Integrated Carded Nonwoven Layer for Soft, Resilient Absorbent Articles
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Solution Overview
Problem
Disposable absorbent articles often face a trade-off between softness and resiliency, with materials that provide cushiony feeling tending to compress and lose shape under use, and resilient materials lacking softness. Additionally, fluid acquisition and stain management are suboptimal, leading to discomfort and potential leakage.
Innovation Solution
Incorporation of a fluid management layer composed of carded, integrated nonwoven material between the topsheet and absorbent core, featuring a caliper factor of at least 0.13 mm, which includes a combination of absorbent, stiffening, and resilient fibers, enhancing softness, resiliency, and fluid handling capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If lofty materials are utilized to provide a thick cushiony feeling article, then softness and cushiony feeling are improved, but resiliency and shape recovery deteriorate
Solution Approach 1:
The absorbent core combines lofty cellulose wadding (providing cushiony feeling) with resilient synthetic fibers (providing shape recovery). This composite structure allows both softness and resiliency to coexist, resolving the contradiction between cushiony feeling and shape recovery.
2Productivity
If higher compressive force is applied to compress the article, then fluid acquisition is improved, but softness and comfort deteriorate
Solution Approach 1:
The absorbent core structure dynamically adapts to applied forces. The lofty materials compress under force to create fluid pathways (improving acquisition), while the resilient synthetic fibers maintain structural integrity and rebound (maintaining softness). This dynamic response resolves the contradiction between fluid acquisition and softness.
3Stability of the object's composition
If resilient materials are used to maintain shape and accommodate forces, then resiliency is improved, but softness and cushiony feeling deteriorate
Solution Approach 1:
The absorbent core combines resilient synthetic fibers (providing shape recovery) with lofty cellulose wadding (providing cushiony feeling). This composite structure allows both resiliency and softness to coexist, resolving the contradiction between maintaining shape and providing comfort.
4Reliability
If the article is designed to be thick and stiff to provide protection, then protection capability is improved, but flexibility and comfort deteriorate
Solution Approach 1:
The absorbent core combines stiffening materials (providing protection capability) with flexible lofty materials (providing flexibility). This composite structure allows the article to be both protective and flexible, resolving the contradiction between protection and comfort.
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 fluid management layer provides improved softness and resiliency in both dry and wet conditions, faster fluid acquisition, and reduced stain visibility, maintaining comfort and effectiveness over time.
Implementation Method 1
The fluid management layer comprises a carded fiber nonwoven material comprising a plurality of integrated fibers
Implementation Method 2
The absorbent article exhibits an average stain size of less than about 2400 mm{circumflex over ( )}2, when measured in accordance with the Stain Size test method
Data Source
AI summary
A disposable absorbent article having a topsheet, a backsheet, an absorbent core disposed between the topsheet and the backsheet, and a fluid management layer disposed between the topsheet and the absorbent core is disclosed. The fluid management layer is an integrated, carded, nonwoven disposed between the topsheet and the absorbent core. The absorbent article exhibits an average stain size of less than about 2400 mm{circumflex over ( )}2, when measured in accordance with the Stain Size test method.