Layered Carded Web Acquisition Distribution Laminate
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Solution Overview
Problem
Absorbent articles, such as diapers and incontinence products, face issues with liquid intake and distribution, leading to leakage and discomfort due to insufficient fluid intake into the absorbent core, resulting in inefficient use of absorbent materials and potential skin health issues.
Innovation Solution
A nonwoven acquisition distribution layer (ADL) comprising layered carded webs with a high denier fiber layer and a low denier fiber layer, combined with a deflection layer made of meltblown fibers, enhancing fluid intake, distribution, and transfer to the absorbent core, particularly effective with high superabsorbent materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional absorbent core is used, then the product can absorb body exudates, but the liquid intake rate is insufficient leading to leakage and pooling
Solution Approach 1:
The acquisition distribution layer is divided into multiple layers with different fiber deniers (high denier layer for rapid liquid intake and distribution, low denier layer for transfer to absorbent core). This segmentation allows each layer to perform its specific function optimally, enabling the system to handle high liquid delivery rates up to 20 ml/sec without leakage
Solution Approach 2:
The ADL uses a composite structure combining carded webs of different fiber compositions with a meltblown deflection layer. The high denier fibers provide rapid wicking, the low denier fibers facilitate transfer, and the meltblown layer deflects liquid laterally for distribution. This composite material approach enables simultaneous achievement of fast intake, good distribution, and reliable leakage prevention
2Productivity
If the absorbent layer is increased to handle high liquid rates, then liquid intake capacity improves, but the product becomes bulky and uncomfortable
Solution Approach 1:
Instead of using a single thick absorbent layer, the system segments the absorbent function across multiple thin layers (high denier layer, low denier layer, meltblown deflection layer) positioned above a compressed absorbent core. This segmentation maintains high liquid intake capacity while keeping each individual layer thin and comfortable against the skin
Solution Approach 2:
The ADL structure provides different local properties at different depths: the upper high denier layer offers rapid wicking for immediate liquid intake, the lower low denier layer provides efficient transfer to the core, and the meltblown layer offers lateral deflection for distribution. This local quality differentiation achieves high productivity without requiring excessive overall thickness, maintaining comfort
3Speed
If fast liquid intake is achieved, then pooling on the bodyside liner is reduced, but distribution throughout the material is insufficient
Solution Approach 1:
The ADL is segmented into a high denier layer for rapid vertical intake, a meltblown deflection layer for lateral distribution, and a low denier layer for transfer to the core. This segmentation enables the system to achieve both fast intake speed and broad distribution coverage by distributing the liquid handling function across different layers with specialized properties
Solution Approach 2:
The meltblown deflection layer acts as an intermediary between the high denier intake layer and the low denier transfer layer. It receives liquid from above, deflects it laterally through its hydrophobic yet porous structure to achieve distribution, and then allows transfer to the absorbent core below. This intermediary function simultaneously supports fast intake and comprehensive distribution
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 ADL design significantly improves fluid intake and distribution, reducing leakage and rewet, allowing twice as much fluid to be transferred to the absorbent core, enhancing skin dryness and overall absorbent system efficiency.
Implementation Method 1
a deflection layer comprising a fibrous nonwoven web wherein the fibrous nonwoven web has at least one component comprising meltblown, said meltblown having a basis weight of from about 15 gsm to about 50 gsm and having an air permeability of from about 45 ft3/min/ft2 to about 350 ft3/min/ft2
Implementation Method 2
an absorbent structure disposed between the bodyside liner and outer cover... an absorbent core which functions to absorb and retain body exudates
Data Source
AI summary
The present invention relates to a nonwoven acquisition distribution layer comprising: a) layered carded webs wherein the first layer comprises a carded web with high denier fibers wherein the denier is greater than about 5 d and a second layer comprising a carded web with low denier fibers wherein the denier is less than about 5 d and is positioned just below and in direct contact with the first layer; and b) a deflection layer comprising a fibrous nonwoven web wherein the fibrous nonwoven web has at least one component comprising meltblown, said meltblown having a basis weight of from about 15 gsm to about 50 gsm and having an air permeability of from about 45 ft3/min/ft2 to about 350 ft3/min/ft2; and wherein the deflection layer is positioned just below and in direct contact with said second layer of said layered carded web.