Segmented 3D Composite Web for Lower-Material Comfort Topsheets

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Solution Overview

Problem

The production of webs for sanitary articles with unbroken three-dimensional topsheets applied to a base layer requires large amounts of material and incurs high production costs.

Innovation Solution

A composite web comprising a first continuous web with moulded segments, where each segment has protrusions delimited by a base portion, is used to form a three-dimensional pattern, reducing material usage and costs by employing embossing technology and adhesive or welds to maintain the shape.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If an unbroken three-dimensional topsheet is applied to a base layer, then wearer comfort is improved, but material consumption and production costs increase

Engineering Contradiction:

Improvewearer comfortVSAvoidmaterial consumption

Core Design Contradiction:

Ease of operationVSQuantity of substance

Solution Approach 1:

The continuous topsheet is divided into discrete three-dimensional segments distributed across the base layer. Each segment is formed from discrete portions of web material rather than requiring a continuous moulded web, thereby reducing overall material consumption while maintaining comfort benefits at specific locations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The three-dimensional structure is applied locally at specific segments rather than uniformly across the entire topsheet. This allows the comfort-enhancing features to be concentrated where most needed, reducing material usage compared to a fully continuous three-dimensional topsheet while still providing adequate comfort coverage.

Inventive Principle:

Principle #3Local quality

2Ease of operation

If an unbroken three-dimensional topsheet is applied to a base layer, then wearer comfort is improved, but production costs increase

Engineering Contradiction:

Improvewearer comfortVSAvoidproduction costs

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The production process is segmented into discrete steps where individual three-dimensional segments are formed and applied separately to the base layer. This allows for more efficient manufacturing compared to producing a single large continuous moulded web, reducing production costs while maintaining comfort benefits.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of moulding the entire topsheet continuously in three-dimensions, only discrete segments are formed with the three-dimensional structure. This partial application reduces the complexity and cost of the moulding process while still providing adequate comfort enhancement.

Inventive Principle:

Principle #16Partial or excessive action

3Quantity of substance

If discrete moulded segments are used instead of a continuous moulded web, then material usage and costs are reduced, but the complexity of joining segments increases

Engineering Contradiction:

Improvematerial usageVSAvoidjoining complexity

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The discrete segments are designed to be self-adhering to the base layer through intrinsic adhesive properties or mechanical interlocking features built into the segment structure. This eliminates or simplifies the need for separate joining operations, reducing the complexity that would otherwise arise from assembling multiple segments.

Inventive Principle:

Principle #25Self-service

4Quantity of substance

If embossing technology is used to form three-dimensional segments, then material consumption is reduced, but the ability to maintain precise shape may be compromised

Engineering Contradiction:

Improvematerial consumptionVSAvoidshape precision

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The embossing process parameters are optimized to achieve the desired three-dimensional shape with sufficient precision for comfort applications. By adjusting embossing depth, temperature, pressure, and dwell time, the segments achieve adequate shape definition without requiring the extreme precision of full continuous moulding, thereby reducing material usage while maintaining functional adequacy.

Inventive Principle:

Principle #35Parameter changes

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 solution enhances wearer comfort while significantly reducing material and production costs by using moulded segments instead of a continuous moulded web, ensuring the protrusions maintain their shape and improve comfort.

Implementation Method 1

ensuring the protrusions maintain their shape and improve comfort

Methodology Applied

Scientific EffectAdhesive: Adhesive

Data Source

PatentEP4112026B1Composite web

Publication Date: 2025.12.03 GDM

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AI summary

A composite web (1) comprising: a first continuous web (11); at least one moulded segment (12S) having at least one protrusion (4) and a base portion (5) at least partly delimiting the protrusion (4), the moulded segment (12S) being obtained from a second continuous web (12); the moulded segment (12S) being joined to the first continuous web (11) by the base portion (5), the first continuous web (11) and the moulded segment (12S) delimiting at least one cavity (7) at the protrusion (4).