Multilayer Non-Woven Topsheet with Semi-Arcuate Bonding
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Solution Overview
Problem
Existing multilayer materials for absorbent sanitary articles face challenges in providing a soft, permeable, and resilient topsheet that allows rapid fluid passage while maintaining dryness and cushioning, with current solutions being costly and inefficient in production.
Innovation Solution
A multilayer material comprising at least two layers, including a non-woven fabric layer and a perforated layer, produced using a process where layers are unwound at different speeds and passed through rotating rollers with projections to form connection regions with a semi-arcuate pattern, enhancing cushioning and softness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the topsheet is made thicker to provide cushioning and softness, then the comfort and cushioning effect are improved, but the liquid permeation ability deteriorates
Solution Approach 1:
The patent employs a non-woven fabric structure with controlled porosity that allows liquid to pass through rapidly while maintaining thickness for cushioning. The fibrous network creates channels for fluid flow without requiring the material to be thin, thus resolving the contradiction between thickness and permeability.
Solution Approach 2:
The topsheet is designed with varying local properties - certain regions have higher density for softness while other areas maintain higher porosity for liquid flow. This spatial variation in material quality allows simultaneous achievement of cushioning and rapid permeation.
2Ease of manufacture
If conventional non-woven fabrics are used to reduce cost, then the manufacturing cost is reduced, but the softness and comfort deteriorate
Solution Approach 1:
The patent uses composite non-woven structures combining different fiber types or configurations to achieve enhanced softness. This allows using cost-effective materials while attaining premium comfort characteristics through intelligent material composition and structure.
3Shape
If ATB technology is used to produce thick materials, then the cushioning effect is improved, but the dryness effect deteriorates and production cost increases
Solution Approach 1:
The patent optimizes key parameters including fiber diameter distribution, basis weight, and porosity to achieve the desired balance. By carefully controlling these parameters, the material provides adequate cushioning while maintaining rapid liquid transmission for dryness, avoiding the limitations of ATB technology.
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 resulting material achieves an excellent three-dimensional effect, ensuring softness and rapid fluid passage while maintaining dryness, suitable for use as a topsheet in absorbent sanitary articles with improved production efficiency.
Implementation Method 1
passed through rotating rollers with projections to form connection regions
Implementation Method 2
a non-woven fabric layer and a perforated layer, produced using a process where layers are unwound at different speeds
Implementation Method 3
allows rapid fluid passage while maintaining dryness
Data Source
Figure 1
Figure 2~3
AI summary
A multilayer material (1) is described comprising at least one layer of pre-tensioned non-woven fabric (2) and a second layer connected to the first layer by means of connection regions (3). The connection regions comprise a plurality of primary patterns (4). Each primary pattern consists of at least one central connection region (5) and two non-rectilinear connection regions (6,7) arranged alongside the central region, but without contact between them and with the central region. The central connection region and the non-rectilinear connection regions form overall an arc region (8) comprising a concave region (9).