Absorbent article
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Solution Overview
Problem
Current absorbent articles face challenges in manufacturing due to the limitations of elastic stretch nonwovens, which can lead to hole formation during the activation process, compromising the material's elastic and soft properties.
Innovation Solution
The use of a pre-stretched elastic nonwoven material with a specific bonding pattern, comprising non-elastic and elastic polymeric components, where bonding points are arranged in a pattern with offset center points and rounded shapes to distribute forces and reduce the risk of hole formation, along with a calender process for bonding and activation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elastic stretch nonwoven materials are used to elastify the chassis, then the fit and comfort of the article are improved, but hole formation occurs during the activation process
Solution Approach 1:
The nonwoven material is pre-stretched in a first direction before the activation step to reduce hole formation during subsequent stretching in a second direction. This preliminary action prepares the material structure to better withstand the activation process while maintaining elastic properties for good fit and comfort.
Solution Approach 2:
The invention changes the physical state and mechanical properties of the nonwoven material through controlled pre-stretching and activation processes. By adjusting stretching parameters (direction, magnitude, sequence) and bonding parameters, the material achieves optimal balance between elasticity for fit/comfort and resistance to hole formation during manufacturing.
2Strength
If the nonwoven material is stretched during activation, then elastic properties are achieved, but hole formation is initiated at bond points
Solution Approach 1:
The nonwoven material is pre-stretched in a first direction before activation to redistribute stresses and reduce hole formation at bond points during subsequent stretching. This preliminary action modifies the material structure to better accommodate the activation process while maintaining elastic properties.
Solution Approach 2:
The invention uses a composite nonwoven material structure combining different fiber types and bonding characteristics. The material comprises elastic and non-elastic fibers in a controlled arrangement, creating a composite structure that provides both elastic properties and resistance to hole formation at bond points during activation.
3Strength
If spandex threads are used for elastification, then elastic properties are achieved, but the material lacks soft and cloth-like haptic properties
Solution Approach 1:
The invention replaces spandex threads with a composite nonwoven material structure comprising elastic and non-elastic fibers. This composite approach maintains the necessary elastic properties for fit while providing soft, cloth-like haptic properties through the non-elastic fiber components and controlled bonding structure.
Solution Approach 2:
The nonwoven material provides different local properties through its composite structure - elastic fibers provide stretch and recovery in specific regions while non-elastic fibers provide softness and cloth-like feel in contact areas. The bonding pattern creates zones of different flexibility and haptic characteristics throughout the material.
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 enhances the material's elasticity and softness, improving the fit and comfort of absorbent articles while minimizing the risk of hole formation during the manufacturing process, resulting in a more durable and aesthetically pleasing product.
Implementation Method 1
The elastic nonwoven material in the absorbent article is pre-stretched and comprises a non-elastic polymeric material component and an elastic polymeric material component
Implementation Method 2
Each of the individual bonding points has a centre point and the centre point of each bonding point in a row of bonding points extending in the cross-direction and/or machine-direction is offset from a centre point of each bonding point in a neighbouring row of bonding points extending in the cross-direction and/or in the machine-direction, respectively
Data Source
AI summary
An absorbent article having a front panel, a rear panel, an intermediate panel joining the front and the rear panels and optionally one or more fitting components is provided. At least one of the panels and/or the fitting components is elastically contractible and made of an elastic nonwoven material that is pre-stretched and has both non-elastic and elastic polymeric material components in the form of fibers. The nonwoven material is bonded by individual bonding points arranged in a pattern. The pattern has rows of individual bonding points extending in a machine-direction and a cross-direction of the nonwoven material, and each has a centre point. The centre point of each bonding point in a row of bonding points extending in the cross-direction and/or machine-direction is offset from a centre point of each bonding point in a neighbouring row of bonding points extending in the cross-direction and/or in the machine-direction, respectively.