Dual-Layer Absorbent Core With C-Fold Channel for Faster Intake
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Solution Overview
Problem
Conventional absorbent cores with high SAP ratios suffer from slow liquid intake speed, premature leakages, and manufacturing inefficiencies due to complex channel configurations, leading to discomfort and increased production downtime.
Innovation Solution
A dual-layer absorbent core system comprising a cellulose-based primary layer and a synthetic, C-folded secondary layer with a central channel, combined with strategically placed acquisition-distribution layers to enhance fluid intake and retention, reducing leakages and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the ratio of SAP is increased in an absorbent core, then the retentive capacity is improved, but the liquid intake speed deteriorates
Solution Approach 1:
The absorbent core is divided into two distinct layers: a first layer with higher SAP ratio (50-90% by weight) for high retentive capacity, and a second layer with lower SAP ratio (10-50% by weight) for faster liquid intake speed. This segmentation allows each layer to perform its specialized function, resolving the contradiction between capacity and speed.
Solution Approach 2:
Different regions of the absorbent core have different material compositions tailored to specific functional requirements. The first layer uses high SAP content for maximum absorption capacity, while the second layer uses lower SAP content with additional fluff material for rapid wicking and distribution, creating local quality variations that solve the overall contradiction.
2Ease of operation
If a premade core with channels is used, then the liquid distribution is improved, but the manufacturing complexity increases due to angle-dependent performance issues
Solution Approach 1:
The channel structure is extracted from the traditional premade core and reimagined as a C-fold configuration formed by folding the edges of the second absorbent layer. This eliminates the need for complex molded channels while maintaining liquid distribution benefits and eliminating angle-dependent performance issues.
Solution Approach 2:
Instead of creating channels by removing material or adding complex structures, the invention inverts the approach by using the folded edges of the second layer to define the channel space. This simple folding technique achieves liquid distribution without the manufacturing complexity of traditional channel designs.
3Reliability
If interrupted channels are used to prevent leakage, then the reliability is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The C-fold channel structure merges the channel formation with the layer folding process itself. The channel is created by folding the edges of the second layer upward, combining the structural formation and channel creation into a single manufacturing step, thereby eliminating the need for separate channel registration processes.
Solution Approach 2:
The folded edges of the second layer self-form the channel structure and automatically prevent leakage at the ends. The C-fold configuration inherently creates closed ends that block liquid flow, making the structure self-regulating and eliminating the need for precise external registration or additional leakage prevention features.
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 dual-layer core system improves liquid acquisition speed, reduces leakages, and optimizes manufacturing efficiency by balancing SAP distribution and channel design, ensuring comfortable and long-lasting absorbency.
Implementation Method 1
cellulose fibers that can help with the wicking
Implementation Method 2
SAP can hold a much higher amount of fluid, like urine
Implementation Method 3
ADL helps with the intake of fluids and also with wicking to take better advantage of the absorbent materials in the core
Implementation Method 4
as the liquid can quickly run out inside the channel due to gravity
Data Source
AI summary
An absorbent system including a first absorbent core layer, the first absorbent core layer made up of cellulose and superabsorbent material, a second absorbent core layer disposed above the first absorbent core layer, the second absorbent core layer made up of synthetic material and superabsorbent material, the second absorbent layer having end portions that are folded so that the second absorbent layer has a C-shape, a first acquisition-distribution layer disposed over the second absorbent core layer, a core wrap disposed around the first absorbent core layer, the second absorbent core layer, and the first acquisition-distribution layer, and a second acquisition-distribution layer disposed over the core wrap.