Absorbent Insert Leg Cuff Structure for Leak-Secure Reusable Shells
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Solution Overview
Problem
Conventional disposable absorbent articles, such as diapers, face challenges in achieving the same level of comfort, absorbent capacity, and leakage security as reusable diapers, particularly due to the arrangement of elastic elements that can lead to poor fit and leakage when folded incorrectly.
Innovation Solution
A disposable absorbent insert designed with leg cuffs that have pre-tensioned elastic elements inside the cuff folds, forming soft, airy wrinkles, and a nonwoven outer cover layer that extends beyond the liquid-impermeable backsheet, providing enhanced leakage resistance and comfort, along with standing gathers for additional security.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elastic elements are arranged between side portions of topsheet and backsheet, then leakage prevention is improved, but the side edge portion becomes frilly and floppy resulting in poor fit
Solution Approach 1:
A non-elasticated side edge portion acts as an intermediary between the elastic elements and the outer shell. This mediator component prevents the elastic elements from directly contacting the shell interior, eliminating the frilly and floppy problem while maintaining leakage prevention functionality.
Solution Approach 2:
The side edge structure is segmented into distinct functional zones: an elasticated portion containing the elastic elements for leakage prevention, and a separate non-elasticated side edge portion that provides structural integrity and proper fit. This segmentation allows each portion to perform its specific function without interfering with the other.
2Loss of time
If disposable absorbent insert is used with reusable shell, then washing frequency is reduced, but leakage security may be compromised
Solution Approach 1:
The insert combines multiple materials with complementary properties: absorbent core materials for liquid absorption, elastic elements for secure fit, and liquid-impermeable materials for leakage prevention. This composite structure achieves diaper-level leakage security in a disposable insert used with a reusable shell.
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 insert improves fit and leakage security by preventing soiling of the reusable shell, maintaining comfort with soft, breathable materials, and ensuring the elastic elements are hidden within the cuffs, reducing the risk of leakage and extending the reusable shell's usage before washing.
Implementation Method 1
a plurality of spaced-apart pre-tensioned elastic elements extending in the longitudinal direction inside the leg cuff fold and being attached between the first part and the second part of the leg cuff fold
Implementation Method 2
an absorbent core disposed between a liquid-permeable and user facing topsheet and the liquid-impermeable backsheet
Implementation Method 3
a liquid-impermeable backsheet having a backsheet first side edge and a backsheet second side edge
Data Source
AI summary
A disposable absorbent insert for a reusable outer shell includes a liquid-impermeable backsheet having a backsheet first side edge and a backsheet second side edge, an absorbent core disposed between a liquid-permeable and user facing topsheet and the liquid-impermeable backsheet, and a nonwoven outer cover layer overlaying the backsheet and forming an outer surface of the insert. Each leg cuff includes a side portion of the outer cover layer being folded back on itself along a fold line and dividing the side portion of the outer cover layer in a first part and a second part which first and second parts together form a leg cuff fold, and a plurality of spaced-apart pre-tensioned elastic elements extending in the longitudinal direction inside the leg cuff fold and being attached between the first part and the second part of the leg cuff fold.