Function-Formed Topsheet Channels for Fluid Distribution and Containment

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Solution Overview

Problem

Current absorbent articles, such as feminine hygiene pads, lack effective methods to rapidly distribute and contain bodily fluids, with existing topsheets failing to provide dramatic three-dimensional structural features that enhance fluid movement and prevent leakage.

Innovation Solution

The topsheet features attenuated regions with lower basis weight and built-up regions with higher basis weight, forming channels and hinges that guide fluid movement into the absorbent structure while preventing lateral spread, combined with controlled filament deposition and airflow to create visually discernible patterns.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If embossing and bonding are applied to nonwoven topsheets, then decorative surface features are improved, but three-dimensional topographical features and functional benefits are insufficient

Engineering Contradiction:

Improvesurface topographical featuresVSAvoidfunctional benefits

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The topsheet is segmented into distinct regions with different basis weights - attenuated regions (lower basis weight) forming channels and built-up regions (higher basis weight) providing containment. This segmentation creates functional three-dimensional topography that simultaneously delivers aesthetic appeal and reliable fluid management performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the topsheet are given different local qualities through varying basis weight. The attenuated regions provide open pathways for fluid movement while built-up regions provide absorption capacity and containment, creating localized functional zones within the single topsheet structure.

Inventive Principle:

Principle #3Local quality

2Reliability

If uniform nonwoven material is used for topsheet, then manufacturing simplicity is maintained, but fluid distribution and containment performance is insufficient

Engineering Contradiction:

Improvefluid distribution and containmentVSAvoidtopsheet structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The basis weight parameter of the nonwoven material is varied across different regions of the topsheet. By changing this physical parameter during manufacturing, the topsheet achieves differentiated functional zones for fluid distribution and containment without requiring assembly of multiple separate components.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Multiple functions (fluid distribution channels, containment barriers, absorption zones) are merged into a single topsheet structure through controlled variation of basis weight. This integration eliminates the need for separate components while achieving superior fluid management performance.

Inventive Principle:

Principle #5Merging (Combining)

3Speed

If current topsheet designs are used, then cost effectiveness is maintained, but rapid fluid acceptance and movement is insufficient

Engineering Contradiction:

Improvefluid acceptance and movement rateVSAvoidmanufacturing complexity

Core Design Contradiction:

SpeedVSEase of manufacture

Solution Approach 1:

The topsheet structure is pre-configured with attenuated regions and built-up zones during manufacturing to create built-in fluid pathways and containment areas. This preliminary structural arrangement enables rapid fluid acceptance and directional movement without requiring additional active components or complex assembly steps.

Inventive Principle:

Principle #10Preliminary action

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 distribution and containment, providing rapid absorption and reducing the risk of leakage, while also offering aesthetic appeal through visible structural features.

Implementation Method 1

The attenuated regions have a first average basis weight and the built-up regions have a second average basis weight greater than the first average basis weight, the difference in basis weights corresponding to disposition of the filaments according to the ordered arrangement

Methodology Applied

Scientific EffectFluid flow through porous material: Porosity

Implementation Method 2

fluid movement across the topsheet along x and y directions beyond the channel portions is inhibited by the built-up regions outside the channel portions

Methodology Applied

Scientific EffectPhysical barrier to fluid flow: Physical Containment

Implementation Method 3

controlled filament deposition and airflow to create visually discernible patterns

Methodology Applied

Scientific EffectAirflow-controlled deposition: Deposition (physical)

Data Source

PatentUS12357514B2Absorbent article with function-formed topsheet, and method for manufacturing

Publication Date: 2025.07.15 PROCTER & GAMBLE CO

AI summary

An absorbent article 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, wherein the first average basis weight is less than the second average basis weight, the difference in basis weights corresponding to disposition of the filaments according to the ordered arrangement. The attenuated region(s) may be included within a configuration of one or more channel portions on the topsheet. Alternatively or in combination, the attenuated region(s) may be included within a hinge portion extending along a wing portion of the topsheet.