Multilayer Absorbent Element With Flat Drainage Layer
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Solution Overview
Problem
Existing multilayer absorbent topsheets for sanitary articles face challenges in adhesion to the absorbent core, storage integrity, and production costs due to the use of heat-retractable fibers, which complicate the manufacturing process and increase costs.
Innovation Solution
A multilayer absorbent element with a flat second layer and a first layer featuring protrusions and holes, where the second layer is devoid of protrusions and depressions, ensuring better adhesion and storage properties, and using thermoplastic fibers without heat-retractable fibers to simplify and reduce production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If heat-retractable fibers are used to create protrusions and depressions in the second layer, then the topsheet becomes softer and more comfortable, but the adhesion to the absorbent core deteriorates and the manufacturing complexity increases
Solution Approach 1:
The invention divides the topsheet into two distinct layers with different functions: the first layer (contact layer) retains the concave-convex structure for comfort, while the second layer (drainage layer) is kept flat for adhesion. This segmentation allows each layer to optimize its specific function without compromising the other.
Solution Approach 2:
The invention applies different structural qualities to different layers: the first layer has protrusions and depressions for softness and comfort, while the second layer maintains a flat structure for reliable adhesion and drainage. Each layer's local quality is optimized for its specific function.
2Ease of operation
If heat-retractable fibers are used to form the concave-convex structure, then the topsheet becomes softer, but the manufacturing cost and process complexity increase
Solution Approach 1:
The invention separates the comfort function (concave-convex structure) from the drainage function (flat layer), allowing the complex structure to be confined to only the first layer while the second layer remains simple and flat, reducing overall manufacturing complexity.
Solution Approach 2:
Instead of making the second layer (drainage layer) concave-convex as in conventional topsheets, the invention inverts the approach by making the first layer (contact layer) concave-convex and the second layer flat, thereby achieving comfort without compromising drainage efficiency.
3Ease of operation
If the second layer is made with protrusions and depressions, then the topsheet is softer, but the storage integrity and adhesion are compromised
Solution Approach 1:
The invention segments the structural features into the first layer only, keeping the second layer flat and stable. This ensures that the concave-convex structure does not interfere with storage integrity or adhesion to the absorbent core, while still providing comfort.
Solution Approach 2:
The invention applies the concave-convex structure locally to the first layer where comfort is needed, while keeping the second layer uniformly flat where stability and adhesion are critical, optimizing both comfort and structural integrity.
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 solution provides improved adhesion to the absorbent core, enhanced storage stability, and reduced production costs, while maintaining absorption efficiency and user comfort, with the option to add pigments for stain masking and acting as an Acquisition Distribution Layer.
Implementation Method 1
The second layer, interposed between the upper layer and the absorbent core, must be denser and provided with greater capillary power with respect to the first layer, so as to dry the latter by draining and transferring the organic fluid to the absorbent core.
Implementation Method 2
The second layer, interposed between the upper layer and the absorbent core, must be denser and provided with greater capillary power with respect to the first layer, so as to dry the latter by draining and transferring the organic fluid to the absorbent core.
Data Source
AI summary
An apparatus for making a multilayer absorbent element apt to be incorporated in a sanitary article is provided. The apparatus has an embossing roller bearing a plurality of protruding elements, a pierced roller bearing a plurality of protruding elements and cavities, and a unit of cohesion and drilling. The configuration of the apparatus is such that, after a first layer of sheet material is deformed by the embossing roll and the perforated roller continues to slide on the pierced roller, a second layer of sheet material is superimposed. The first and second layer of sheet material are then carried to the joining and piercing unit in which, at the intermediate zones of the first layer, it forms a plurality of holes passing through the first and second layer and joins them near or at the plurality of holes.