Absorbent Article Leg Cuff Design for Leakage Control
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Solution Overview
Problem
Current absorbent articles, such as diapers, face issues with leakage due to the spacing of outer leg elastic strands, which affects the fit and appearance, leading to potential leakage risks and discomfort, and existing designs do not effectively contain fecal material, causing soiling and contamination.
Innovation Solution
A disposable absorbent article with a leg gasketing system featuring a folded outer cuff design and a leg gasketing system pocket that includes an opening on the inboard longitudinal edge, which reduces runny bowel movement leaks and contains fecal material by providing additional void volumes within the leg cuffs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If outer leg elastic strands are spaced inboard from the longitudinal edge to prevent cutting exposure during manufacturing, then manufacturing safety is improved, but the ability of elastic strands to control the edge of the article diminishes leading to random distribution of larger gathers and potential leakage
Solution Approach 1:
A folded cuff structure is introduced as an intermediary element between the elastic strands and the longitudinal edge. The cuff includes a cuff body portion and a folded portion that extends toward the edge, allowing the elastic strands to be positioned inboard for manufacturing safety while the folded cuff structure transmits the elastic forces to control the edge and prevent leakage.
2Reliability
If outer leg elastic strands are spaced closer together, then edge control is improved, but the elasticized zone becomes narrow resulting in less finished and less comfortable appearance
Solution Approach 1:
The cuff structure is folded back toward the crotch region, adding a dimensional element that extends the influence of the elastic strands beyond the narrow elasticized zone. This folding action allows the elastic forces to be transmitted over a longer distance along the leg, improving edge control without requiring the elastic strands to be spaced closer together.
3Shape
If outer leg elastic strands are spaced farther apart, then a wider finished leg cuff appearance is achieved, but the gathers separate further from the skin leading to perception of potential leakage risk
Solution Approach 1:
The folded cuff structure acts as a mediator that transmits the elastic forces from the spaced-apart strands to the longitudinal edge. Even though the elastic strands are spaced farther apart for aesthetic purposes, the folded portion of the cuff ensures continuous contact and force transmission to the edge, preventing gather separation and maintaining the perception of secure fit.
4Ease of manufacture
If a polymeric film layer is used in the outer cuff to prevent adhesive penetration, then manufacturing contamination is reduced, but the article has a plastic-like look and noisy application process
Solution Approach 1:
The specification changes the material parameters of the cuff body portion, requiring it to be made from a nonwoven material with specific basis weight ranges (10-30 gsm). This nonwoven material provides sufficient opacity and structural integrity to prevent adhesive penetration and molten adhesive passage without requiring a polymeric film layer, thereby avoiding the plastic-like appearance and noisy application process.
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 design enhances the fit and aesthetic appeal of absorbent articles by ensuring closer proximity of elastic strands to the skin, reducing leakage risks, and effectively containing fecal material, thereby minimizing soiling and contamination.
Implementation Method 1
The leg gasketing system may comprise a first elastic member and a second elastic member spaced apart in the lateral direction, each extending in the longitudinal direction and attached to the chassis. The waist elastic members can be spaced closer to the longitudinal edges of the chassis, and the crotch elastic members can be spaced closer to the longitudinal edges of the chassis
Data Source
AI summary
A disposable absorbent article may include a chassis that includes a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet; and a leg gasketing system. The leg gasketing system may include an inner cuff and an outer cuff; the inner cuff may include an inner cuff folded edge and an inner cuff material edge and the outer cuff may include an outer cuff folded edge and an outer cuff material edge such that the web of material is folded laterally inward to form the outer cuff folded edge and folded laterally outward to form the inner cuff folded edge. The leg gasketing system may also include a leg gasketing system pocket with an opening on an inboard longitudinal edge of the pocket.