Laminate Web Structure for Fluid Drainage and Stain Masking
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Solution Overview
Problem
Existing laminate webs with microtextured polymer films face challenges in fluid drainage and visibility of trapped fluid, leading to premature perception of product exhaustion, and post-formation macrostructures can damage microtextures, affecting surface smoothness and fluid transport.
Innovation Solution
A laminate web structure featuring a nonwoven layer with fibers extending from a polymer film, incorporating discrete first elements and macroscopic second elements such as protrusions or recesses, which enhance fluid drainage and mask stains by enlarging open ends of elements for improved fluid acquisition and opacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polymer film layer is used to provide a barrier function, then protection against leakage and bacterial growth is improved, but the laminate becomes less breathable and less conformable to the body
Solution Approach 1:
The patent employs a polymer film layer with specific micropore characteristics (porosity of 0-80%, average pore size 0.01-10 micrometers) that acts as a flexible barrier. This thin film structure provides leakage and bacterial protection while maintaining breathability through controlled porosity, resolving the contradiction between barrier function and breathability.
Solution Approach 2:
The polymer film layer is designed with micropores that allow vapor transmission while blocking liquid and bacteria. The controlled porosity (0-80%) and pore size (0.01-10 micrometers) enable the material to provide barrier protection without compromising breathability, as vapor can pass through the porous structure while larger contaminants are blocked.
2Reliability
If a polymer film layer is used to provide a barrier function, then protection against leakage and bacterial growth is improved, but conformability to the body is reduced
Solution Approach 1:
The polymer film layer is designed as a thin, flexible structure that can conform to body contours. The film's thinness and flexibility allow it to adapt to the curved surfaces of the body while maintaining its barrier function, resolving the contradiction between protection and conformability.
3Stability of the object's composition
If the polymer film is made thinner to improve conformability, then comfort and body contouring are improved, but the barrier function and protection are reduced
Solution Approach 1:
The polymer film utilizes a porous structure where the barrier function is provided by the pore size (0.01-10 micrometers) rather than film thickness. This allows the film to be made thin for conformability while maintaining barrier protection through the controlled pore dimensions that block bacteria and liquid.
Solution Approach 2:
The patent changes the critical parameters from film thickness to pore size and porosity percentage (0-80%) to define barrier performance. By controlling pore dimensions rather than relying on thickness, the film can be thin and conformable while maintaining effective barrier function against bacteria and leakage.
4Productivity
If absorbent capacity is increased to reduce changing frequency, then productivity and efficiency are improved, but the risk of bacterial growth and leakage increases
Solution Approach 1:
The laminate structure divides functions into different layers with specific local properties: the polymer film layer provides barrier protection (0-80% porosity) to prevent bacterial growth, while the superabsorbent polymer layer provides high absorbent capacity. This functional segmentation allows high capacity without compromising hygiene.
Solution Approach 2:
The patent combines a polymer film layer with micropore structure and a superabsorbent polymer layer in a composite laminate structure. The polymer film provides barrier function to prevent bacterial growth, while the superabsorbent layer provides high absorbent capacity, resolving the contradiction between capacity and hygiene through material composition.
Data Source
Figure 1~2A
Figure 2B~3
Figure 4A~4B
AI summary
The invention is directed to a laminate web comprising a polymer film layer comprising polymer film, a nonwoven layer comprising a nonwoven web, a first side comprising the polymer film, a second side opposed to the first side comprising the nonwoven web, and a plurality of first elements extending from the polymer film. The web comprises a plurality of second elements such as recesses, protrusions, apertures, embossing and combinations thereof. The web has one or more than one first element having an open distal end at least 1.5 times larger than the largest distal open end of a first element in a land between the two adjacent second elements.