Apertured Nonwoven Intermediate Layer for Fast Fluid Acquisition
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Solution Overview
Problem
Existing disposable absorbent articles face challenges in rapidly transferring body fluids from the topsheet to the absorbent core while minimizing fluid retention on the topsheet, often due to high flow resistance caused by small pore sizes that enhance wicking and capillary force but slow acquisition speed.
Innovation Solution
A nonwoven structure comprising absorbent fibers and ultrafine fibers with specific weight percentages, hydraulic diameters, and air permeability, along with a plurality of apertures, is introduced to enhance fluid transfer and distribution, featuring a wicking rate and air permeability that facilitate rapid liquid acquisition and distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If small pore sizes are used in the ADS material to enhance wicking property and capillary force, then the wicking property and capillary force are improved, but the flow resistance increases resulting in slow acquisition speed
Solution Approach 1:
The ADS material is segmented into multiple nonwoven layers with different pore size characteristics. The first nonwoven layer has smaller pores for high capillary force and wicking, while the second nonwoven layer has larger pores for low flow resistance and high acquisition speed. This segmentation allows each layer to specialize in one function, resolving the contradiction between wicking performance and acquisition speed.
Solution Approach 2:
The solution transitions from a single-layer uniform pore structure to a multi-layer heterogeneous pore structure. By adding the dimensional complexity of layering with different pore size distributions, the system can simultaneously achieve high capillary force (in the first layer) and high acquisition speed (in the second layer), effectively resolving the performance-speed contradiction.
2Reliability
If small pore sizes are used in the ADS material to enhance capillary force, then the capillary force is improved, but the flow resistance increases resulting in slow liquid transfer
Solution Approach 1:
The ADS material is divided into two nonwoven layers with different pore size characteristics. The first layer provides high capillary force through smaller pores, while the second layer enables high liquid transfer efficiency through larger pores with lower flow resistance. This functional segmentation resolves the contradiction between capillary force and liquid transfer efficiency.
Solution Approach 2:
The ADS material is constructed as a composite of two different nonwoven materials with complementary pore structures. The composite structure combines the high capillary force material (first nonwoven) with the high permeability material (second nonwoven), achieving both high capillary force and high liquid transfer efficiency simultaneously.
3Reliability
If the ADS material has high flow resistance to maintain small pore sizes for wicking, then the wicking property is improved, but the acquisition speed decreases
Solution Approach 1:
The ADS is segmented into two layers where the first layer handles wicking through small pores (higher flow resistance) and the second layer handles rapid acquisition through large pores (lower flow resistance). This segmentation allows the system to achieve both good wicking property and fast acquisition, reducing the time loss without sacrificing wicking performance.
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 structure achieves fast fluid transfer and reduced fluid retention on the topsheet, providing a dry sensory feel and efficient liquid management in absorbent articles.
Implementation Method 1
an ADS material is required to have a good wicking property to distribute the liquid along a planar direction of the ADS material to lower the liquid concentration at the loading point and a high capillary force to suck the liquid from a topsheet
Implementation Method 2
at least most of the apertures have a hydraulic diameter in the range of about 600 μm to about 4500 μm
Data Source
AI summary
The present disclosure relates to an absorbent article comprising a liquid pervious topsheet, a liquid impervious backsheet, an absorbent core disposed between the topsheet and the backsheet, and an intermediate layer disposed between the topsheet and the absorbent core, wherein the intermediate layer comprises a nonwoven which comprises a plurality of apertures, absorbent fibers, and ultrafine fibers. The nonwoven comprises the ultrafine fibers of about 3% to about 35% by weight of the nonwoven, and at least most of the plurality of apertures have a hydraulic diameter in the range of about 600 μm to about 4500 μm.