Methods of making laminates for absorbent articles
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Solution Overview
Problem
Existing absorbent articles, such as diapers, lack an aesthetically pleasing appearance and comfortable fit, and do not resemble clothing or underwear, due to irregular textures that are not cost-effective to produce.
Innovation Solution
A method of making laminates for absorbent articles by forming densified regions in substrates and attaching elastic elements in a prestrained state, allowing them to contract and create rugosities that form patterns, which improve the texture and appearance without significant cost increases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If additional materials are used to provide textures on absorbent articles, then aesthetic appearance is improved, but manufacturing cost increases
Solution Approach 1:
The substrate surface is divided into multiple densified regions with different densities, creating varied textures without adding separate materials. Each densified region acts as an independent texture element, achieving aesthetic diversity through spatial segmentation of density properties
Solution Approach 2:
The invention changes the density parameter of substrate regions through controlled densification processes. By varying density across different regions, diverse textures are created from a single material, eliminating the need for additional materials and reducing manufacturing costs
2Ease of operation
If elastic elements are attached to substrates, then fit and comfort are improved, but the substrates require pre-straining and densification processes that increase manufacturing complexity
Solution Approach 1:
Elastic elements are pre-strained before attachment to substrates, and substrates are pre-densified in specific regions before elastic elements are attached. This preliminary preparation ensures proper fit and comfort while organizing the manufacturing process into sequential, manageable steps
Solution Approach 2:
Densification is applied locally to specific regions of the substrate rather than uniformly across the entire substrate. This localized densification creates specific texture patterns and mechanical properties where needed, reducing overall manufacturing complexity while achieving the desired fit 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 method enhances the fit and appearance of absorbent articles, making them more comfortable and aesthetically pleasing, resembling clothing or underwear while maintaining cost-effectiveness.
Implementation Method 1
allowing the elastic elements to at least partially contract
Data Source
AI summary
A method of making a laminate for an absorbent article is provided. The laminate comprises elastic elements disposed at least partially intermediate two substrates. The first substrate has a primary fiber bond pattern formed therein and comprising a plurality of primary fiber bonds. The method comprises forming densified regions in the first substrate. A perimeter of each of the densified regions is larger than a perimeter of each of the primary fiber bonds. The densified regions together form a pattern of densified regions in the first substrate. The method comprises adhesively attaching the elastic elements to the first substrate, joining the second substrate to the first substrate or to some of the elastic elements, and forming a plurality of rugosities in the first substrate by allowing the elastic elements to at least partially contract. The frequency and amplitude ranges of the rugosities result from the pattern of the densified regions.