Disposable Absorbent Article Elasticized Outer Leg Cuff Design
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Solution Overview
Problem
Existing disposable absorbent articles with elasticized outer leg cuffs suffer from discomfort due to exposed cut or trimmed side edges, poor appearance, and inefficiencies in forming a cost-effective and simple operation for a tailored cuff design.
Innovation Solution
A disposable absorbent article featuring a T-shaped elasticized outer leg cuff with a base and gasket cuff supported by the base, where the gasket cuff is formed by folding the distal flap at least twice inwardly to create a thin flat sleeve-like shape, providing a tailored edge and enhanced sealing without exposing the elastic material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the side flap is cut or trimmed to define the longitudinal side edge, then the manufacturing process is simple, but the wearer feels discomfort when the side edge touches the skin and the appearance is poor
Solution Approach 1:
The harmful cut or trimmed side edge is extracted and removed from the final product. Instead of having the side flap edge directly define the article boundary, the invention folds the side flap inward to create a finished edge that does not contact the wearer, eliminating the discomfort and appearance problems while maintaining manufacturing simplicity
Solution Approach 2:
The side flap is folded inward and nested within the absorbent article structure. The distal end of the side flap is folded back toward the absorbent core, creating a nested configuration where the raw edge is hidden inside the article rather than exposed to the wearer, thus eliminating discomfort while keeping the manufacturing process simple
2Ease of manufacture
If the side edge of the side flap is left flexible and untrimmed, then the manufacturing process is simple, but the side edge folds inward toward the absorbent core and cannot resist bunching
Solution Approach 1:
The side flap is pre-folded inward at its distal end during manufacturing, creating a preliminary structural configuration that prevents the edge from folding inward during use. This preliminary folding action establishes the stability needed to resist bunching while maintaining manufacturing simplicity
Solution Approach 2:
The side flap is folded to create a curved or angled configuration rather than a straight flexible edge. This curved structure provides structural stability and resistance to bunching while maintaining the simplicity of the manufacturing process
3Device complexity
If an elasticized outer leg cuff is formed from a single sheet, then the device complexity is reduced, but the operation to form the cuff becomes complicated
Solution Approach 1:
The cuff formation process is segmented into distinct folding operations. The side flap is divided into functional zones (proximal, intermediate, distal) that are folded in sequence, making the operation manageable and systematic rather than complicated, while maintaining the simplicity of a single-sheet construction
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 solution enhances skin comfort, prevents the cuff from flipping inwardly, and offers a cost-effective, simple manufacturing process while providing a tailored appearance and improved sealing efficacy.
Implementation Method 1
The gasket cuff is provided with an elastic material and has an inner cuff extending laterally inwardly from the joint and an outer cuff extending laterally outwardly from the joint
Data Source
AI summary
A disposable absorbent article having an elasticized outer leg cuff is disclosed. The disposable absorbent article comprises a liquid pervious topsheet, a liquid impervious backsheet, an absorbent core disposed therebetween, and a side flap extending laterally outwardly from the absorbent core. The absorbent article further comprises an elasticized outer leg cuff. The elasticized outer leg cuff is disposed adjacent to the longitudinal side edge in the crotch region and has a base and a gasket cuff supported by the base at a joint of the base to the gasket cuff. The gasket cuff is provided with an elastic material and has an inner cuff extending laterally inwardly from the joint and an outer cuff extending laterally outwardly from the joint. The gasket cuff is formed by folding the distal flap at least twice laterally inwardly toward the longitudinal centerline of the absorbent article.