Laminate Substrate Densification for Textured Absorbent Articles
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Solution Overview
Problem
Existing absorbent articles, such as diapers, lack an aesthetically pleasing appearance and comfortable fit, and typically require additional materials to achieve texture patterns, increasing costs.
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 enhance the texture and appearance without significant cost additions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If additional materials are used to create texture patterns on absorbent articles, then the aesthetic appearance and texture are improved, but the manufacturing cost increases significantly
Solution Approach 1:
The patent extracts the texture creation function from separate additional materials and integrates it into the existing substrate structure through densified regions. Instead of adding separate texture materials, the invention creates texture by modifying the substrate itself through localized densification, thereby achieving aesthetic appearance without significant cost increase.
Solution Approach 2:
The patent applies local quality by creating densified regions with specific properties (higher density, different texture) in localized areas of the substrate. These densified regions provide varied texture patterns and aesthetic appearance in specific zones rather than uniformly across the entire article, allowing cost-effective texture enhancement where needed.
2Shape
If irregular textures are applied throughout the entire surface of absorbent articles, then aesthetic appearance is improved, but the comfortable feel and fit are compromised
Solution Approach 1:
The patent uses local quality to confine irregular textures to specific densified regions rather than applying them uniformly across the entire surface. This allows aesthetic textures to be concentrated in areas where they enhance appearance without compromising the comfort and fit in other areas of contact with the wearer's body.
Solution Approach 2:
The patent segments the surface into different regions: densified regions with irregular textures for aesthetic purposes, and non-densified regions with regular structures for comfort and fit. This segmentation allows the article to simultaneously achieve aesthetic appearance and comfortable feel by assigning different functions to different zones.
3Ease of manufacture
If elastic elements are attached without prestraining, then the manufacturing process is simpler, but the resulting rugosities do not form the desired patterns
Solution Approach 1:
The patent applies preliminary action by prestraining the elastic elements before attachment to the substrate. This prestraining prepares the elastic elements to generate the desired rugosity patterns upon relaxation, ensuring precise pattern formation. The prestraining step is integrated into the manufacturing process, maintaining ease of manufacture while achieving the required manufacturing precision for pattern formation.
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 improves the fit and appearance of absorbent articles, making them more comfortable and resembling clothing or underwear, while maintaining cost-effectiveness.
Implementation Method 1
allowing the elastic elements to at least partially contract
Implementation Method 2
forming densified regions in the first substrate
Implementation Method 3
adhesively attaching the elastic elements to the first substrate
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.