Multi-layer Nonwoven Composite for Absorbent Articles
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Solution Overview
Problem
Current absorbent cores in hygienic products are often thick, stiff, and uncomfortable due to limited space for superabsorbent particles to swell, affecting their absorbency and pliability.
Innovation Solution
A multi-layer nonwoven or composite structure with continuous attachment lines between layers, incorporating a high percentage of superabsorbent polymer particles, allowing for increased absorbency and pliability by enabling the particles to swell without leakage, and featuring a backsheet, topsheet, and optional acquisition distribution layer for enhanced fluid management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If absorbent cores contain superabsorbent particles to provide enhanced absorbency, then absorbency is improved, but the cores become thick and stiff
Solution Approach 1:
The absorbent core is divided into multiple thin layers (first layer, second layer, third layer) rather than using a single thick layer. This segmentation allows the core to maintain high absorbency through distributed SAP particles while improving pliability by reducing the thickness of each individual layer and creating a more flexible multi-layer structure.
2Stability of the object's composition
If superabsorbent particles are immobilized to prevent movement, then particle stability is improved, but absorbency is reduced
Solution Approach 1:
Different regions of the absorbent core have different properties: the first layer provides particle immobilization stability, the second layer provides swelling space for absorbency, and the third layer provides additional stability. This local differentiation allows each layer to optimize for its specific function without compromising the other requirements.
3Quantity of substance
If SAP particles are allowed to swell freely, then absorbency is improved, but particles may leak out
Solution Approach 1:
The first and third layers are positioned at the boundaries of the absorbent core before fluid contact occurs, creating a containment structure in advance. These outer layers prevent SAP particles from leaking out while the second layer in the middle provides the necessary space for particles to swell and absorb fluid.
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 absorbency, comfort, and pliability in absorbent products by allowing superabsorbent particles to swell without limiting their capacity, while maintaining product integrity and reducing adhesive usage.
Implementation Method 1
As SAP particles absorb moisture, they swell.
Implementation Method 2
the lower side of a first layer of the at least two layers is attached to the upper side of an adjacent second layer of the at least two layers with a pattern of continuous attachment lines
Data Source
AI summary
A nonwoven composite including at least two layers with each layer being made of nonwoven and/or tissue and having a lower side and an upper side. The lower side of a first layer of the at least two layers is attached to the upper side of an adjacent second layer of the at least two layers with a pattern of continuous attachment lines extending in a machine direction across a cross direction width of the nonwoven or composite.