Disposable Absorbent Bonding Pattern for Tear Resistance
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Solution Overview
Problem
Absorbent articles with low-cost web materials having weak cross-directional strength tend to tear during use due to conventional bonding patterns, which can increase stiffness if more bonding points are added to prevent tearing.
Innovation Solution
A bonding pattern with discrete columnar protrusions on one web and a secondary web, featuring a specific spacing and distribution of bonding points to prevent tearing without increasing stiffness, using a precursor web with macroapertures and discrete protruded extensions for enhanced strength and fluid permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of bonding points is increased to prevent tearing of weak web materials, then the strength and reliability of the article is improved, but the stiffness of the material increases making it less comfortable
Solution Approach 1:
The bonding pattern applies different bonding characteristics to different regions of the web material. High-bonding areas are strategically placed at locations prone to tearing (side regions and end regions), while the central region maintains lower bonding to preserve softness and comfort. This localized differentiation resolves the contradiction by providing tear resistance where needed without compromising overall comfort.
Solution Approach 2:
The bonding pattern is segmented into distinct regions with different bonding densities: high-bonding regions at the sides and ends where tearing is most likely, and low-bonding regions in the center where comfort is prioritized. This segmentation allows the article to achieve both tear resistance and comfort by treating different areas differently rather than applying uniform bonding throughout.
2Strength
If more bonding points are used to bond web materials together, then the strength of the bonded structure is improved, but the tactile softness and flexibility deteriorate
Solution Approach 1:
Different bonding intensities are applied to different regions: strong bonding in side and end regions provides structural strength, while weak bonding in the central region preserves tactile softness. This local quality differentiation allows the article to simultaneously achieve both strength and comfort.
Solution Approach 2:
The bonding pattern segments the web into high-strength regions (sides and ends) and soft-comfort regions (center). This segmentation enables the bonded structure to have sufficient strength for functionality while maintaining tactile softness in the areas that contact the user.
3Reliability
If bonding points are densely distributed to prevent tearing, then the reliability of the article is improved, but the flexibility and comfort are reduced
Solution Approach 1:
The bonding pattern creates local quality variations with dense bonding at vulnerable edges and ends for tear prevention, while sparse bonding in the central region maintains flexibility. This resolves the contradiction by providing tear prevention where structurally necessary without compromising overall flexibility.
Solution Approach 2:
The bonding distribution is segmented into high-density regions (sides and ends) for reliability and low-density regions (center) for flexibility. This segmentation allows the article to achieve both tear prevention and flexibility by optimizing bonding density for each specific region's functional requirements.
Data Source
AI summary
In accordance with an embodiment of the disclosure, an article includes a first web and second web underlying the first web. The first web includes a precursor web having a pattern of discrete substantially columnar protruded extensions extending only from a first surface of the precursor web, each of the protruded extensions having a sidewall defining an open proximal portion and a closed distal portion. The article further includes a bonding pattern. The bonding pattern includes a plurality of discrete bonding points and a sized spacing between each adjacent bonding point sufficient to have inscribed therein a circle having a diameter of about 1 mm to about 12 mm The article comprises between about 70 to 100 discrete bonding points for every 25 to 40 mm along a longitudinal axis of the article.