Absorbent Article Ears Integrated Chassis Tophatting
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Solution Overview
Problem
Multipiece diapers suffer from 'tophatting,' which results in a stair step-like appearance and adverse fit characteristics, leading to sagging, fold-over, and leakage due to the line of tension being remotely located from the waist edge, compromising both functionality and aesthetics.
Innovation Solution
The design incorporates first and second elastically elongatable ears with asymmetric fastening tabs, positioning the line of tension closer to the waist edge and minimizing the use of particulate absorbent polymer material, thereby reducing tophatting and enhancing the diaper's fit and appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If discrete elastic back ears are attached to the chassis, then the diaper provides customized fit and elastic recovery, but the waist edge exhibits a stair step-like appearance with tophatting
Solution Approach 1:
The patent merges the back ear with the chassis by forming the back ear as an integral part of the chassis structure rather than attaching it as a discrete component. This integration eliminates the gap between the chassis and back ear that causes tophatting, while maintaining the elastic properties needed for customized fit through incorporated elastic elements within the integrated structure.
2Ease of operation
If the fastening system is positioned on discrete back ears, then the diaper allows refastening capability, but the line of tension is located remotely from the waist edge causing sagging and fold-over
Solution Approach 1:
The patent repositions the fastening system from the traditional discrete back ear location to a position on the chassis that is closer to the waist edge in the longitudinal dimension. This dimensional repositioning moves the line of tension closer to the waist edge, improving fit stability and preventing sagging while maintaining refastening capability through the preserved fastening system functionality.
3Adaptability or versatility
If elastic materials are incorporated into back ears, then the diaper provides elastic recovery and adjusted fit, but the cost of the diaper increases due to high cost of elastomeric materials
Solution Approach 1:
The patent applies elastic materials locally within specific regions of the integrated back ear structure rather than throughout the entire back ear. This localized application of elastomeric materials provides the necessary elastic recovery and customized fit while minimizing the total quantity of expensive elastic material used, thereby reducing overall cost.
4Ease of operation
If the waist edge transitions from the rear waist section to the attached back ear, then the diaper forms a waist opening, but the waist edge abruptly drops creating a notch-like appearance
Solution Approach 1:
The patent merges the back ear with the chassis to create a continuous, integrated structure that eliminates the abrupt transition and gap between separate components. This integration ensures the waist edge maintains a smooth, continuous contour from the rear waist section through the back ear region, preventing the notch-like appearance while preserving waist opening formation functionality.
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 configuration ensures a smooth, continuous waist edge, improves fit by locating the line of tension closer to the waist edge, reduces sagging and fold-over, and enhances the diaper's ability to maintain a snug, leak-resistant interface with the wearer.
Implementation Method 1
first and second elastically elongatable ears, each of the first and second ears having upper and lower edges and a transverse axis
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A disposable absorbent article may include a chassis, an absorbent core, a pair of elastically elongatable ears and a pair of fastening tabs. The elastically elongatable ears and the fastening tabs have a transverse axis. The ears are connected to the chassis such that the transverse axis of the fastening tabs is located in specific portions of the article. The absorbent core is free of cellulosic fibers.