Absorbent Article Shell Elastic Tension Control for Curl Reduction
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Solution Overview
Problem
Body adhering absorbent articles often curl due to residual stretch in the elastic shell material, leading to issues with peel strip removal, attachment, fit, and packaging, which increases defects and machine downtime.
Innovation Solution
Reducing or eliminating shell elastic tension in regions where components are attached, by selectively activating or zoning the shell material to minimize residual stretch, and using a segmented shell design to reduce curl during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the elastic shell material is kept in a tensioned state during assembly, then the components can be laminated to form a composite web, but the residual stretch causes the individual articles to curl after die cutting
Solution Approach 1:
The shell web is divided into multiple separate shell pieces, each containing individual absorbent articles. This segmentation allows each piece to be handled independently and reduces the propagation of residual stretch effects across the entire web, thereby reducing curl of individual articles while maintaining the ability to form composite webs during assembly
Solution Approach 2:
The patent applies different properties to different regions of the shell material. Specifically, the shell pieces are designed with controlled elastic tension characteristics that allow lamination during assembly while minimizing residual stretch in the final product. This local differentiation of material properties resolves the contradiction between maintaining tension for assembly and eliminating curl in finished articles
2Ease of manufacture
If the shell material maintains elastic tension during manufacturing, then components can be attached to form the composite web, but the residual stretch increases defects and machine downtime
Solution Approach 1:
By segmenting the shell web into separate shell pieces, the manufacturing process can attach components to individual pieces rather than managing the entire web. This reduces complexity and minimizes defects while maintaining the elastic tension needed for attachment. The segmented approach also reduces machine downtime by allowing independent handling of smaller units
Solution Approach 2:
The shell pieces are prepared in advance with controlled elastic properties before component attachment. This preliminary preparation ensures that the material is ready for efficient assembly while minimizing the generation of residual stretch that would otherwise cause defects and require rework or machine downtime
3Ease of manufacture
If the shell web is used in a tensioned state for lamination, then the composite web can be formed, but the individual articles curl toward the elasticized shell material in laminated regions
Solution Approach 1:
The lamination process is applied to segmented shell pieces rather than a continuous tensioned web. This allows the components to be laminated to each shell piece independently while the segmented structure prevents the accumulation and propagation of residual stretch that would cause curling in the final individual articles
Solution Approach 2:
The shell pieces are designed with localized elastic properties that enable lamination during manufacturing while controlling the distribution of residual stretch. By differentiating the elastic characteristics in different regions of the shell material, the patent achieves effective lamination while minimizing curl in the laminated regions of finished articles
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 method effectively reduces or eliminates curl in body adhering absorbent articles, improving fit, function, and manufacturing efficiency, leading to enhanced customer satisfaction and reduced defects.
Implementation Method 1
residual stretch present in the shell material in the laminated regions
Implementation Method 2
residual stretch present in the shell material
Implementation Method 3
a pair of adhesive webs comprising a body attachment adhesive
Data Source
AI summary
The present disclosure provides a method of manufacturing body adhering absorbent articles orientated in the cross-machine direction, body adhering absorbent article having reduced or eliminated curl. The articles are manufactured with reduced curl by selectively reducing or eliminating the shell elastic tension in regions where components of the body adhering absorbent article are to be attached to form the composite absorbent article web. In certain aspects the body adhering absorbent articles are manufactured by supplying an elastic web of shell material having a longitudinal and transverse direction, that is stretchable only in the transverse direction, attaching at least one component to form a composite web material, and cutting the composite web material to form a body adhering absorbent article.