Composite Transfer Layer for Absorbent Articles
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Solution Overview
Problem
Current transfer layers in absorbent articles do not effectively distribute fluids over the absorbent core, leading to surface wetness and rewet issues, which affect wearer comfort and fluid retention.
Innovation Solution
A composite transfer layer web comprising a first layer with three-dimensional capillaries and two-dimensional drains, and a second layer with smaller capillaries and optional three-dimensional drains or a nonwoven web, designed to promote fluid distribution and reduce rewet by providing a physical barrier and buffer functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-layer transfer layer is used, then the structure is simple, but fluid distribution effectiveness is insufficient
Solution Approach 1:
The transfer layer is divided into multiple layers (first layer with larger capillaries, second layer with smaller capillaries, and optionally a third layer) to create a gradient structure that progressively distributes fluid from macro to micro scales, improving distribution effectiveness while managing complexity
Solution Approach 2:
The invention introduces multi-layering (adding a vertical dimension) to the transfer layer structure, transforming a single-plane fluid distribution system into a three-dimensional gradient system that enhances fluid distribution capability
2Speed
If larger capillaries are used in the transfer layer, then fluid acquisition is faster, but surface wetness increases
Solution Approach 1:
The transfer layer is segmented into multiple layers with progressively smaller capillary sizes (first layer has larger capillaries for fast acquisition, second layer has smaller capillaries for reduced wetness), allowing each layer to perform its specific function optimally
Solution Approach 2:
Different regions (layers) of the transfer layer have different capillary sizes tailored to specific functions: the first layer uses larger capillaries for rapid fluid uptake, while the second layer uses smaller capillaries to minimize surface wetness, creating localized optimal properties
3Productivity
If a multi-layer composite transfer layer is used, then fluid distribution is improved, but manufacturing complexity increases
Solution Approach 1:
The transfer layer is segmented into multiple functional layers that can be manufactured separately and then bonded together, allowing each layer to be optimized independently while simplifying the overall manufacturing process through modular assembly
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 transfer layer significantly reduces rewet and surface wetness, providing near instantaneous dryness after an insult, improving user comfort and fluid retention efficiency.
Implementation Method 1
the first layer comprises a formed film having three-dimensional capillaries and two-dimensional drains and the second layer comprises a formed film having three-dimensional capillaries, wherein the capillaries in the second layer are smaller than the capillaries in the first layer
Data Source
AI summary
A composite particularly suited for use as a transfer layer in an absorbent article has a first layer comprising a formed film having a plurality of capillary-sized apertured protuberances and a plurality of two-dimensional drains, and a second layer in intimate contact with an apertured end of said capillary-sized protuberances and spaced from the first layer in a z-direction, the second layer is either a three-dimensional apertured formed film or a nonwoven web. In embodiments where the second layer is a three-dimensional formed film, the film contains a plurality of capillary sized protuberances that are of smaller diameter compared to the protuberances in the first layer and optionally also contains a plurality of drains, which can be either two-dimensional or three-dimensional, or combinations thereof.