Acquisition Layer Nonwoven Structure for Cushioning and Flexibility
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Solution Overview
Problem
Existing absorbent articles face a challenge in achieving a balance between cushioning and flexibility while maintaining economic production, as increasing cushioning often compromises flexibility, and there is a need for a material that is both cushy and highly flexible, particularly for use as an acquisition layer in disposable absorbent articles.
Innovation Solution
A nonwoven material with specific properties, including a Horizontal Bending Drop at 100 mm of at least 75 mm and a Z-Compliance Index of at least 50 mm³/N, is developed, utilizing integrated carded webs with fiber integration processes like needlepunching and spunlacing, which combines absorbent, stiffening, and resilient fibers to enhance cushioning and flexibility without the need for adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the amount of soft material is increased to improve cushiness, then the flexibility is compromised
Solution Approach 1:
The nonwoven material combines different fiber types (cellulosic fibers for softness, polyester or polypropylene fibers for structure) to create a composite structure that simultaneously provides cushioning and flexibility. This allows the acquisition layer to deliver both comfort and adaptability without the trade-off inherent in using single-material solutions.
Solution Approach 2:
The invention creates regions with different properties within the nonwoven structure - softer regions for comfort and more structured regions for flexibility. The carded web structure with integrated fibers creates local variations in density and composition that allow different areas to fulfill different functional requirements.
2Ease of manufacture
If traditional nonwoven materials are used for acquisition layer, then manufacturing is economical, but the balance between cushioning and flexibility is not achieved
Solution Approach 1:
The carded web structure with integrated fibers provides self-bonding through the carding process itself, eliminating the need for additional adhesive applications or complex bonding equipment. The fibers interlock and bond during the carding and integration process, making the material self-sufficient for its own assembly and reducing manufacturing steps.
Solution Approach 2:
The invention modifies the physical parameters of the nonwoven material during processing - specifically the fiber arrangement, density, and integration degree - to achieve the desired balance between cushioning and flexibility. By controlling these parameters during carding and integration, the material properties are optimized without requiring post-processing adhesives.
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 nonwoven material achieves a balance between cushioning and flexibility, providing effective fluid acquisition and distribution while maintaining comfort and economic production, suitable for use as an acquisition layer in absorbent articles.
Implementation Method 1
utilizing integrated carded webs with fiber integration processes like needlepunching and spunlacing
Implementation Method 2
utilizing integrated carded webs with fiber integration processes like needlepunching and spunlacing
Implementation Method 3
The porous, fibrous structure of a nonwoven may be configured to be liquid permeable or impermeable
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A nonwoven having the following properties: a Horizontal Bending Drop (1) at 100 mm of at least 75 mm; and a Z-Compliance Index of at least 50 mm3/N. The nonwoven is suitable for use in an absorbent article (20), in particular as acquisition layer (54) between an absorbent core (28) and the topsheet (24).