Function-Formed Nonwoven Topsheet Channels for Reduced Rewetting
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Solution Overview
Problem
Current absorbent articles, such as feminine hygiene pads, face challenges in effectively imparting three-dimensional structural features to nonwoven web materials for topsheets, which affect fluid distribution and retention, leading to issues like fluid retention in the topsheet and rewetting.
Innovation Solution
The method involves forming nonwoven web materials with attenuated regions defining channel portions and built-up regions, using a forming belt to create visually discernible patterns that enhance fluid distribution and containment, while maintaining aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If nonwoven web materials are used for topsheets to ensure liquid permeability and wearer comfort, then fluid can pass through to reach absorbent material, but the materials lack sufficient three-dimensional structural features to enhance fluid distribution and prevent retention
Solution Approach 1:
The nonwoven web material is segmented into distinct regions: built-up regions with higher fiber density and attenuated regions with lower fiber density forming channel portions. This segmentation creates three-dimensional structural features that enhance fluid distribution while maintaining manufacturing feasibility through region-specific fiber deposition control
Solution Approach 2:
Different regions of the nonwoven web material are given different local qualities: built-up regions provide fluid retention and structural support, while attenuated regions provide fluid transport channels. This local differentiation of properties enables enhanced fluid distribution without requiring complete restructuring of the entire material
2Reliability
If conventional nonwoven topsheets are used to maintain aesthetic appeal and cost effectiveness, then manufacturing remains simple, but fluid retention in the topsheet and rewetting occur
Solution Approach 1:
The topsheet is segmented into channel portions (attenuated regions) that actively transport fluid away from discharge locations, preventing fluid retention. This segmentation ensures reliable fluid distribution while maintaining the overall integrity and aesthetic appearance of the topsheet
Solution Approach 2:
The attenuated regions act as intermediary fluid transport pathways between the discharge location and the absorbent material below. These channel portions facilitate efficient fluid movement, preventing direct fluid retention in the topsheet and subsequent rewetting
3Object-generated harmful factors
If three-dimensional structural features are imparted to nonwoven topsheets to enhance fluid distribution, then fluid retention is reduced, but manufacturing complexity and cost increase
Solution Approach 1:
The formation of three-dimensional structural features is merged with the existing nonwoven web manufacturing process. By integrating region-specific fiber deposition and bonding into the standard production line, the patent achieves enhanced fluid distribution without requiring separate manufacturing steps, thus controlling complexity
Solution Approach 2:
The manufacturing process utilizes parameter changes in fiber deposition density and bonding intensity to create built-up and attenuated regions. By controlling these parameters during web formation, three-dimensional structural features are imparted without fundamentally changing the manufacturing process or significantly increasing complexity
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 enhances fluid acceptance and movement into the absorbent structure, reduces fluid retention on the topsheet, and minimizes rewetting, providing improved comfort and functionality.
Implementation Method 1
forming nonwoven web materials with attenuated regions defining channel portions and built-up regions, using a forming belt to create visually discernible patterns
Implementation Method 2
the topsheet is adapted to be liquid permeable such that liquid body exudates may pass therethrough, to reach the absorbent material contained in the envelope structure, and be absorbed and retained by the absorbent material
Implementation Method 3
attenuated regions defining channel portions... enhance fluid distribution and containment... enhances fluid acceptance and movement into the absorbent structure, reduces fluid retention on the topsheet
Data Source
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AI summary
An absorbent article in the form of a feminine hygiene pad is disclosed. The article includes a topsheet formed of a section of formed nonwoven web material having an ordered arrangement of zones, each zone comprising one or more attenuated regions adjacent to one or more built-up regions, wherein the attenuated regions have a first average basis weight and the built-up regions have a second average basis weight. Through configuration of the regions and the ordered arrangement, inclusion of melt additive to the resin(s) from which the filaments are spun and/or application of a surfactant to a surface of the topsheet, the topsheet may be imparted with a Rewet of no greater than 0.50 g and an Acquisition Time of no greater than 25 seconds, balancing competing topsheet performance characteristics in a manner acceptable or preferable for consumers/users.