Composite Web Printing for Absorbent Articles
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Solution Overview
Problem
There is a need to print high-quality visual signals on low-basis-weight nonwoven webs used in absorbent articles while minimizing ink blow-through and maintaining manufacturing line hygiene and cost-effectiveness.
Innovation Solution
A process involving the creation of a composite web by combining a nonwoven layer with a second layer, such as an apertured film, to form a composite structure with low air permeability, allowing for controlled ink application with minimal blow-through, where a portion of the ink is applied to the nonwoven layer and another portion to the second layer, resulting in a visual signal visible from the first layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a low-basis-weight nonwoven web is used for the topsheet, then the absorbent article achieves lower weight and better comfort, but ink blow-through increases during printing
Solution Approach 1:
The patent applies composite materials by combining a low-basis-weight nonwoven topsheet with a second layer (apertured film or nonwoven web) to form a composite web structure. This composite structure provides sufficient mass and integrity to prevent ink blow-through during printing while maintaining the lightweight benefit of the low-basis-weight topsheet. The composite web has a combined basis weight that is sufficient to accept ink without excessive penetration, yet the individual low-basis-weight layer preserves comfort and wearability.
2Ease of manufacture
If ink is applied directly to a low-basis-weight nonwoven web, then the visual signal can be printed, but manufacturing line hygiene deteriorates due to ink blow-through
Solution Approach 1:
The patent uses an intermediary layer (the second layer in the composite web) that acts as a barrier between the ink and the low-basis-weight nonwoven web. This intermediary structure prevents ink from blowing through to the manufacturing line while still allowing the visual signal to be printed on the composite web. The second layer serves as a mediator that enables printing functionality without transmitting harmful ink blow-through to the manufacturing environment.
3Manufacturing precision
If the basis weight of the nonwoven web is increased to reduce ink blow-through, then printing quality improves, but the article becomes heavier and less comfortable
Solution Approach 1:
The patent segments the weight-bearing function from the printing-receiving function. The low-basis-weight nonwoven topsheet provides the comfort and wearability (low weight), while the second layer in the composite web provides the necessary mass and integrity for high-quality printing. By segmenting these functions across two layers, the patent achieves printing quality equivalent to high-basis-weight materials without the penalty of increased overall article weight, since only the composite structure needs sufficient mass for printing, not the entire article.
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
This approach reduces ink blow-through to less than 10% and enhances the quality of the printed image, maintaining manufacturing line hygiene and cost-effectiveness by utilizing a composite web structure with a higher combined basis weight, improving the perceived quality and reliability of the visual signal.
Implementation Method 1
combining a nonwoven layer with a second layer, such as an apertured film, to form a composite structure with low air permeability
Data Source
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AI summary
A composite web comprising a nonwoven layer, wherein the composite web can be incorporated into an absorbent article. A volume of ink is applied to the composite web such that when the composite web is incorporated into the absorbent article, a visual signal is produced. Methods of printing on the composite web are also provided.