Composite Web Structure With Integrated ADL for 3D Topsheets
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Solution Overview
Problem
The production of absorbent sanitary articles with three-dimensional topsheets involves high material usage and costs due to the inclusion of multiple layers such as a three-dimensional layer, a base layer, and a liquid acquisition and distribution layer (ADL).
Innovation Solution
A composite web is developed comprising a first web with molded protrusions and a second web segment, where the segment acts as an ADL, joined to the first web to maintain the molded shape and reduce material usage, thereby integrating both comfort and liquid distribution functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a three-dimensional layer, base layer and ADL are included in the topsheet, then wearer comfort is improved, but material consumption and production costs increase
Solution Approach 1:
The patent merges the base layer and ADL into a single integrated layer. This layer simultaneously provides structural support (base layer function) and liquid acquisition/distribution (ADL function), eliminating the need for separate layers and reducing overall material consumption while maintaining wearer comfort through the three-dimensional protrusions
Solution Approach 2:
The integrated layer performs multiple functions: it acts as a base layer for structural support, as an ADL for liquid acquisition and distribution, and as a support layer for the three-dimensional protrusions. This multi-functionality reduces the total number of layers and material required while preserving the comfort benefits
2Productivity
If multiple layers (three-dimensional layer, base layer, ADL) are used in the topsheet, then liquid distribution efficiency is improved, but production complexity increases
Solution Approach 1:
By combining the base layer and ADL into a single integrated layer, the patent reduces the number of separate production steps and assembly operations required. The integrated layer is applied in one operation rather than requiring separate applications of base layer and ADL, simplifying the production process while maintaining liquid distribution efficiency
Data Source
AI summary
A composite web including a first continuous web having a first face and a second face; the first web includes a molded portion having at least one protrusion, at least partly delimited by a base portion, on the first face; the composite web includes a segment of a second continuous web joined to the second face of the first web at least at the base portion.