Elastic Panels with Discrete Bonding for Breathable Absorbent Articles
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Solution Overview
Problem
Existing stretch laminates in disposable absorbent articles are difficult and expensive to manufacture, and there is a need for improved stretch laminates that provide enhanced softness, breathability, and comfort while reducing the risk of skin irritation.
Innovation Solution
The absorbent article features elastically elongatable panels with a cover layer and an elastomeric film joined by mechanical bonding at discrete elements, incorporating wrinkles and openings to enhance breathability and comfort, with a water vapor transmission rate that increases with elongation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If stretch laminates are used to provide expandability and fit, then the article can conform to a wide range of body types, but the manufacturing becomes difficult and expensive
Solution Approach 1:
The elastic laminate is segmented into discrete bonding elements rather than continuous bonding, creating regions of flexibility between bonded areas. This segmentation allows the material to stretch and conform to body types while simplifying the manufacturing process by using spot bonding instead of continuous complex lamination.
Solution Approach 2:
The laminate has varying bond densities in different regions - higher bond density in areas requiring stability and lower bond density in areas requiring flexibility. This local variation in bonding quality provides both fit and comfort while simplifying manufacturing compared to uniform complex lamination.
2Adaptability or versatility
If traditional stretch laminates are used, then expandability is achieved, but breathability is reduced and skin irritation risk increases
Solution Approach 1:
The laminate incorporates porous structures and openings within the bonding elements that allow water vapor and air to pass through. This porosity maintains breathability and reduces skin irritation while the surrounding bonded regions provide the necessary expandability and fit.
Solution Approach 2:
The laminate combines different materials with complementary properties - bonded regions providing structural integrity and expandability, and porous regions providing breathability. This composite structure achieves both expandability and reduced skin irritation risk.
3Strength
If continuous bonding is used to join cover layer and elastomeric film, then structural integrity is improved, but breathability is reduced
Solution Approach 1:
The continuous bonding is segmented into discrete bonding elements distributed across the laminate. Each bonding element provides localized structural integrity, while the spaces between elements maintain breathability. This segmentation resolves the contradiction between strength and breathability.
Solution Approach 2:
The bonding is concentrated in specific local regions rather than distributed uniformly. The bonded areas provide structural integrity where needed, while unbonded or porous areas maintain breathability. This local differentiation of bonding quality achieves both strength and breathability.
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
The solution provides improved breathability and comfort by allowing incremental increase in water vapor transmission with elongation, reducing the risk of skin irritation, and potentially lowering manufacturing costs.
Implementation Method 1
an elastomeric film attached to the cover layer, wherein said least one cover layer and elastomeric film are joined by mechanical bonding at a plurality of discrete bonding elements
Implementation Method 2
said panel comprises a plurality of openings extending through the film and/or the cover layer(s) and wherein said openings are positioned outboard and/or inboard of said discrete bonding elements
Implementation Method 3
the panel comprises an average of no more than two wrinkles between two consecutive discrete bonding elements along a panel length extending substantially parallel to the transverse axis
Implementation Method 4
an absorbent article... comprising at least one elastically elongatable panel joined to the chassis
Data Source
AI summary
An absorbent article comprising: a chassis comprising a liquid permeable topsheet, a liquid impermeable backsheet, and an absorbent core positioned between said topsheet and backsheet, and comprising a longitudinal axis (y) extending along a length of said chassis and a transverse axis being substantially perpendicular to the longitudinal axis and extending along a width of said chassis, wherein said length extends along the longest dimension of said chassis; and at least one elastically elongatable panel joined to the chassis, wherein the elastically elongatable panel comprises: a. at least one cover layer; and b. an elastomeric film attached to the cover layer, wherein said least one cover layer and elastomeric film are joined by mechanical bonding at a plurality of discrete bonding elements, and wherein each said panel comprises a plurality of wrinkles having peaks and troughs formed on at least one of said cover layer, and wherein the said panel comprises a plurality of openings extending through the film and/or the cover layer(s) and wherein said openings are positioned outboard and/or inboard of said discrete bonding elements so that said openings and said bonding elements do not substantially coincide.