Nonwoven Intermediate Layer for Softer Flexible Absorbent Articles
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Solution Overview
Problem
Existing absorbent articles, particularly those with high superabsorbent polymer content, suffer from a grainy feel and increased stiffness due to the addition of intermediate layers, which compromises flexibility and increases production costs.
Innovation Solution
Incorporating an intermediate layer with a nonwoven web that has a specific tensile and thickness basis weight, along with thermoplastic fibers of differing melting temperatures, to provide cushiony feel and flexibility without excessive stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an intermediate layer is added to reduce grainy feel, then comfort is improved, but stiffness increases and flexibility deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the basis weight (5-20 g/m²) and thickness (0.03-0.1 mm) of the intermediate layer, and by selecting specific fiber types with different melting points (first thermoplastic fibers: 100-150°C, second thermoplastic fibers: 150-200°C). These parameter optimizations allow the intermediate layer to reduce grainy feel while maintaining flexibility and avoiding excessive stiffness.
2Object-affected harmful factors
If basis weight of soft nonwoven layer is increased to reduce grainy feel, then comfort is improved, but production cost increases
Solution Approach 1:
The patent optimizes the basis weight of the intermediate layer to a specific range (5-20 g/m²) to achieve the desired comfort level while controlling production costs. This parameter optimization avoids both excessive material usage and insufficient comfort improvement.
Solution Approach 2:
The patent uses composite materials by combining two types of thermoplastic fibers with different melting points in the intermediate layer. This composite structure provides effective grainy feel reduction at optimized material costs, avoiding the need for expensive single-material solutions with higher basis weight.
3Object-affected harmful factors
If more materials are added to reduce grainy feel, then comfort is improved, but article becomes stiffer
Solution Approach 1:
The patent controls the thickness of the intermediate layer within 0.03-0.1 mm and basis weight within 5-20 g/m² to provide sufficient grainy feel reduction while preventing excessive stiffness. These parameter constraints ensure the layer remains thin and flexible.
Solution Approach 2:
The patent applies local quality by positioning the intermediate layer specifically between the absorbent core and backsheet, rather than throughout the entire article. This localized application provides grainy feel reduction only where needed (at the garment-facing surface) while minimizing impact on overall article flexibility.
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 intermediate layer effectively reduces the grainy feel and maintains flexibility while minimizing production costs by optimizing fiber bonding for high thickness under compression and low stiffness.
Implementation Method 1
applying heat to the nonwoven web so that at least part of the first thermoplastic fibers are heat-fused one another, wherein the heat has a temperature between the first melting temperature and lower than the second melting temperature
Data Source
AI summary
The present disclosure relates to an absorbent article comprising a topsheet, a backsheet, and a layer of absorbent material disposed between the topsheet and the backsheet, wherein the layer of absorbent material comprises superabsorbent polymer, and an intermediate layer comprising a nonwoven web. The intermediate layer is disposed between the layer of absorbent material and the backsheet, wherein the intermediate layer has a MD tensile/basis weight no greater than about 0.75 N/5 cm/g/m2 as measured according to Tensile Strength Test, and a thickness/basis weight no less than about 0.078 mm/g/m2, as measured FTT Test.