Absorbent Core Basin Shaping for Diaper Leakage
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Solution Overview
Problem
Modern diapers tend to sag and leak due to the weight of absorbed urine, leading to loss of contact with the wearer's thighs and increased leakage, especially in thinner airfelt-free designs, which also compromise dry and wet fit, comfort, and fluid handling while being costly and difficult to apply symmetrically.
Innovation Solution
A package of absorbent articles with a central portion and side portions separated by folding guides, featuring winglets and gaps that compress between 5% to 50% and stack to a height of 72 mm to 120 mm, allowing the articles to form a three-dimensional basin when unfolded and applied, enhancing retention and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the absorbent article is made thinner to improve discretion and conformability, then the article conforms better to body shape, but the article sags more and leaks more due to weight of absorbed fluid
Solution Approach 1:
The absorbent core is divided into multiple functional layers including a first absorbent layer, a second absorbent layer, and intermediate layers. The core is also divided into a front portion, back portion, and winglets, with folding guides that enable the core to be folded into a basin shape. This segmentation allows each layer and portion to perform specific functions while maintaining overall structural integrity and leak prevention.
Solution Approach 2:
The absorbent core is configured to fold from a flat two-dimensional structure into a three-dimensional basin shape when the article is worn. The folding guides enable the core to form upwardly extending side walls and a bottom portion, creating a three-dimensional containment structure that prevents leakage while maintaining thin profile when not in use.
2Reliability
If elastic waist bands and barrier leg cuffs are added to maintain contact and fit, then contact and fit are improved, but the device complexity and cost increase
Solution Approach 1:
The absorbent core is segmented into a front portion, back portion, and winglets, with folding guides positioned at specific locations. This segmentation allows the core to fold into a basin shape that maintains contact with the wearer's body without requiring additional elastic components, thereby reducing device complexity while maintaining reliability.
3Volume of stationary object
If the absorbent article is compressed for packaging to reduce volume, then the package density improves, but the article's functionality and fluid handling properties may be compromised
Solution Approach 1:
The absorbent core is pre-configured with folding guides and a basin-shaped structure before packaging. This preliminary configuration allows the core to maintain its functional three-dimensional shape when activated during use, even after being compressed during packaging. The folding guides ensure proper formation of the basin shape, preserving fluid handling functionality.
Solution Approach 2:
The absorbent core transitions from a compressed two-dimensional state during packaging to a three-dimensional basin shape during use. The folding guides enable this dimensional transformation, allowing the core to achieve its functional three-dimensional configuration after compression, thereby maintaining fluid handling functionality while reducing package volume.
4Length of moving object
If airfelt-free cores are used to reduce thickness and cost, then the article is thinner and less expensive, but the dry and wet fit and wearing comfort are compromised
Solution Approach 1:
The absorbent core uses a composite structure with a first absorbent layer comprising SAP particles and a second absorbent layer comprising cellulose fibers, separated by an intermediate layer. This composite material structure provides both thin profile and improved wearing comfort by combining the benefits of different absorbent materials while maintaining structural integrity and fluid handling properties.
Data Source
AI summary
A package comprising a stack of absorbent articles which are bi- or tri-folded, and each article comprises a topsheet, a backsheet, and an absorbent core between the topsheet and the backsheet. The absorbent core comprises an absorbent layer comprising a central portion, a first side portion and a second side portion, a first folding guide between the central portion and the first side portion, and a second folding guide between the central portion and the second side portion. Each side portion comprises a plurality of winglets, each winglet having a proximal side relative to a folding guide and extending outward from this proximal side. Neighboring winglets are separated by a gap between their neighboring sides. When the absorbent core is folded along the folding guides, the central portion and the side portions form a three-dimensional basin and the gaps between the winglets decrease, the neighboring sides optionally coming into contact. The articles in the package are either bi-folded along a transversal fold line and are compressed at an In-Bag Compression Rate of from 5% to 50%, or the articles are tri-folded along a first fold line and a second fold line parallel to the transversal direction.