Breathable Tri-Laminate Absorbent Article via Ultrasonic Bonding

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Solution Overview

Problem

Existing disposable absorbent articles, such as diapers and briefs, are not breathable, leading to moisture trapping and discomfort for users, as they are designed to prevent leakage but lack ventilation, and existing stretchable laminates do not adequately address this issue.

Innovation Solution

A breathable laminate structure is created using a moisture-pervious inner layer, an absorbent layer, and a moisture-impervious outer layer, with a polymeric film sandwiched between nonwoven layers, and ultrasonic bonding to form apertures that allow vapor passage, providing both elasticity and breathability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If disposable absorbent articles are constructed from materials designed to capture urine and prevent leakage, then leakage protection is improved, but breathability deteriorates leading to moisture trapping and discomfort

Engineering Contradiction:

Improveleakage protectionVSAvoidmoisture trapping and discomfort

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The laminate is divided into three distinct layers: an inner nonwoven layer for comfort and vapor transmission, a middle elastomeric film layer for stretch and containment, and an outer nonwoven layer for leakage protection. This segmentation allows each layer to perform its specific function without compromising the others, enabling both breathability and leakage protection to coexist.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a composite laminate structure combining different materials (nonwoven fabrics and elastomeric film) with complementary properties. The nonwoven layers provide breathability and comfort, while the elastomeric film provides stretch and leakage prevention. This composite approach resolves the contradiction by integrating materials that individually address different aspects of the problem.

Inventive Principle:

Principle #40Composite materials

2Ease of operation

If stretch elastic laminates are used to replace spandex strands for better fit and discretion, then fit and discretion are improved, but breathability may deteriorate

Engineering Contradiction:

Improvefit and discretionVSAvoidmoisture trapping

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The elastomeric film layer serves as a flexible shell that provides the necessary stretch and fit while remaining thin enough to allow vapor transmission through the overall laminate structure. This thin flexible film maintains discretion and fit without creating a moisture-trapping barrier.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The laminate structure provides different properties at different locations: the inner layer facing the skin is optimized for breathability and comfort, while the outer layers provide stretch and containment. This local differentiation allows the garment to be breathable where needed while maintaining fit and discretion elsewhere.

Inventive Principle:

Principle #3Local quality

3Object-affected harmful factors

If a polymeric film is sandwiched between nonwoven layers and ultrasonically bonded, then elasticity and breathability are improved, but manufacturing complexity increases

Engineering Contradiction:

Improvebreathability and vapor passageVSAvoidmanufacturing process

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

Ultrasonic bonding replaces traditional mechanical bonding methods (such as stitching or adhesive bonding) with a vibration-based welding process. This substitution enables seamless bonding of the laminate layers while simultaneously creating breathable apertures, reducing the need for additional components or complex assembly steps despite the advanced bonding technology.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 breathable laminate structure reduces discomfort by allowing moisture vapor transmission, improving wearability and discretion while maintaining leakage protection, enhancing user comfort and reducing irritation.

Implementation Method 1

a polymeric film layer (62) and at least one nonwoven layer (58, 60), wherein both the polymeric film layer (62) and both nonwoven layers (58, 60) extend substantially throughout the area of the laminate (24)

Methodology Applied

Scientific EffectVapor transmission: Permeation

Implementation Method 2

Ultrasonic bonding to form apertures that allow vapor passage

Methodology Applied

Scientific EffectUltrasonic bonding: Ultrasonic Vibration

Data Source

PatentUS10226388B2Stretch breathable protective absorbent article using tri-laminate

Publication Date: 2019.03.12 MEDLINE INDUSTRIES

AI summary

A disposable absorbent article of a brief or pull-up type incorporates a breathable laminate material composed of three layers. The laminate is an elastic material and may include non-elastic portions created by deactivating the material. The laminate material may be made breathable by the ultrasonic bonding process used to create the laminate. The absorbent article includes an absorbent assembly that overlaps with the non-elastic portions of the laminate.