Thin Flexible Absorbent Core With Heterogeneous Foam Structure
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Solution Overview
Problem
Existing absorbent articles are either too thick and bulky to absorb fluids quickly or too thin and stiff, failing to maintain shape and absorption capacity under compressive forces, leading to reduced fluid absorption rates and comfort issues during daily use.
Innovation Solution
A two-layer absorbent core structure with a heterogeneous mass layer comprising open-cell foam pieces and enrobeable elements, optimized for high caliper expansion and low dry peak stiffness, enhancing fluid acquisition rate and retention while maintaining a thin, flexible form.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the absorbent article is made thicker to increase fluid storage volume, then the absorption capacity is improved, but the flexibility and comfort are worsened
Solution Approach 1:
The patent changes the physical parameters of the absorbent core by reducing dry peak stiffness and increasing caliper expansion ratio. This allows the core to be thinner while maintaining flexibility and comfort, yet still provide sufficient fluid storage volume through controlled deformation under compressive forces.
Solution Approach 2:
The patent uses a composite absorbent core structure combining materials with specific mechanical properties to achieve both thinness and flexibility. The composite structure maintains shape stability while allowing necessary deformation for fluid absorption, resolving the contradiction between thickness and flexibility.
2Ease of operation
If the absorbent article is made thinner to improve flexibility, then the comfort is improved, but the fluid storage volume is worsened
Solution Approach 1:
The patent changes the mechanical parameters of the absorbent core, specifically the caliper expansion ratio and dry peak stiffness, to enable thin structures to expand and store fluid effectively. The core can deform under compressive forces to increase storage volume when needed while maintaining thinness for comfort during normal wear.
3Productivity
If faster super absorbent polymers are used to increase absorption speed, then the absorption rate is improved, but the thickness is worsened
Solution Approach 1:
The patent changes the mechanical parameters of the absorbent core to achieve thinness while maintaining high absorption speed. By optimizing dry peak stiffness and caliper expansion ratio, the thin core can rapidly absorb fluid without requiring the bulky structure of traditional fast-absorbing products.
4Ease of operation
If the absorbent article is made more flexible to improve comfort, then the ease of operation is improved, but the shape retention under compressive forces is worsened
Solution Approach 1:
The patent precisely controls the dry peak stiffness parameter to achieve an optimal balance: the absorbent core is flexible enough for comfort but maintains sufficient shape retention under compressive forces. The caliper expansion ratio is optimized to allow necessary deformation while preventing excessive buckling.
5Shape
If the absorbent article is made stiffer to maintain shape, then the shape retention is improved, but the flexibility is worsened
Solution Approach 1:
The patent optimizes the dry peak stiffness parameter to achieve the right balance between shape retention and flexibility. The absorbent core is neither too stiff nor too soft, but precisely tuned to maintain shape while remaining flexible for comfort during daily activities.
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 enables absorbent articles to efficiently absorb fluids quickly and maintain shape under compressive forces, providing superior absorption capacity and comfort by balancing caliper expansion and stiffness, thus addressing the limitations of previous designs.
Implementation Method 1
The upper layer is a heterogeneous mass layer comprising a longitudinal axis, a lateral axis, a vertical axis, one or more fibers as enrobeable elements, and one or more discrete open-cell foam pieces that enrobe the fibers
Data Source
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AI summary
The present invention relates to an absorbent article, comprising a fluid permeable topsheet, a backsheet and an absorbent element disposed between the topsheet and the backsheet wherein the absorbent article has a ratio of the acquisition rate to the dry peak stiffness is at least 0.5 ml/Ns.