Composite Web with Sinusoidal Separation Lines
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Solution Overview
Problem
The complexity and material waste associated with producing disposable absorbent articles, such as diapers, increase due to the need for multiple components like elasticized waistbands and containment flaps, which require additional process steps and equipment.
Innovation Solution
A composite web with integrated lines of separation, including sinusoidal and interconnecting lines, allows for the formation of multiple components without trim waste, simplifying the production process and reducing material usage by enabling the simultaneous creation of components like front and back ears from a single web.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple components (waist elastics, leg elastics, containment flaps, ears) are added to enhance absorbent articles, then the functionality and fit of the article is improved, but the production process complexity increases due to added process steps and equipment
Solution Approach 1:
The patent merges multiple separate components (waist elastics, leg elastics, containment flaps, ears) into a single integrated composite web structure. This allows all components to be produced simultaneously from one web without requiring separate production processes for each component, thereby reducing production process complexity while maintaining enhanced functionality.
Solution Approach 2:
The composite web serves multiple functions simultaneously - it provides waist elastics for waist adjustment, leg elastics for leg containment, containment flaps for front/back coverage, and ears for aesthetic/functional purposes. This multi-functional design eliminates the need for separate production processes for each component.
2Adaptability or versatility
If multiple components are produced through separate process steps, then each component can be optimized independently, but material waste increases due to trim waste from cutting and assembling separate parts
Solution Approach 1:
By combining all components into a single composite web, the patent eliminates trim waste that would result from cutting and assembling separate components. The integrated design allows the entire web to be utilized efficiently without material loss during the cutting and assembly processes.
Solution Approach 2:
The composite web is pre-configured with all necessary components and their relative positions during the web formation process. This preliminary integration eliminates the need for subsequent cutting and assembly operations that would generate trim waste, as all components are already in their final positions within the web.
3Adaptability or versatility
If separate components are produced and assembled, then component functionality can be optimized, but production time increases due to additional assembly steps
Solution Approach 1:
The patent combines the production of multiple components into a single simultaneous process. Instead of producing waist elastics, leg elastics, containment flaps, and ears separately and then assembling them, all components are produced together from the composite web in one operation, significantly increasing production speed.
Solution Approach 2:
All components are pre-positioned and pre-formed within the composite web during the web production process. This preliminary action eliminates the need for subsequent assembly steps, as the components are ready for direct application to the absorbent article, thereby reducing production time.
Data Source
AI summary
Disclosed is a composite web including a base web, a first web of fastener material, a first sinusoidal line of separation and a second sinusoidal line of separation. In one aspect, the composite web can be used to form components for absorbent articles.