Structured Topsheet Channels for Faster Fluid Uptake and Low Rewet
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Solution Overview
Problem
Current absorbent articles with nonwoven topsheets face challenges in rapid fluid acceptance and movement into the absorbent structure, fluid retention, and rewetting, necessitating improved performance for enhanced fluid management.
Innovation Solution
The topsheet is designed with attenuated regions forming channel portions and hinge portions, featuring varying filament and fiber densities to create visually discernible channels and barriers that guide fluid flow towards the absorbent structure, while providing flexibility and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a nonwoven topsheet is used for cost effectiveness and wearer comfort, then the article is economical and comfortable to wear, but fluid acceptance and movement into the absorbent structure is slow
Solution Approach 1:
The topsheet is segmented into different regions with distinct functions: hydrophobic regions for fluid guidance and hydrophilic regions for rapid absorption. This segmentation allows the topsheet to maintain overall nonwoven construction for cost-effectiveness while creating specialized zones that dramatically improve fluid acceptance and movement rates.
Solution Approach 2:
Different regions of the topsheet are given different local qualities through varying hydrophobicity and filament density. The hydrophobic regions have lower filament density to guide fluid, while hydrophilic regions have higher filament density for rapid absorption. This local differentiation resolves the contradiction by optimizing each region for its specific function while maintaining overall cost-effectiveness.
2Ease of operation
If a nonwoven topsheet is used for wearer comfort, then the article feels soft against the skin, but fluid retention and prevention of rewetting is insufficient
Solution Approach 1:
The topsheet is divided into hydrophobic barrier regions and hydrophilic absorption regions. The hydrophobic regions prevent fluid from spreading laterally across the wearer-facing surface, while the hydrophilic regions rapidly draw fluid into the absorbent core. This segmentation maintains the soft nonwoven comfort while dramatically improving fluid retention reliability.
Solution Approach 2:
The hydrophobic regions act as an intermediary barrier that redirects fluid flow toward the hydrophilic absorption zones. This intermediary structure prevents direct lateral spread of fluid across the comfort layer while guiding it to regions optimized for rapid uptake and retention, thus resolving the contradiction between comfort and reliability.
3Device complexity
If uniform filament density is used throughout the topsheet, then the structure is simple to manufacture, but fluid distribution and containment is poor
Solution Approach 1:
The topsheet employs local quality variations in filament density and hydrophobicity to optimize fluid distribution. Hydrophobic regions have lower filament density to facilitate fluid guidance, while hydrophilic regions have higher filament density for rapid absorption. This localized differentiation improves fluid distribution efficiency without significantly complicating the overall manufacturing process.
Solution Approach 2:
The invention changes key parameters (hydrophobicity and filament density) in different regions of the topsheet to optimize fluid distribution. By varying these parameters locally rather than uniformly, the structure achieves superior fluid containment and distribution while maintaining relative manufacturing simplicity through the use of standard nonwoven techniques.
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 structured topsheet enhances fluid distribution and containment, reducing the risk of leakage and improving user satisfaction by ensuring rapid absorption and minimizing fluid spread across the surface.
Implementation Method 1
The section of formed nonwoven web material may be comprised of hydrophobic filaments and/or fibers
Implementation Method 2
channels may be imparted to a nonwoven material... that may serve to visually indicate a path of fluid flow across an outer surface of an absorbent article and/or to facilitate wicking of aqueous fluid away from a wearer-facing surface
Data Source
AI summary
An absorbent article having a nonwoven topsheet, a backsheet, an absorbent core disposed therebetween, and a fluid management layer disposed between the topsheet and the absorbent core is disclosed. The fluid management layer is an integrated nonwoven material having a basis weight in a range of from 40 gsm to 75 gsm and has 10 percent to about 60 percent by weight of absorbent fibers, from between about 15 percent to about 70 percent of resilient fibers, and from between about 25 percent to about 70 percent stiffening fibers. The absorbent article exhibits a third dose acquisition time of less than 10 seconds, more preferably less than 8 seconds, and most preferably less than 7 seconds, and a Rewet of no greater than 0.40 g, more preferably less than about 0.3 grams, or most preferably less than about 0.2 grams.