Composite Absorbent Tape With Embedded Particles and No Adhesives
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Solution Overview
Problem
Existing absorbent structures in hygiene products face challenges such as high production costs, complexity in recycling due to adhesive use, and reduced production flexibility, while off-line forming methods require additional tape wrapping and compromise particle containment.
Innovation Solution
A composite tape is developed with continuous microfilaments mixed with particles, formed within high thickness tapes, eliminating the need for adhesives and enhancing particle containment through a manufacturing process that integrates particle entrapment within the tape's pores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If particles are incorporated into preformed tapes using known methods, then particle containment is achieved, but additional tape wrapping is required and particle containment is compromised
Solution Approach 1:
The patent applies preliminary action by forming particles and microfilaments together into a composite structure before integration into the absorbent core. The particles are embedded within the porous matrix during tape formation, eliminating the need for subsequent wrapping operations and ensuring inherent particle containment throughout the product lifecycle
Solution Approach 2:
The patent implements nesting by placing particles inside the porous structure of the microfilament matrix. The particles are positioned within the pores of the high thickness tape, creating a nested configuration where particles are contained within the three-dimensional network of microfilaments, providing structural containment without additional wrapping
2Stability of the object's composition
If adhesives are used to secure particles in absorbent structures, then particle stability is improved, but recycling complexity increases and ecological footprint expands
Solution Approach 1:
The patent extracts adhesives from the absorbent structure by relying on the inherent mechanical interlocking between particles and the porous microfilament matrix. The physical structure of the tape provides particle stability through its three-dimensional pore network, eliminating the need for adhesive bonding and enabling easier recycling and reduced ecological impact
Solution Approach 2:
The patent applies self-service by allowing the porous matrix structure to inherently secure particles through its physical architecture. The microfilament network automatically provides particle containment through its pore structure without requiring additional adhesive materials, making the structure self-sufficient for particle stability
3Productivity
If off-line forming methods are used to produce composite tapes, then production volumes increase, but additional handling systems and conversion equipment are required
Solution Approach 1:
The patent merges particle incorporation and tape formation into a single integrated off-line manufacturing process. The composite tape is produced as a unified structure with particles embedded in the matrix during formation, combining multiple functions (particle containment, tape structure, absorbency) into one component that reduces handling system complexity at conversion lines
Solution Approach 2:
The patent creates a universal composite tape structure that serves multiple functions: it provides particle containment, forms the absorbent core structure, and integrates directly with conversion line equipment. The standardized tape format with embedded particles can be universally applied across different absorbent article types without requiring specialized handling systems
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 solution achieves high production volumes with cost-effective materials, improved particle containment, and simplified recycling, maintaining efficiency during use without compromising production speed or flexibility.
Implementation Method 1
a mixture comprising particles and continuous microfilaments, mutually mixed together, is deposited on a high thickness tape
Implementation Method 2
at least in part, the mixture of continuous microfilaments and particles penetrates into the pores of the high thickness tape
Implementation Method 3
the whole is then calendered, so as to ensure entrapment of the particles within the pores
Data Source
AI summary
A composite tape (1) is provided comprising one or more matrices (2) of high thickness polymeric fibres comprising pores; at least one first layer (3) in contact with the matrix (2) and including a mixture (30) at least in part penetrating the pores, and comprising, mutually mixed together, a plurality of cellulose particles (31), and a plurality of continuous first polymer filaments (32) defining, before being mixed with the particles (31), a development axis (32a) and defining at least in part a plurality of mutually identical outlines (33) arranged in succession along the development axis (32a); a second layer (4) of continuous second polymer filaments (40) forming a surface layer of the tape (1) and placed in contact with the matrix (2) and/or the first layer (3) without penetrating the pores; wherein the outline (33) is determined on a section plane (32b) normal to the development axis (32a), defining a first extension area on the section plane (32b) and being inscribable in a circle determined on the section plane (32b) and defining a second extension area on the section plane (32b); and wherein the first extension area is less than 90% of the second extension area.