Composite Sheet Material for Absorbent Articles
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Solution Overview
Problem
Existing nonwoven fabrics used in absorbent articles face challenges in achieving optimal fluid transport without compromising tensile strength, flexibility, and elongation.
Innovation Solution
A composite sheet material is developed, comprising a nonwoven substrate layer, such as carded nonwoven fabric or high loft spunbond nonwoven, combined with a microperforated film layer. The microperforated film layer is bonded to the nonwoven substrate, featuring apertured protuberances that enhance fluid transport and distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If materials are selected to rapidly transport fluids from the top sheet into the absorbent core, then fluid transport speed is improved, but tensile strength and durability may be compromised
Solution Approach 1:
The patent employs a composite acquisition distribution layer combining a nonwoven fabric substrate with a thermoplastic polymer coating layer. The nonwoven substrate provides mechanical strength and structural integrity, while the thermoplastic coating creates hydrophilic channels for rapid fluid transport. This composite structure resolves the contradiction by integrating materials with complementary properties: the nonwoven fabric contributes tensile strength and durability, while the thermoplastic polymer enables fast fluid wicking through capillary action along the fiber surfaces.
2Loss of time
If the nonwoven fabric is engineered for rapid fluid transport, then fluid acquisition time is reduced, but flexibility and elongation may deteriorate
Solution Approach 1:
The patent applies local quality by creating hydrophilic regions with thermoplastic polymer coating on specific areas of the nonwoven fabric surface. The coating is applied as a thin layer that selectively modifies the surface properties to enhance fluid wicking where needed, while leaving the bulk fabric structure intact to maintain flexibility and elongation. The thermoplastic polymer forms hydrophilic channels along the fiber surfaces, concentrating the fluid transport function in specific zones without compromising the overall mechanical properties of the nonwoven substrate.
3Productivity
If a microperforated film layer is added to enhance fluid transport, then fluid distribution is improved, but device complexity increases
Solution Approach 1:
The patent merges the functions of fluid distribution and structural support into a single integrated composite layer. Rather than adding a separate microperforated film layer, the thermoplastic polymer coating is applied directly to the nonwoven fabric substrate, creating hydrophilic channels that serve both as fluid distribution pathways and as part of the structural matrix. This merging approach achieves effective fluid distribution while avoiding the complexity of multi-layer assemblies with separate functional layers.
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 composite sheet material exhibits improved fluid acquisition times, reduced rewet values, and maintains good mechanical properties, making it suitable for use as an acquisition-distribution layer in absorbent articles.
Implementation Method 1
the film comprises a plurality of apertured protuberances extending outwardly from a face of the film, the apertures including a first opening disposed opposite the nonwoven substrate, a second opening at a vertex of the aperture, and a continuous sidewall extending between the first and second openings
Implementation Method 2
a polymer defining the microperforated film layer is contacted with a surface of the nonwoven substrate in a molten or semi-molten state such that the polymer is at least partially integrated into and between the fibers of the nonwoven substrate to form a mechanical bond between the nonwoven substrate and the film layer
Data Source
AI summary
A composite sheet material having improved fluid management properties is provided. The composite sheet material includes a nonwoven substrate comprising a carded nonwoven having a basis weight greater than about 16 gsm, or a high loft spunbond nonwoven and a film layer having a plurality of apertured protuberances extending outwardly from a face of the film. The composite sheet material is particularly useful in the preparation of absorbent articles.