Composite Web with Segmented ADL for Stable 3D Protrusions
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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 a three-dimensional layer, a base layer, and an additional liquid acquisition and distribution layer (ADL), which are not efficiently integrated.
Innovation Solution
A composite web comprising a first web with moulded protrusions and a second web segment, such as a liquid acquisition and distribution layer (ADL), where the second web segment is joined to the first web at the base portions to maintain the shape of the protrusions and define cavities, reducing material usage and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a continuous second web is used to maintain the shape of the three-dimensional layer, then the structural stability is improved, but the material usage and production costs increase
Solution Approach 1:
The patent applies segmentation by replacing the continuous second web with discrete segments joined at specific locations. The second web is divided into multiple segments that are joined to the first web at spaced-apart locations, maintaining shape stability while reducing overall material usage. This segmentation approach allows the structure to maintain integrity at critical points without requiring continuous material coverage.
Solution Approach 2:
The patent implements local quality by providing the second web segments at specific localized positions where shape maintenance is most critical, rather than uniformly across the entire surface. The segments are strategically placed to support the three-dimensional layer at key locations, providing localized structural reinforcement where needed while minimizing material consumption in less critical areas.
2Reliability
If a liquid acquisition and distribution layer is added to improve liquid management, then the functional performance is improved, but the device complexity and production costs increase
Solution Approach 1:
The patent merges the liquid acquisition and distribution layer with the second web structure. The ADL is integrated into the composite web formation process, combining multiple functions (structural support and liquid management) into a unified structure. This merging approach reduces overall device complexity by eliminating separate components while maintaining improved liquid management performance.
Solution Approach 2:
The patent applies multi-functionality by designing the second web segments to serve multiple purposes: providing structural support to maintain the three-dimensional layer shape, acting as a liquid acquisition and distribution layer for liquid management, and reducing material usage compared to a continuous web approach. This multi-functional design improves liquid management performance while controlling complexity.
3Ease of operation
If multiple layers are integrated to achieve three-dimensional embossed effect, then the wearer comfort is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies preliminary action by forming the three-dimensional embossed pattern on the first web before joining the second web segments. The embossed three-dimensional layer is created in advance on the first web, and then the second web segments are joined at spaced-apart locations to maintain the pre-formed shape. This sequence allows for easier control of embossing precision while achieving the desired wearer comfort.
Data Source
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Figure 5A
AI summary
A composite web (1) comprising a first continuous web (2) having a first face (2A) and a second face (2B); the first web (2) comprises a moulded portion (3) having at least one protrusion (4), at least partly delimited by a base portion (5), on the first face (2A); the composite web (1) comprises a segment (6) of a second continuous web (16) joined to the second face (2B) of the first web (2) at least at the base portion (5).