Microperforated Laminate Webs for Soft High-Speed Absorbent Articles
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Solution Overview
Problem
Existing laminate processes struggle to maintain flexibility and softness while operating at high velocities, leading to challenges in producing laminate webs with desirable properties for absorbent articles.
Innovation Solution
A method involving extrusion coating of a semi-molten polymer film with a nonwoven web, followed by aperturing and macroperforating to create microperforations and macroperforations, using heat and pneumatic pressure differential, to form a microperforated nonwoven web with enhanced fluid transport and softness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a lamination process is used to create laminate webs with microtextured polymer film and nonwoven layers, then fluid transport and drainage capabilities are improved, but the laminate web becomes less flexible and soft
Solution Approach 1:
The patent applies parameter changes by controlling the basis weight of the polymer film layer within a specific range (7-17 gsm) and the nonwoven layer (9-40 gsm), and by optimizing the microperforation density (35-120 perforations per 2.54 cm). These parameter optimizations enable the laminate to achieve both improved fluid transport through the microperforations and maintained flexibility/softness through appropriate layer thickness and composition.
2Productivity
If the lamination process is operated at high velocities to increase production output, then productivity is improved, but the quality and properties of the laminate web deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-cooling the extruded polymer film to a semi-molten temperature before it contacts the nonwoven layer. This preliminary temperature reduction allows the polymer to maintain sufficient viscosity for proper lamination bonding at high production velocities while still enabling the formation of controlled microperforations, thus preserving laminate quality even at increased production speeds.
3Productivity
If microperforations are created in the polymer film to improve fluid handling, then fluid drainage is improved, but the structural integrity and softness of the laminate is reduced
Solution Approach 1:
The patent applies porous materials by creating a controlled array of microperforations in the polymer film layer. These microperforations provide fluid drainage pathways while the overall porous structure is designed with appropriate density (35-120 perforations per 2.54 cm) to maintain sufficient structural integrity. The nonwoven layer also contributes to the overall porous structure, providing both fluid handling capability and mechanical strength.
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 process enables the production of flexible and soft laminate webs suitable for absorbent articles, with improved fluid handling and drainage capabilities, while maintaining high production velocity.
Implementation Method 1
aperturing said semi-molten polymer film through heat and pneumatic pressure differential to create microperforations
Implementation Method 2
aperturing said semi-molten polymer film through heat and pneumatic pressure differential to create microperforations
Implementation Method 3
reducing the temperature of the extruded molten polymer film to a semi-molten temperature to make a semi-molten polymer film
Data Source
AI summary
A laminate web having a polymer film layer and a nonwoven layer is disclosed. The polymer film layer makes up a first side of the laminate web and the nonwoven layer makes up a second side of the laminate web. The laminate web has a plurality of first elements extending from the polymer film. The web also has a plurality of second elements such as recesses, protrusions, apertures, embossing and combinations thereof.