Backsheet Design for Distinct Print Visibility
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Solution Overview
Problem
Existing backsheets for absorbent articles face challenges in achieving a high-quality, distinct print design due to the limitations of printing on nonwoven materials, which often result in obstructed visibility of the inner film layer and a disrupted textile-like appearance.
Innovation Solution
A backsheet design featuring an inner liquid-impermeable film layer with printed areas and an outer nonwoven layer with a basis weight less than 20 g/m², where the outer layer's printing extends around but not into the inner film layer's printed areas, allowing for a cohesive and aesthetically pleasing design without altering the nonwoven structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If printing is applied directly on the outer nonwoven layer, then the textile-like appearance is maintained, but the print quality is less distinct and cannot achieve distinct lines or fully coloured areas
Solution Approach 1:
The backsheet is divided into two functional layers: an inner film layer for high-quality printing and an outer nonwoven layer for textile appearance. This segmentation allows each layer to perform its specialized function without compromising the other.
Solution Approach 2:
The inner film layer acts as an intermediary printing surface that mediates between the printing process and the outer nonwoven layer. It provides a suitable substrate for distinct printing while the outer layer maintains the desired textile appearance.
2Illumination intensity
If the outer nonwoven layer is made opaque to provide coverage, then the underlying film layer is hidden, but the aesthetic effect of visible printed figures is lost
Solution Approach 1:
The outer nonwoven layer exhibits local quality variation: it is opaque in most areas to provide coverage and comfort, but transparent in specific printed areas to allow the printed figures on the inner film layer to be visible, creating the desired aesthetic effect.
Solution Approach 2:
The outer nonwoven layer incorporates transparency changes in specific areas, allowing light to pass through and reveal the printed figures on the inner film layer, while maintaining opacity in other areas for coverage.
3Manufacturing precision
If the outer nonwoven layer structure is locally changed to improve printing, then print quality improves, but the manufacturing complexity increases
Solution Approach 1:
Instead of modifying the outer nonwoven layer to improve printing, the approach is inverted: the inner film layer is used as the printing surface, and the outer nonwoven layer is kept structurally simple with only transparency variations, thereby maintaining manufacturing simplicity while achieving high print quality.
Data Source
Figure 1~2
Figure 3
AI summary
The present invention relates to a backsheet for an absorbent article comprising an inner liquid-impermeable film layer (1´) and an outer layer (3´) of nonwoven, said inner liquid-impermeable film layer including at least one printed area (2). According to the invention said outer layer of nonwoven (3´) is provided with printing (4) in all areas except in an area or areas (5) covering said at least one printed area (2) of said inner liquid-impermeable film layer, the basis weight of said outer nonwoven layer being less than 20 g/m2.