Elastomeric Apertured Web for Breathable Diaper Backsheet

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Solution Overview

Problem

Existing absorbent articles, such as disposable diapers, face challenges in achieving both high protection and comfort due to the limited breathability and stretchability of backsheet covers, which require separate stretchable side panels to compensate for the limited stretchability of microporous films used in backsheet covers.

Innovation Solution

A method for producing an elastomeric apertured web that combines incremental stretching of a zero-strain laminate comprising an elastomeric ply and an extensible ply, followed by forming apertures using intermeshing rollers with tapered teeth, resulting in a breathable and stretchable laminate with a WVTR greater than 1000 g/m2/day.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If microporous films are used in backsheet covers to provide vapor permeability, then breathability is improved, but stretchability deteriorates

Engineering Contradiction:

Improvevapor permeabilityVSAvoidstretchability

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent combines microporous film and elastic film into a single laminated structure, merging the vapor permeability function of the microporous film with the stretchability function of the elastic film. This integrated laminate achieves both breathability (WVTR ≥ 1000 g/m2/day) and stretchability (≥20% elongation) simultaneously, eliminating the need for separate stretchable side panels.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If separate stretchable side panels are added to compensate for limited stretchability of microporous films, then stretchability is improved, but device complexity increases

Engineering Contradiction:

ImprovestretchabilityVSAvoidstructure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The invention integrates the stretchability function directly into the backsheet cover laminate itself, combining microporous film and elastic film into a unified structure. This eliminates the need for separate stretchable side panels, simplifying the overall diaper structure while maintaining adequate stretchability (≥20% elongation).

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The laminated backsheet cover performs multiple functions simultaneously: it provides vapor permeability for breathability, stretchability for body conformation, and liquid impermeability for leakage protection. This multi-functional design eliminates the need for separate specialized components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If elastic film and nonwoven laminates are used to provide stretchability, then stretchability is improved, but breathability deteriorates

Engineering Contradiction:

ImprovestretchabilityVSAvoidbreathability

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent merges elastic film and microporous film (rather than nonwoven) into a laminated structure, maintaining the vapor permeability characteristics of the microporous film while adding the stretchability of the elastic film. The resulting laminate achieves both stretchability (≥20% elongation) and breathability (WVTR ≥ 1000 g/m2/day).

Inventive Principle:

Principle #5Merging (Combining)

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 a breathable and stretchable laminate that enhances comfort and protection by allowing vapor permeability while maintaining elasticity, addressing the limitations of traditional backsheet covers.

Implementation Method 1

The precursor web is subjected to incremental stretching whereby the second ply is permanently elongated forming an elastomeric precursor web

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

apertures are formed in the elastomeric precursor web material as the teeth on the second member penetrate the mating member forming an elastomeric apertured web

Methodology Applied

Scientific EffectMechanical piercing: Mechanical Force

Implementation Method 3

The elastomeric apertured web exhibits a WVTR of at least about 1000 g/m2/day

Methodology Applied

Scientific EffectVapor permeability: Permeation

Data Source

PatentUS9034230B2Method for making an elastomeric apertured web

Publication Date: 2015.05.19 PROCTER & GAMBLE CO

AI summary

A method for making an elastomeric apertured web comprises providing a precursor web comprising a laminate which is subjected to incremental stretching to form an elastomeric precursor web. A forming apparatus is provided comprising a first member and a second member, wherein the first member comprises a mating member, and the second member comprises teeth which are joined to the second member. The elastomeric precursor web is moved through the forming apparatus, wherein apertures are formed in the elastomeric precursor web material as the teeth on the second member penetrate the mating member forming an elastomeric apertured web. The elastomeric apertured web exhibits a WVTR of at least about 1000 g/m2/day.