Absorbent Article Octagonal Cell Pattern for Leakage Prevention
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Solution Overview
Problem
Conventional cell absorbers face challenges in easy coalescence of adjacent cells and insufficient increase in cell volume relative to the number of coalesced cells, leading to reduced absorption capacity and comfort issues due to swelling pressure and potential leakage of superabsorbent polymer particles.
Innovation Solution
The absorbent article features a pattern of octagonal and diamond-shaped cells with weakly bonded portions that can be peeled off by swelling pressure, allowing for smooth and rapid coalescence, along with strategically placed strong bonded portions to enhance cell volume expansion and prevent leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the volume of superabsorbent polymer particles in saturated absorption state is sufficiently larger than the cell volume, then the absorption capacity is improved, but the absorption rate is lowered due to gel blocking and the comfort is deteriorated due to swelling pressure
Solution Approach 1:
The absorber is divided into multiple cells with bonded portions and non-bonded portions. The non-bonded portions allow superabsorbent polymer particles to swell freely without gel blocking, while the bonded portions maintain structural integrity. This segmentation enables both high absorption capacity and fast absorption rate.
Solution Approach 2:
The bonded portions are designed to be peelable under swelling pressure, allowing the cell structure to dynamically change from a confined state to an expanded state. This dynamic behavior enables the superabsorbent polymer particles to expand freely when needed while maintaining structural stability during manufacturing and wear.
2Quantity of substance
If the superabsorbent polymer particles are allowed to swell freely, then the absorption capacity is improved, but the comfort is deteriorated due to swelling pressure making the cell hard
Solution Approach 1:
The absorber is segmented into multiple small cells rather than one large continuous structure. This segmentation distributes the swelling pressure across multiple small compartments, preventing any single area from becoming too hard while maintaining overall absorption capacity.
Solution Approach 2:
The cell structure transitions from a confined state during manufacturing to an expanded state during absorption. The peelable bonded portions allow controlled expansion that accommodates swelling while maintaining comfort through gradual volume increase rather than sudden hardness.
3Ease of manufacture
If the front surface side sheet and back surface side sheet are nonwoven fabrics, then the manufacturing is simplified, but the superabsorbent polymer particles may leak from gaps among fibers
Solution Approach 1:
The absorber is divided into cells with bonded portions that create physical barriers. These bonded portions act as retention structures that prevent particle leakage through the nonwoven fabric gaps while maintaining the simplicity of using nonwoven materials for the sheets.
4Volume of stationary object
If the bonded portions are designed to peel off during absorption, then the cell volume can be enlarged by coalescence of adjacent cells, but the ease of coalescence and volume increase relative to number of coalesced cells is insufficient
Solution Approach 1:
Different portions of the bonded structure have different peeling characteristics. The bonded portions are designed with specific peeling strengths that facilitate easy coalescence of adjacent cells while maintaining structural integrity where needed. This local differentiation of bonding strength enables efficient cell coalescence.
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
This design enables efficient coalescence of adjacent cells, increasing the absorbent volume while maintaining comfort by reducing the contact area with the skin and preventing local thickness increases, thus improving absorption capacity and wearability.
Implementation Method 1
a plurality of cells each of which is surrounded by bonded portions of the front surface side sheet and the back surface side sheet and inside each of which the front surface side sheet and the back surface side sheet are not bonded
Implementation Method 2
the volume of the superabsorbent polymer particles in the state of saturated absorption in each cell is sufficiently larger than the volume of the cell, the superabsorbent polymer particles fill in the cell upon the absorption
Implementation Method 3
the bonded portions positioned on at least continuous two sides in each of the octagonal cells are weak bonded portions which can be peeled off due to the swelling force of the superabsorbent polymer particles in the cells adjacent to the bonded portions
Data Source
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AI summary
An absorbent article includes an absorber (50) including cells (55), each of which is surrounded by bonded portions (54) of a front surface side sheet (51) and a back surface side sheet (52) and in each of which the front surface side sheet (51) and the back surface side seat (52) are not bonded, and including superabsorbent polymer particles (53) contained in each of the cells (55). The bonded portions are arranged in dotted line shapes according to a pattern in which same-sized octagonal portions having all interior angles of 135°, and having two pairs of opposite sides whose facing directions are mutually orthogonal are equal in length, and diamond-shaped portions each having equal length of all sides and being formed in portions among the octagonal portions, are arranged without any space in the front-back direction (LD) or the width direction (WD). The bonded portions (54) positioned on at least two continuous sides in each of the octagonal cells (55A) are weak bonded portions (54b) that is peeled off due to the swelling force of the superabsorbent polymer particles (53) in the cells (55) adjacent to the bonded portions (54).