Embossed Topsheets for Disposable Absorbent Articles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing disposable absorbent articles with smooth, flat topsheets lack aesthetic appeal and struggle to achieve deep embossments in relatively thin materials, limiting their ability to create a visually appealing and effective absorbent design.
Innovation Solution
A method involving a continuous topsheet web advanced through an embossing nip with a rotating patterned embossing roll and anvil roll, allowing for deeper patterns to be embossed by combining the topsheet with a liquid acquisition layer and a cellulose-free absorbent core, resulting in discrete indented regions greater than 100 µm and specific density variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If embossing is performed on relatively thin topsheet material using conventional methods, then the topsheet can be modified to provide a three-dimensional appearance, but the embossment depth is limited and difficult to achieve deep patterns
Solution Approach 1:
The patent combines the topsheet with the acquisition layer and absorbent core to form a composite structure before embossing. This merging allows the embossing roll to create deeper patterns by distributing the compression across multiple layers, achieving embossment depths greater than 100 micrometers while maintaining pattern definition.
Solution Approach 2:
The invention nests the topsheet within the acquisition layer and absorbent core, creating a layered configuration where the topsheet is positioned between the acquisition layer and the embossing roll. This nesting structure enables the thin topsheet to receive deep embossments without compromising its integrity, as the surrounding layers provide structural support during the embossing process.
2Volume of moving object
If the topsheet is made thinner to reduce article thickness, then the article becomes more compact, but the ability to emboss deep patterns is reduced
Solution Approach 1:
By merging the topsheet with the acquisition layer and absorbent core into a integrated assembly, the patent enables deep embossing in thin topsheets. The combination of layers allows the embossing force to be distributed, creating patterns deeper than 100 micrometers even when the topsheet itself remains relatively thin, thus maintaining compact article thickness while achieving desired embossment depth.
3Ease of manufacture
If conventional embossing methods are used on thin topsheets, then the manufacturing process remains simple, but the aesthetic appearance and visual appeal are compromised
Solution Approach 1:
The patent maintains ease of manufacture by using a continuous web processing approach where the topsheet, acquisition layer, and absorbent core are combined and embossed in a single integrated process. This merging allows deep, aesthetically pleasing embossments with depths greater than 100 micrometers to be achieved without adding significant process complexity, as the embossing is performed on the assembled structure rather than requiring separate operations.
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 enables the creation of absorbent articles with aesthetically pleasing, deep embossments without compromising liquid acquisition performance or the integrity of the core, enhancing the article's absorbency and appearance.
Implementation Method 1
the rotating patterned embossing roll contacts the continuous topsheet web... the depth of the discrete indented regions are greater than 100 µm
Implementation Method 2
liquid acquisition layer... substantially cellulose free absorbent core... function to absorb and/or contain the discharged materials
Implementation Method 3
absorbent core... function to absorb and/or contain the discharged materials
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present disclosure relates to absorbent articles with embossed topsheets. Such absorbent articles may be fabricated with a continuous topsheet web having a first surface and an opposing second surface advanced in a machine direction. A liquid acquisition layer and an absorbent core are combined with the continuous topsheet web. And the combined continuous topsheet web, liquid acquisition layer, and absorbent core advance through the embossing nip to emboss a pattern in the continuous topsheet web. As the combined continuous topsheet web, liquid acquisition layer, and absorbent core advance through the embossing nip, the rotating patterned embossing roll contacts the continuous topsheet web. And the rotating anvil roll contacts the absorbent core. By advancing the topsheet together with the acquisition layer and absorbent core through the embossing nip, a relatively deeper pattern can be embossed into the topsheet than otherwise might be possible when embossing relatively thin topsheet web materials.