Absorbent article with leg cuffs
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Solution Overview
Problem
Conventional absorbent articles face issues with leakage and sagging due to inadequate leg cuff design, leading to a less comfortable and aesthetically pleasing fit, and the use of polymeric film layers results in a plastic-like appearance and manufacturing challenges.
Innovation Solution
A disposable absorbent article with a leg gasketing system featuring a folded outer cuff design and a channeled absorbent core, which includes a web of material forming an inner and outer cuff with folded edges, providing improved fit and leakage protection without the need for a polymeric film layer, and an opacity strengthening patch for added stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polymeric film layer is used in the leg cuff to prevent adhesive penetration and provide opacity, then leakage protection and manufacturing reliability are improved, but the article acquires a plastic-like appearance and noisy application process
Solution Approach 1:
The patent replaces the polymeric film layer with a porous nonwoven material that allows adhesive to be contained while maintaining breathability and a natural appearance. The porous structure provides the necessary barrier function without the plastic-like characteristics of film materials.
Solution Approach 2:
The patent uses a composite nonwoven structure combining different fiber types and densities to achieve both opacity and adhesive containment properties previously requiring a polymeric film layer. The composite material provides multifunctionality without the aesthetic drawbacks of film.
2Reliability
If outer leg elastic strands are spaced inboard from the longitudinal edge to prevent cutting exposure, then manufacturing reliability is improved, but the edge control ability diminishes leading to random gathers and perceived leakage risk
Solution Approach 1:
The patent extends the elastic strands to the longitudinal edge of the article, utilizing the full lateral dimension available. This eliminates the need for inboard spacing while maintaining manufacturing reliability through the folded cuff design that protects the elastics.
Solution Approach 2:
The folded cuff design is constructed beforehand to contain and protect the elastic strands at the edge, preventing cutting exposure during manufacturing while allowing the elastics to function at the optimal edge position for maximum control.
3Device complexity
If fewer outer leg elastics (2-3 per side) are used to create gathers, then device complexity is reduced, but achieving desired appearance and wide finished leg cuff becomes difficult
Solution Approach 1:
The patent divides the leg cuff into multiple segments with elastics distributed throughout the cuff structure rather than relying on just 2-3 elastics. This segmentation allows for better distribution of gathering forces while maintaining a manageable number of elastic components.
Solution Approach 2:
The patent nests multiple elastic strands within the folded cuff structure, allowing several elastics to work together in a compact arrangement that achieves the desired wide finished appearance without excessive complexity.
4Reliability
If the absorbent article is designed with traditional outer cuff to provide coverage and secondary containment, then leakage protection is improved, but the article acquires a less garment-like appearance
Solution Approach 1:
The patent uses porous nonwoven materials for the cuff structure that provide containment functionality while maintaining a soft, fabric-like appearance reminiscent of garment cuffs rather than plastic film coverage.
Solution Approach 2:
The patent inverts the traditional approach by using the folded edge of the nonwoven material itself to provide the coverage and containment function, rather than adding a separate polymeric film layer over the cuff.
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 appearance of the absorbent article, providing better leakage protection and preventing sagging, while maintaining a garment-like appearance even when loaded with bodily fluids.
Implementation Method 1
The outer cuff contains the outer leg elastic strands, which create the contraction forces and gathers
Implementation Method 2
absorbent articles such as conventional absorbent articles (e.g., diapers, adult incontinence articles, feminine hygiene pads) offer the benefit of receiving and containing urine and/or other bodily exudates
Implementation Method 3
The barrier leg cuff may be made using a hydrophobic nonwoven and may be disposed on the body-facing surface of the absorbent article
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, and the leg gasketing system further including a leg gasketing system pocket with an opening on an inboard longitudinal edge of the leg gasketing system pocket. The disposable absorbent article also includes at least one channel in the absorbent core.