Absorbent Article Thickness Reduction via Segmented SAP Layers
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Solution Overview
Problem
Conventional absorbent articles with polymer sheets and pulp fiber absorbers face challenges in reducing thickness while maintaining effective water absorption and preventing leakage, as the polymer sheet can lift and cause discomfort due to swelling, and the absorption rate decreases with repeated fluid absorption.
Innovation Solution
The absorbent article design features a polymer sheet with super absorbent polymer between upper and lower layers, where pulp fiber is placed adjacent to the skin side in the discharge region, and the super absorbent polymer is not arranged in areas overlapping with the fiber absorber, allowing fluid to penetrate and spread into the polymer sheet for absorption, preventing gel blocking and leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a polymer sheet with super absorbent polymer is used as an absorber, then thickness reduction and large body fluid retention are achieved, but gel blocking occurs and water absorption power is reduced
Solution Approach 1:
The absorber is divided into multiple independent absorbent layers, each containing super absorbent polymer particles between sheet materials. This segmentation prevents gel blocking by distributing the absorption function across multiple discrete units, allowing body fluid to penetrate between layers rather than being blocked by surface-gelled polymer.
Solution Approach 2:
Each absorbent layer has a specific structure with sheet materials having predetermined aperture sizes that match the super absorbent polymer particles. This local structural quality control allows optimal fluid penetration and absorption while preventing gel blocking at each layer interface.
2Volume of moving object
If a polymer sheet with super absorbent polymer is used as an absorber, then thickness reduction is achieved, but aggregates of super absorbent polymer prevent easy body fluid infiltration
Solution Approach 1:
The absorber is divided into multiple thin absorbent layers rather than one thick layer. This segmentation creates multiple interfaces with sheet materials that facilitate body fluid penetration, preventing the formation of large polymer aggregates that would block fluid infiltration.
Solution Approach 2:
Sheet materials with predetermined aperture sizes are used as structural components of the absorbent layers. These porous sheet materials facilitate body fluid infiltration by providing controlled pathways through and between the absorbent layers, preventing aggregate formation that would block fluid flow.
3Reliability
If pulp fiber and polymer sheet are laminated to improve absorption rate and return amount, then absorption performance is improved, but thickness reduction is insufficient
Solution Approach 1:
Multiple absorbent layers are combined in a stacked configuration to form a unified absorber structure. This merging of multiple thin layers achieves both thickness reduction and improved absorption performance, eliminating the need for separate pulp fiber and polymer sheet laminates.
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 design achieves a reduction in thickness without compromising water absorption rate, prevents leakage, and improves wearing comfort by avoiding unnecessary lifting of the fiber absorber, ensuring consistent performance even with repeated fluid absorption.
Implementation Method 1
a body fluid is not easily infiltrated into the inner part of the polymer aggregates and flows around the surface of the above polymer aggregates
Implementation Method 2
super absorbent polymer (SAP) is arranged between an upper layer sheet and a lower layer sheet
Implementation Method 3
an upper sheet absorption layer, a fiber assembled layer, and a lower sheet absorption layer in this order
Data Source
AI summary
An absorbent article comprising a polymer sheet 4 in which a super absorbent polymer 12 exists between an upper layer sheet 10 arranged on the skin side and a lower layer sheet 11 arranged on the non-skin side is included. A fiber absorber 5 including pulp fiber is disposed adjacent to the surface on the skin side of an area corresponding to a body fluid discharge region H of a wearer in the polymer sheet 4. The super absorbent polymer 12 is not arranged in an area which overlaps with the fiber absorber 5, and is arranged in the other area. The water absorption rate of the absorbent article is not reduced even when water is repeatedly absorbed. Additionally, leakage is prevented, a wearing feeling is not worsened, and the adsorbent article may have a reduction in thickness.