles often curl due to residual stretch in the elastic shell material, leading to manufacturing difficulties, fit issues, and customer dissatisfaction.
Innovation Solution
Reducing or eliminating shell elastic tension in specific regions where components are attached, or maintaining the shell material in an untensioned state during the manufacturing process to minimize curling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the elastic shell material is stretched during the assembly process to form the composite web, then the components can be attached to form the absorbent article, but residual stretch in the shell material causes the article to curl after die cutting
Solution Approach 1:
The shell material web is divided into multiple lanes, with each lane forming a separate absorbent article. This segmentation allows independent control of tension and stretching in each lane, enabling components to be attached while minimizing residual stretch that causes curling in the final product
Solution Approach 2:
Different regions of the shell material web are subjected to different tension levels during the assembly process. The shell material is tensioned in specific areas to facilitate component attachment while maintaining reduced tension in other areas to prevent curling, creating local variations in mechanical properties
2Ease of manufacture
If the shell material is kept in a tensioned state during component attachment, then assembly is facilitated, but the resulting article experiences curling that interferes with fit and gasketing
Solution Approach 1:
Components are attached to the shell material web in a predetermined sequence and configuration before the final cutting step. This preliminary assembly allows the shell material to be properly positioned and tensioned during attachment, while subsequent cutting and release minimize residual stretch that would otherwise compromise fit and gasketing
3Productivity
If the absorbent article curls after manufacturing, then production defects increase and machine downtime increases, but maintaining proper tension during assembly is necessary for component attachment
Solution Approach 1:
The tension state of the shell material web is dynamically adjusted during the manufacturing process. The web is tensioned during component attachment to facilitate assembly, then the tension is released or reduced after cutting to minimize curling defects, allowing the system to adapt its mechanical state to different process requirements
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 method effectively reduces or eliminates curling, enhancing the fit and functionality of the absorbent articles, improving manufacturing efficiency and customer satisfaction.
Implementation Method 1
supplying an elastic web of shell material having a longitudinal and transverse direction; stretching the web of shell material in the longitudinal direction
Data Source
AI summary
The present disclosure provides methods of manufacturing a body adhering absorbent article oriented in the machine direction wherein the body adhering absorbent articles have reduced or eliminated curl. The articles are manufactured with reduced curl by selectively reducing or eliminating the shell elastic tension in regions where components of the body adhering absorbent article are to be attached to form the composite absorbent article web. In certain aspects the body adhering absorbent articles are manufactured by supplying an elastic web of shell material having a longitudinal and transverse direction, stretching the web of shell material in the longitudinal direction, deadening at least one region of the stretched web of shell material, attaching at least one absorbent article component to at least a portion of the longitudinal deadened zone to form a composite web material, and cutting the composite web material to form a body adhering absorbent article.