Textile Backsheet Composite for Lint Reduction

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Solution Overview

Problem

Conventional absorbent articles with liquid impermeable backsheets often cause linting, leading to discomfort and diaper rash due to the use of nonwoven materials that provide a soft feel but result in undesirable lint formation.

Innovation Solution

A textile backsheet comprising a nonwoven fabric directly or indirectly bonded to a vapor-permeable and liquid impermeable film, with a basis weight ranging from 3 to 12 grams-per-square-meter, offering improved abrasion resistance and reduced lint formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If nonwoven materials are used to provide a soft feel, then comfort is improved, but lint formation increases

Engineering Contradiction:

Improvesoft feelVSAvoidlint formation

Core Design Contradiction:

Ease of operationVSObject-generated harmful factors

Solution Approach 1:

The patent uses a composite structure combining a nonwoven fabric layer (for softness) with a film layer (for lint resistance). The nonwoven fabric is bonded to a vapor-permeable liquid-impermeable film, creating a composite material that provides both comfort and reduced linting by leveraging the properties of each individual material.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The backsheet is divided into separate functional layers: a nonwoven fabric layer that provides softness and a film layer that provides liquid impermeability and lint resistance. This segmentation allows each layer to perform its specific function optimally without compromising the other.

Inventive Principle:

Principle #1Segmentation

2Ease of operation

If film basis weight is reduced to 3-12 gsm, then flexibility and comfort are improved, but liquid barrier performance may be compromised

Engineering Contradiction:

ImproveflexibilityVSAvoidliquid barrier performance

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent employs a composite structure where a thin film layer (3-12 gsm) is bonded to a nonwoven fabric. The film provides the liquid barrier function even at low basis weight, while the nonwoven fabric provides structural support and softness, ensuring both flexibility and reliable liquid protection.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent uses a thin film layer (3-12 gsm) that maintains flexibility and comfort while providing effective liquid barrier performance. The film's thinness allows it to bend and conform to body movements, while its material properties ensure it remains an effective barrier against liquid penetration.

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of operation

If nonwoven fabric is used to enhance softness, then user comfort is improved, but abrasion resistance decreases

Engineering Contradiction:

ImprovesoftnessVSAvoidabrasion resistance

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The patent creates a composite structure where the nonwoven fabric layer (providing softness) is bonded to a film layer (providing abrasion resistance). This combination allows the backsheet to maintain softness for comfort while the film layer protects against wear and tearing, improving overall durability.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS20230025746A1Textile Backsheet

Publication Date: 2023.01.26 MAGNERA CORP

AI summary

Textile backsheets including a nonwoven fabric and film, such as a vapor-permeable and liquid impermeable (VPLI) film or a non-permeable film, are provided, wherein the nonwoven fabric is directly or indirectly bonded to the film. Methods of making such textile backsheets and absorbent articles including the textile backsheets are also provided.