Nonwoven Web Repeat Unit With Intersecting 3D Features

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Solution Overview

Problem

Nonwoven webs used in absorbent articles lack the tactile properties and visual appeal of traditional woven materials, making them less desirable to consumers who prefer softer, more cloth-like textures and appearances.

Innovation Solution

The development of nonwoven webs with a visually discernible pattern of three-dimensional features, comprising intersecting substantially linear segments at specific angles and varying lengths, creating a woven-like appearance and feel by incorporating regions with different visual, tactile, and performance properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If nonwoven webs are made with regular embossed texture patterns, then manufacturing precision and structural uniformity are improved, but visual appeal and tactile softness deteriorate

Engineering Contradiction:

Improvetexture pattern uniformityVSAvoidtactile softness and visual appeal

Core Design Contradiction:

Manufacturing precisionVSShape

Solution Approach 1:

The patent applies asymmetry by creating irregular three-dimensional features with varying heights, widths, and spacing patterns on the nonwoven web surface. The pattern includes regions of different densities and protrusion levels that break the regularity of conventional embossed textures, thereby improving tactile softness and visual appeal while maintaining manufacturing feasibility through controlled irregularity in the embossing or forming process

Inventive Principle:

Principle #4Asymmetry

2Stability of the object's composition

If nonwoven webs are made with regular embossed texture patterns, then structural uniformity is improved, but cloth-like appearance and woven material feel deteriorate

Engineering Contradiction:

Improvestructural uniformityVSAvoidcloth-like appearance

Core Design Contradiction:

Stability of the object's compositionVSShape

Solution Approach 1:

The patent implements local quality by creating spatially varying three-dimensional features with different characteristics in different regions of the nonwoven web. The pattern includes areas with higher protrusion, areas with lower protrusion, and regions with different spacing, mimicking the local variations found in woven materials. This localized differentiation gives the nonwoven web a more cloth-like appearance and feel while maintaining overall structural integrity through controlled pattern repetition

Inventive Principle:

Principle #3Local quality

Data Source

PatentEP3962426B1Nonwoven webs with one or more repeat units

Publication Date: 2025.01.01 PROCTER & GAMBLE CO

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AI summary

A nonwoven web for an absorbent article is provided. The nonwoven web includes a first surface and a second surface. The nonwoven web includes a repeat unit comprising a visually discernible pattern of three-dimensional features on the first surface or the second surface. The three-dimensional features comprise one or more first regions and a plurality of second regions. The one or more first regions are different than the plurality of second regions. The one or more first regions comprise a plurality of substantially linear segments. A first group of the plurality of substantially linear segments intersects with a second group of the plurality of substantially linear segments at angles of intersection. The angles of intersection are in the range of about 70 degrees to about 110 degrees.