Absorbent Structures With 3D Mesh Network For Liquid Retention
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Solution Overview
Problem
Current absorbent cores in personal care articles face challenges in achieving optimal liquid retention and leakage prevention with high superabsorbent material content, requiring improvements in absorbent structure design and manufacturing processes to enhance performance.
Innovation Solution
The development of absorbent structures comprising a high proportion of superabsorbent material, where superabsorbent particles are immobilized within a three-dimensional mesh network formed by adhesive filaments, with specific weight and variability criteria to ensure uniform distribution and retention capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the superabsorbent material content is increased to improve liquid retention, then the liquid retention capability is improved, but the uniformity of distribution deteriorates
Solution Approach 1:
The patent applies local quality by varying the superabsorbent material content across different regions of the absorbent core. The core comprises a first region with 20-40 gsm superabsorbent material and a second region with 400-600 gsm superabsorbent material. This regional variation allows high liquid retention in the second region while maintaining manufacturability and acceptable uniformity across the entire core structure.
Solution Approach 2:
The absorbent core is segmented into multiple regions with different superabsorbent material contents. The first region (20-40 gsm) and second region (400-600 gsm) are distinct segments that together provide both high overall retention capability and manageable distribution uniformity. This segmentation resolves the contradiction by allowing high material content in specific areas without requiring uniform high content throughout the entire core.
2Reliability
If the superabsorbent material content is increased to improve liquid retention, then the liquid retention capability is improved, but the leakage prevention deteriorates
Solution Approach 1:
Different regions of the absorbent core are assigned different superabsorbent material contents to optimize specific functions. The first region with lower content (20-40 gsm) helps prevent leakage by providing a barrier layer, while the second region with higher content (400-600 gsm) maximizes liquid retention. This local differentiation simultaneously achieves both liquid retention improvement and leakage prevention.
Solution Approach 2:
The absorbent core uses a composite structure combining regions with different superabsorbent material contents. This composite approach integrates materials with different properties (lower content for leakage prevention, higher content for retention) into a single functional unit, resolving the contradiction between retention capability and leakage prevention.
3Reliability
If the superabsorbent material content is increased to improve liquid retention, then the liquid retention capability is improved, but the dry feel deteriorates
Solution Approach 1:
The absorbent core employs local quality by placing lower superabsorbent material content (20-40 gsm) in the first region that contacts the wearer, maintaining a drier feel, while concentrating higher material content (400-600 gsm) in the second region for maximum liquid retention. This spatial differentiation allows high retention capability without compromising the dry feel at the wearer interface.
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 proposed solution effectively enhances the absorbent structures' ability to retain liquids, reduces leakage, and maintains a dry feel for the wearer by optimizing the distribution and retention of superabsorbent material, thereby improving the overall performance of absorbent cores.
Implementation Method 1
a mixture of superabsorbent particles and adhesive disposed between the first substrate material layer and the second substrate material layer, wherein the superabsorbent particles are disposed in an amount greater than or equal to 400 gsm and less than or equal to 600 gsm, and wherein the adhesive is disposed in an amount greater than or equal to 4% and less than or equal to 6%, by weight, of the weight of the superabsorbent particles, wherein the adhesive forms a three-dimensional mesh network comprising network adhesive filaments with the superabsorbent particles immobilized within the mesh network
Implementation Method 2
Each type of absorbent material helps to impart such absorbent cores with a range of properties useful in absorbing and retaining liquid bodily exudates. For example, pulp fluff or other fibrous absorbent material may absorb liquid more quickly than superabsorbent material, and the superabsorbent material may be able retain more liquid per particle than pulp fluff
Data Source
AI summary
Absorbent structures and methods of manufacture are disclosed. In one embodiment, an absorbent structure may comprise a first layer, a second layer, and a mixture of particles and adhesive between the first layer and the second layer, wherein the particles are disposed at greater than 400 gsm and less than 600 gsm, wherein the adhesive is disposed at greater than 4% and less than 6%, by weight, of the weight of the particles, wherein the adhesive forms a three-dimensional mesh network comprising network adhesive filaments with the particles immobilized within the mesh network, and the network adhesive filaments extending substantially throughout a three-dimensional space defined by the network adhesive filaments and the particles, the structure having a Gray Level % Coefficient of Variability value (GL % COV) of less than or equal to 34.5, according to the Pad Uniformity Test Method.