Absorbent Article Top-Surface Sheet Non-Skin Side Embossing
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Solution Overview
Problem
Existing absorbent articles face issues with reduced joining strength between the top-surface sheet and the second sheet, leading to poor fluid transfer and surface damage during embossing processes, which compromises the soft touch feeling and strength of cotton-based top-surface sheets.
Innovation Solution
A method involving a laminate structure with a non-heat fusible cellulose fiber layer on the skin side and a heat-fusible layer on the non-skin side, where compressed parts are formed on the non-skin side surface to enhance joining strength and prevent fiber entanglement release, using hydroentanglement for fiber entangling and maintaining surface smoothness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If embossing is performed by compression from a top-surface side on a cotton nonwoven fabric top surface sheet, then a soft touch feeling of cotton can be achieved, but heat at the tip ends of the emboss protrusions is not sufficiently transferred to the heat-fusible fiber, resulting in lower joining strength between the second sheet and the top surface sheet
Solution Approach 1:
The patent inverts the embossing direction from the conventional top-surface side to the non-skin side. By compressing the laminate from the non-skin side, heat is effectively transferred to the heat-fusible fiber layer, ensuring sufficient joining strength while maintaining the cotton soft touch feeling on the skin-contact surface.
Solution Approach 2:
The patent changes the embossing approach from a single-sided (top-surface) compression to a multi-layered compression system where the non-skin side is compressed. This dimensional change in the compression application point allows simultaneous achievement of heat transfer efficiency and surface quality preservation.
2Ease of operation
If a top-surface sheet is made of cotton fiber to achieve a soft touch like underwear, then skin comfort is improved, but the top-surface sheet itself has high liquid retention property and a sticky feeling tends to remain on the surface
Solution Approach 1:
The patent segments the top-surface sheet into two functional layers: a cotton nonwoven fabric layer for soft touch feeling and a heat-fusible fiber layer for liquid permeability. This segmentation allows each layer to perform its specific function without compromising the other, eliminating the sticky feeling while maintaining skin comfort.
Solution Approach 2:
The patent creates a composite structure combining cotton fibers and heat-fusible fibers in a laminated configuration. The cotton layer provides softness while the heat-fusible fiber layer provides liquid permeability, achieving a synergistic effect that resolves the contradiction between soft touch and sticky feeling.
3Ease of operation
If ordinary degreased cotton fiber is contained in the top-surface sheet to achieve softness, then skin comfort is improved, but the top-surface sheet has high liquid retention property causing sticky feeling on surface
Solution Approach 1:
The patent divides the liquid management function between two layers: the cotton layer retains softness while the heat-fusible fiber layer manages liquid transport. This segmentation prevents excessive liquid retention on the cotton surface, eliminating the sticky feeling.
Solution Approach 2:
The heat-fusible fiber layer acts as an intermediary between the cotton layer and the absorber. It facilitates liquid transfer from the cotton layer to the absorber, preventing liquid accumulation on the cotton surface and thus preventing sticky feeling.
4Productivity
If heat-fusible fiber sheet is interposed between the top surface sheet and absorber to improve liquid movement, then liquid permeability is improved, but joining strength between the second sheet and top surface sheet becomes lower due to insufficient heat transfer
Solution Approach 1:
The patent inverts the compression direction to apply heat from the non-skin side, ensuring effective heat transfer to the heat-fusible fiber layer. This maintains joining strength while preserving the liquid movement functionality provided by the heat-fusible fiber sheet.
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 method allows for effective fluid transfer from the top-surface sheet to the second sheet without deteriorating the soft touch feeling of cotton, maintaining surface smoothness, and enhancing the overall strength of the absorbent article.
Implementation Method 1
the convex roll is heated at least at a time of compression, and a laminate of the top-surface sheet and the second sheet is allowed to pass between the flat roll and the convex roll, thereby heat-fusing and joining the second sheet and the heat-fusible fiber of the heat-fusible layer to each other
Implementation Method 2
heat-fusing and joining the second sheet and the heat-fusible fiber of the heat-fusible layer to each other
Implementation Method 3
the nonwoven fabric is made of hydroentangled fibers
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
[Problem to be solved] To allow a body fluid absorbed by a top-surface sheet to move to a non-skin side without deteriorating a soft touch feeling of cotton. [Solution] A top-surface sheet 3 has a multi-layer structure including a non-heat fusible layer 10 made of a cellulose fiber and arranged on a skin side and a heat-fusible layer 11 made of a heat-fusible fiber and arranged on the non-skin side. A second sheet 6 made of a heat-fusible fiber is arranged on the non-skin side of the top-surface sheet 3. A large number of compressed parts 15 ... are formed in the non-skin side of the second sheet 6 by integrally recessing the second sheet 6 and the top-surface sheet 3 toward the skin side. The non-heat fusible layer 10 and the heat-fusible layer 11 are joined in a state in which fibers of the non-heat fusible layer 10 and the heat-fusible layer 11 are entangled with each other. The second sheet 6 is formed at a lower basis weight and in a lower density than the heat-fusible layer 11. The compressed parts 15 are formed in an intermittent pattern.