Point Bonded Extrusion Laminates for Disposable Absorbent Articles

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing disposable absorbent articles, such as diapers, face challenges in providing a secure fit and preventing leakage due to limited elasticity and surface roughness in certain areas.

Innovation Solution

A point bonded extrusion laminate (PEL) is developed, comprising a first nonwoven layer and an elastic film laminated together via discrete bond sites, creating a rugose outer surface through nonbonded portions of the nonwoven layer that extend beyond the x-y plane.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a continuous bond pattern is used to laminate the nonwoven layer to the elastic film, then bonding strength is improved, but the surface roughness and elasticity are reduced

Engineering Contradiction:

Improvebonding strengthVSAvoidsurface roughness

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The continuous bond pattern is segmented into discrete bond sites arranged in specific patterns (e.g., rows, columns, or clusters). This segmentation allows the laminate to maintain adequate bonding strength through multiple distributed attachment points while leaving intervening areas unbonded, thereby preserving surface roughness and elastic properties in those regions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the laminate are given different bonding characteristics: bonded regions provide strength and attachment, while unbonded regions maintain the original nonwoven layer properties including surface roughness and elasticity. This local differentiation resolves the contradiction by allowing each region to optimize for its specific function.

Inventive Principle:

Principle #3Local quality

2Stability of the object's composition

If the nonwoven layer is fully bonded to the elastic film, then structural stability is improved, but the rugose surface texture is lost

Engineering Contradiction:

Improvestructural stabilityVSAvoidrugose surface texture

Core Design Contradiction:

Stability of the object's compositionVSShape

Solution Approach 1:

The bonding is segmented into discrete sites rather than continuous coverage. The unbonded portions between these sites retain the rugose surface texture while the distributed bond sites provide sufficient structural stability to hold the laminate together during use.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of fully bonding the entire surface, only a partial area (the discrete bond sites) is bonded. This partial action is sufficient to achieve the required structural stability while deliberately leaving enough unbonded area to preserve the rugose surface texture for comfort and fit.

Inventive Principle:

Principle #16Partial or excessive action

3Shape

If discrete bond sites are used instead of continuous bonding, then surface roughness and elasticity are improved, but bonding area is reduced

Engineering Contradiction:

Improvesurface roughnessVSAvoidbonded area

Core Design Contradiction:

ShapeVSArea of stationary object

Solution Approach 1:

The bonding is concentrated at specific discrete locations rather than distributed uniformly. This allows the bonded areas to be optimized for strength while the unbonded areas maintain surface roughness and elasticity, effectively decoupling the requirements for bonding area and surface quality.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The bonding function is segmented into multiple discrete sites that are strategically positioned to provide adequate overall bonding strength. The segmentation allows the total bonded area to be reduced while maintaining functional performance through optimized placement of bond sites.

Inventive Principle:

Principle #1Segmentation

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 PEL enhances the elasticity, softness, and surface roughness of disposable absorbent articles, improving their fit and leakage prevention capabilities.

Implementation Method 1

laminating the elastic film onto the first nonwoven layer by passing the elastic film and the first nonwoven layer through a roller nip comprising a point bond nip roll to form an intermediate material, wherein the point bond nip roll includes a first plurality of discrete protrusions that form a first plurality of discrete bond sites

Methodology Applied

Scientific EffectPressure: Pressure Increase

Implementation Method 2

melt extruding an elastic film onto the first nonwoven layer; activating the intermediate material to form the PEL

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 3

activating the intermediate material to form the PEL, wherein activating the intermediate material forms deformed portions that project outwardly from an x-y plane

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS20250032329A1Point bonded extrusion laminates

Publication Date: 2025.01.30 MAGNERA CORP

AI summary

Point bonded extrusion laminates (PEL) are provided. The PELs include at least a first nonwoven layer and an elastic film that have been laminated together via a first plurality of discrete bond sites bonding the first nonwoven layer to a first side of the elastic film. The first plurality of discrete bond sites define a first bonded area and a first bond pattern between the first nonwoven layer and the first side of the elastic film. The PELs also include first nonbonded portions of the first nonwoven layer located between the first plurality of discrete bond sites, in which the first nonbonded portions of the first nonwoven layer are not bonded to the first side of the elastic film.