Hydroentangled Acquisition-Distribution Layer for Fluid Management
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Solution Overview
Problem
There is a need for an acquisition-distribution-layer (ADL) in absorbent articles that can promptly absorb and distribute fluids across a wide area of the absorbent core, improving fluid capture and reducing rewet values.
Innovation Solution
The ADL comprises a hydroentangled composite with a first outer layer of synthetic fibers, a second outer layer of synthetic fibers, and at least one core layer of cellulose fibers, which are physically entangled together. This composite features a three-dimensional topography with raised and recessed portions, and may include apertures to enhance fluid acquisition and distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional acquisition web and distribution layer are used separately, then the structure is simple and easy to manufacture, but the fluid capture rate and distribution efficiency are insufficient
Solution Approach 1:
The patent combines the acquisition web and distribution layer into a single integrated acquisition-distribution layer (ADL). The ADL comprises a topsheet with acquisition regions and a distribution layer with distribution regions, where the distribution regions are in direct communication with the acquisition regions. This merging eliminates the need for separate components while maintaining both acquisition and distribution functions, thereby improving fluid capture rate without proportionally increasing structural complexity.
Solution Approach 2:
The acquisition-distribution layer performs multiple functions simultaneously: it acts as both an acquisition web (receiving and temporarily storing liquid) and a distribution layer (distributing liquid to the absorbent core). The topsheet portion provides acquisition functionality while the distribution layer portion provides distribution functionality, all within a single composite structure. This multi-functionality improves productivity by consolidating tasks that previously required separate components.
2Area of stationary object
If the ADL uses a flat structure, then the manufacturing process is simple, but the fluid distribution area and efficiency are limited
Solution Approach 1:
The distribution layer is configured with a three-dimensional topography including raised portions and recessed portions, transitioning from a flat two-dimensional structure to a three-dimensional structure. The raised portions define distribution regions that extend toward the topsheet, creating channels and pathways for fluid flow. This dimensional change increases the effective fluid distribution area and improves distribution efficiency without significantly complicating the manufacturing process, as the topography can be formed during the web formation process.
Solution Approach 2:
The ADL features localized regions with different properties: the topsheet has acquisition regions with specific porosity and hydrophilicity for fluid reception, while the distribution layer has raised portions and recessed portions creating channels for fluid transport. The raised portions are strategically positioned to define distribution pathways, and the recessed portions facilitate fluid flow toward the absorbent core. This local differentiation of structure and function maximizes fluid distribution area and efficiency.
3Reliability
If synthetic fibers are used exclusively in the outer layers, then the structural integrity is maintained, but the fluid absorption and distribution performance is reduced
Solution Approach 1:
The acquisition-distribution layer uses a composite fiber structure: the topsheet is made of hydrophilic fibers (natural or synthetic) to facilitate fluid acquisition, while the distribution layer incorporates both hydrophobic synthetic fibers (for structural integrity) and hydrophilic fibers (for fluid distribution). The interfacial region between acquisition and distribution layers contains a mixture of fiber types to ensure both structural stability and fluid transport efficiency. This composite material approach balances structural requirements with fluid management performance.
Solution Approach 2:
Different fiber compositions are used in different regions of the ADL: the topsheet uses predominantly hydrophilic fibers for fluid reception, the distribution layer uses a combination of hydrophobic and hydrophilic fibers for structured fluid transport, and the interfacial region uses a mix to ensure both structural integrity and fluid transfer. This spatial variation in material properties optimizes both structural reliability and fluid distribution efficiency in their respective locations.
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 hydroentangled composite ADL achieves a high fluid capture rate and low rewet value, efficiently distributing fluids across a large area of the absorbent core, thereby improving the performance of absorbent articles.
Implementation Method 1
the first plurality of synthetic fibers, the second plurality of synthetic fibers, and the cellulose fibers are physically entangled together
Implementation Method 2
The hydroentangled composite, in accordance with certain embodiments of the invention, may further comprise a three-dimensional topography defined by a first outermost surface of the hydroentangled composite, wherein the three-dimensional topography includes a plurality raised portions and a plurality of recessed portions
Data Source
AI summary
Acquisition-distribution-layers (ADL) comprising a hydroentangled composite are provided. The hydroentangled composite includes (a) a first outer layer including a first plurality of synthetic fibers, (b) a second outer layer including a second plurality of synthetic fibers, and (c) at least one core layer including cellulose fibers comprising natural cellulose fibers, synthetic cellulose fibers, or a combination thereof, in which the at least one core layer is located directly or indirectly between the first outer layer and the second outer layer. The first plurality of synthetic fibers, the second plurality of synthetic fibers, and the cellulose fibers are physically entangled together. The hydroentangled composite further comprises a three-dimensional topography defined by a first outermost surface of the hydroentangled composite, in which the three-dimensional topography includes a plurality raised portions and a plurality of recessed portions.