Absorbent Article Leg Cuff Gasketing and Waist Sealing
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Solution Overview
Problem
Current absorbent articles face challenges in providing a snug, leak-proof fit, especially with fecal material, leading to soiling and leakage issues due to gaps between the article and the wearer's legs or waist, and existing designs often result in a less comfortable, less aesthetically pleasing appearance.
Innovation Solution
The development of a disposable absorbent article with a leg gasketing system featuring a folded outer cuff and waist gasketing element, which includes a pocket to contain runny bowel movements and fecal material, reducing leakage by providing additional void volumes and maintaining a close proximity to the skin for improved fit and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If outer leg elastic strands are spaced inboard from the longitudinal edge to prevent inadvertent cutting, then manufacturing safety is improved, but the ability to control the edge of the article diminishes leading to random distribution of larger gathers
Solution Approach 1:
The leg cuff is divided into two distinct layers: an inner cuff layer containing the barrier leg cuff and outer leg elastic strands, and an outer cuff layer comprising the polymeric film. This segmentation allows the elastic strands to be positioned inboard for manufacturing safety while the outer cuff layer extends to the longitudinal edge to provide edge control and maintain close skin contact.
2Device complexity
If only two to three outer leg elastics per side are used, then device complexity is reduced, but achieving the desired appearance of a wide finished leg cuff with garment-like design becomes difficult
Solution Approach 1:
The outer cuff layer is constructed from a polymeric film that is flexible and forms a thin, garment-like structure. This film extends to the longitudinal edge of the article and provides the appearance of a wide finished leg cuff similar to the elasticized hemmed edge of a sweater arm cuff, without requiring multiple elastic strands.
3Reliability
If polymeric film layer is used for outer cuff to prevent adhesive pass-through, then leakage protection is improved, but plastic-like look and noisy application process result
Solution Approach 1:
A polymeric film layer is used as the outer cuff layer to provide substantial liquid impermeability and prevent molten adhesive from passing through to the garment-facing surface. The film is designed to be thin and flexible, forming a soft, comfortable, and aesthetically pleasing outer surface that resembles garment fabric rather than plastic, while still providing the necessary leakage protection.
4Reliability
If outer cuff is designed to extend to longitudinal edge for close skin contact, then leakage protection is improved, but manufacturing complexity increases due to tracking and combining materials
Solution Approach 1:
The outer cuff layer is pre-formed as a separate polymeric film component before assembly. This allows the film to be manufactured with precise dimensions and properties, and then attached to the chassis during the assembly process. The pre-formed nature of the outer cuff layer simplifies the manufacturing process by reducing tracking and combining complexity while ensuring the cuff extends to the longitudinal edge for close skin contact.
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 effectively reduces leakage and blowouts by containing fecal material within the article, enhancing user comfort and appearance with a garment-like design while maintaining effective leakage protection.
Implementation Method 1
the at least one waist gasketing element including at least one elastic material
Data Source
Figure 1
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Figure 4
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 and a waist gasketing element. 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. When tested by the Blowout Method Test as described herein, the disposable absorbent article has a Blowout Percent Leakage of less than about 9.0%.