Perforated Laminate Topsheet for Fluid Type Separation
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Solution Overview
Problem
Current absorbent articles, such as diapers and sanitary napkins, are inadequate in distinguishing between fluid types, often failing to absorb body sweat in addition to menstrual fluid, leading to wearer discomfort.
Innovation Solution
A perforated laminate topsheet comprising at least two layers with apertures extending through the first layer, joined at the periphery, where the first layer is a nonwoven or formed film and the second layer is a nonwoven absorbent structure with small wet pore diameters, allowing for improved fluid distribution and absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single-layer absorbent structure is used, then manufacturing is simple, but the ability to distinguish and handle different fluid types is insufficient
Solution Approach 1:
The absorbent article is divided into distinct functional layers: a topsheet layer with apertures for fluid distribution and a separate absorbent layer for fluid absorption. This segmentation allows each layer to be optimized for its specific function, enabling the structure to handle different fluid types effectively while maintaining manufacturing feasibility through standardized layering processes.
Solution Approach 2:
The invention uses a composite laminate structure combining a topsheet material (such as woven or nonwoven fabric) with an absorbent layer (such as fluff pulp or superabsorbent polymer). This composite construction integrates materials with different properties to achieve both fluid distribution and absorption functions, enhancing adaptability to different fluid types without excessive complexity.
2Ease of operation
If all fluid is absorbed by the underlying layer, then absorption capacity is maximized, but comfort is reduced due to inability to redirect excess fluid
Solution Approach 1:
The topsheet incorporates apertures of specific sizes and distributions at strategic locations to create local variations in fluid handling. Smaller apertures allow capillary action for sweat absorption, while larger apertures enable direct fluid passage to the absorbent layer. This local quality variation optimizes both comfort through sweat management and overall absorption capacity.
Solution Approach 2:
The laminate structure dynamically responds to different fluid types and quantities: for small fluid quantities like sweat, capillary action through the topsheet material and small apertures provides absorption; for larger fluid quantities, the aperture system redirects excess fluid to the absorbent layer. This dynamic response enhances wearer comfort while preserving absorption capacity.
3Adaptability or versatility
If apertures are added to the topsheet, then fluid distribution and redirection capability is improved, but manufacturing complexity increases
Solution Approach 1:
Instead of using complex mechanical perforation equipment, the invention employs thermal or chemical methods to create apertures in the topsheet. Thermal bonding with perforating needles or chemical etching processes can create the required aperture patterns more efficiently, reducing manufacturing complexity while maintaining fluid distribution capability.
Solution Approach 2:
The aperture parameters (size, shape, distribution, and density) are optimized to achieve the desired fluid distribution capability with minimal manufacturing complexity. By carefully selecting aperture dimensions and patterns that work effectively with standard manufacturing processes, the invention balances adaptability with ease of manufacture.
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 laminate effectively absorbs small fluid quantities through micropores and capillaries, while larger apertures redirect larger fluid amounts to underlying absorbent layers, enhancing comfort and functionality in absorbent articles.
Implementation Method 1
The laminate effectively absorbs small fluid quantities through micropores and capillaries
Implementation Method 2
larger apertures redirect larger fluid amounts to underlying absorbent layers
Implementation Method 3
The at least first and second layers are primarily joined at the periphery of the perforated apertures, and typically are joined together through entanglement and/or contact bonding
Data Source
Figure 1~2
Figure 3~4
AI summary
A perforated laminate (10) comprising at least first (12) and second layers (14) and apertures (16) extending through at least the first layer (12). The first layer (12) is a nonwoven or formed film material, and the second layer (14) comprises an absorbent structure. The at least first (12) and second layers (14) are primarily joined at the periphery of the perforated apertures (16). The laminate (10) is particularly useful as a topsheet for an absorbent article, such as a disposable diaper or sanitary napkin. Also described are various materials and methods used to create such laminates.