Wet-Laid Distribution Material Maintaining Void Volume Under Compression
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current air-laid distribution materials in absorbent articles suffer from loss of structure and effectiveness when exposed to liquid bodily exudates and compressive loads, leading to reduced wet strength and integrity.
Innovation Solution
The development of wet-laid and wet-formed distribution materials with a three-dimensional fibrous substrate comprising at least 80% pulp fibers, featuring a continuous network region and discrete zones, which maintain their structure and void volume even after wetting and compression, ensuring efficient liquid distribution to the absorbent core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If air-laid distribution materials are used, then the materials are easy to manufacture and have good initial structure, but they lose their structure and effectiveness when exposed to liquid bodily exudates and compressive loads
Solution Approach 1:
The patent applies parameter changes by transitioning from air-laid to wet-laid or wet-formed fibrous substrates, fundamentally changing the manufacturing process parameters. This results in materials that maintain their three-dimensional structure and void volume after exposure to liquid bodily exudates and compressive loads, thereby improving wet strength and integrity while remaining manufacturable
Solution Approach 2:
The patent employs composite materials by creating a fibrous substrate with a specific composition comprising at least 80% pulp fibers by weight. This composite structure, combined with the wet-laid or wet-formed manufacturing process, produces a material that maintains structural integrity and void volume under wet and compressed conditions, resolving the contradiction between ease of manufacture and reliability
2Shape
If air-laid distribution materials are used, then the materials have initial structural form, but they collapse or lose structure after receiving liquid bodily exudates
Solution Approach 1:
The patent changes the manufacturing parameters from air-laid to wet-laid or wet-formed processes, which create a denser, more cohesive fibrous substrate structure. This structural transformation enables the material to maintain its three-dimensional form and void volume stability after receiving liquid bodily exudates, directly addressing the shape stability issue
Solution Approach 2:
The patent applies preliminary action by pre-forming the fibrous substrate with a stable three-dimensional structure and appropriate void volume during the wet-laid or wet-formed manufacturing process. This pre-established structure is designed to resist collapse when liquid bodily exudates are introduced, preventing the structure loss that occurs with air-laid materials
3Device complexity
If air-laid distribution materials are used, then the materials are simple in construction, but they suffer from caliper loss and tearing under compressive loads
Solution Approach 1:
The patent changes the construction parameters by adopting wet-laid or wet-formed fibrous substrates with at least 80% pulp fiber content. This construction approach creates a cohesive, interlocked fiber matrix that resists caliper loss and tearing under compressive loads during wear, while maintaining relative construction simplicity
Solution Approach 2:
The patent uses composite materials with a specific fiber composition (at least 80% pulp fibers) arranged in a wet-laid or wet-formed structure. This composite construction provides enhanced strength and tear resistance under compressive loads compared to simple air-laid constructions, while preserving manufacturing efficiency
4Ease of manufacture
If distribution materials collapse after wetting, then manufacturing is easier, but liquid distribution effectiveness is reduced
Solution Approach 1:
The patent changes the manufacturing parameters to wet-laid or wet-formed processes that produce a fibrous substrate maintaining its void volume and three-dimensional structure after wetting. This parameter change ensures that the distribution material remains effective at distributing liquid bodily exudates to the absorbent core, preventing the effectiveness loss that occurs with collapsed structures
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
These materials provide improved wet strength and integrity, maintaining their three-dimensional structure and void volume, leading to better liquid distribution and retention within absorbent articles, enhancing their performance and durability.
Implementation Method 1
the wet-laid or wet-formed distribution materials of the present disclosure have the ability to maintain a three-dimensional structure after receiving one or more liquid bodily exudates insults and wearer induced strains, thereby allowing them to maintain a suitable void volume
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An absorbent: article comprises a liquid permeable topsheet, a liquid impermeable backsheet, an absorbent core positioned at least partially intermediate the topsheet and the backsheet, and a distribution material comprising a wet-laid, three-dimensional fibrous substrate comprising at least 80% pulp fibers by weight of the wet-laid, three-dimensional fibrous substrate. The wet-laid, three-dimensional fibrous substrate comprises a continuous network region and. a plurality of discrete zones. The discrete zones are dispersed throughout the continuous network region. The continuous network region and the plurality of discrete zones have a common intensive property. The common intensive property of the continuous network region has a first value. The common intensive property of the plurality of discrete zones has a second value. The first value is different than the second value.