Perforated Liner Bonding for Rapid Liquid Inlet in Absorbent Articles
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Solution Overview
Problem
Conventional absorbent articles face issues with low liquid acquisition rates and rewet due to the interaction between the bodyside liner and liquid transfer layer, leading to potential liquid leakage and a wet surface for the wearer.
Innovation Solution
The absorbent article incorporates a bodyside liner and liquid transfer layer bonded with thermoplastic material at specific bonding sites, creating a three-dimensional structure with alternating raised and depressed regions, increasing friction and enhancing liquid absorption and distribution, while maintaining a dry surface for the wearer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a porous liquid transfer layer is used to quickly receive and store liquid, then liquid acquisition rate is improved, but liquid may leak back through the liner causing rewet
Solution Approach 1:
The liner is segmented into raised regions and depressed regions with perforations located in the depressions. This segmentation creates multiple liquid flow paths while maintaining surface integrity, allowing rapid liquid acquisition through the depressed regions while preventing rewet by controlling liquid distribution across the segmented surface.
Solution Approach 2:
Different regions of the liner are given different properties: the depressed regions contain perforations for liquid intake, while the raised regions provide a smooth surface to prevent rewet. The bonding sites are strategically positioned to enhance liquid distribution in specific areas while maintaining overall liner integrity and preventing liquid leakage back to the wearer.
2Reliability
If the liner and transfer layer are bonded together, then liquid distribution is improved, but friction between layers increases
Solution Approach 1:
The bonding between liner and transfer layer is segmented into discrete bonding sites rather than continuous bonding. This segmentation provides sufficient adhesion for liquid distribution while maintaining friction for liquid flow control, allowing the layers to move together for distribution but slide independently for friction-based liquid management.
Solution Approach 2:
Bonding sites are strategically positioned at specific locations rather than uniformly distributed. This creates localized strong bonding areas for liquid distribution while leaving non-bonded areas with higher friction for liquid flow control, optimizing both liquid distribution and friction characteristics simultaneously.
3Strength
If thermoplastic material is used for bonding, then bonding strength is improved, but manufacturing complexity increases
Solution Approach 1:
The bonding process replaces complex mechanical bonding mechanisms with thermal melting of thermoplastic material. By applying heat to melt the thermoplastic and then allowing it to cool and solidify, strong bonding is achieved through a relatively simple thermal process rather than complex mechanical assembly, reducing manufacturing complexity while maintaining bonding strength.
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
This configuration improves liquid acquisition and prevents rewet, ensuring rapid absorption and a dry surface for the wearer by optimizing the interaction between the liner and transfer layer through controlled bonding and topography.
Implementation Method 1
both of said bodyside liner and said transfer layer contain thermoplastic material and are bonded together in a plurality of bonding sites within which the thermoplastic material has been caused to at least partially soften or melt and thereby bond together the bodyside liner and the transfer layer
Implementation Method 2
the bodyside liner comprises a plurality of perforations and the bonding sites in at least in a central part of the article, corresponding to the so called wetting area, the bonding sites cover an area of between 0.2% and 11% of the total area of said part of the liner that is circumscribed by said bonding sites and that each bonding site has an area of no more than 13 mm2, said liner having a three-dimensional structure of alternating raised and depressed regions
Implementation Method 3
the bodyside liner comprises a plurality of perforations
Implementation Method 4
said liquid transfer layer having the ability to quickly receive large amounts of liquid, to distribute it and temporarily store it before it is absorbed by the underlying absorbent core
Data Source
AI summary
absorbent article comprising a liquid transfer layer (5) positioned between a liquid pervious bodyside liner (6) and an absorbent core (2). The liner (6) comprises a plurality of perforations (7). The liner and the transfer layer are bonded together in a plurality of bonding sites (11) covering an area of between 0.5% and 11% of the area of the liner (6) that is circumscribed by the bonding sites and wherein each bonding site has an area of no more than 13 mm2. The combined perforated liner (6) and transfer layer (5) provides a quick inlet of liquid and a low rewet against the wearer. The liner (6) has a three-dimensional structure of alternating raised and depressed regions and the perforations (7) are present in the bottoms of the depressions (8) of said liner as seen from the body facing side of the liner.