Absorbent Article Top Sheet with Projections and Fiber Orientation
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Solution Overview
Problem
Absorbent pads used by bedridden elderly individuals exhibit inferior urine absorption properties due to the presence of solid components in urine, which clog the top sheet and inhibit absorption, often leading to leakage.
Innovation Solution
An absorbent article with a liquid-permeable top sheet and a liquid-impermeable back sheet, featuring a nonwoven fabric with projections that have a higher fiber orientation in the thickness direction, maintaining wet thickness at 85% of dry thickness, and comprising durable hydrophilic and non-durable hydrophilic fibers to facilitate urine absorption and prevent leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional top sheets are used, then the structure is simple, but solid components clog the top sheet and inhibit absorption property
Solution Approach 1:
The top sheet is divided into multiple fiber layers (first fiber layer with durable hydrophilicity, second fiber layer with non-durable hydrophilicity) rather than using a single uniform layer. This segmentation allows different regions to perform different functions: the first layer provides sustained liquid wicking while the second layer offers initial rapid absorption, preventing clogging by solid components through the combined action of multiple specialized layers
Solution Approach 2:
The top sheet uses a composite structure combining fibers with durable hydrophilicity and fibers with non-durable hydrophilicity. This composite material approach creates a multi-functional top sheet where the durable hydrophilic fibers maintain long-term liquid transport capability while non-durable hydrophilic fibers provide initial absorption, together preventing solid component clogging more effectively than conventional single-material top sheets
2Reliability
If projections are formed on the nonwoven fabric surface, then liquid permeability and skin feel are improved, but fiber orientation in thickness direction increases which may reduce absorption capacity
Solution Approach 1:
The nonwoven fabric has different fiber orientation characteristics at different locations: projections have higher fiber orientation in the thickness direction for liquid permeability, while other sections maintain different orientation for absorption capacity. This local quality variation allows each region to optimize its function without compromising the overall performance of the top sheet
3Ease of operation
If wet thickness is reduced to improve fit, then comfort is improved, but absorption capacity may be reduced
Solution Approach 1:
The patent optimizes the wet thickness parameter to be at least 85% of dry thickness, maintaining sufficient thickness for absorption capacity while ensuring adequate fit. This parameter optimization, combined with the multi-layer fiber structure, allows the top sheet to maintain both comfort and absorption performance despite the presence of solid components in urine
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 absorbent article effectively absorbs urine containing solid components without leakage, capable of handling multiple absorptions, reducing the frequency of pad changes and minimizing nighttime disturbances for the elderly and their caregivers.
Implementation Method 1
the top sheet is a nonwoven fabric with a skin side surface in which a projection is formed, a content of fibers oriented in the thickness direction at the projection of the nonwoven fabric is greater than a content of fibers oriented in the thickness direction at a section other than the projection of the nonwoven fabric
Implementation Method 2
the first fiber layer is composed of fibers with durable hydrophilicity and the second fiber layer is composed of fibers with durable hydrophilicity and fibers with non-durable hydrophilicity
Implementation Method 3
In the nonwoven fabrics described in PTLs 2 to 13, it is possible to improve the liquid permeability and feel on the skin of the nonwoven fabric by the projections formed on the surface
Data Source
AI summary
As absorbent article for absorbing urine includes a topsheet which is a nonwoven fabric that has a skin-side surface having projections formed thereon. The content by percentage of fibers oriented in the thickness direction in each projection of the nonwoven fabric is greater than the content by percentage of fibers oriented in the thickness direction in sections of the nonwoven fabric other than the projections. The thickness of the nonwoven fabric when wet is greater than or equal to 85% the thickness of the nonwoven fabric when dry. The nonwoven fabric includes a first fiber layer and a second fiber layer. The first fiber layer is constituted by durable hydrophilic fibers, and the second fiber layer is constituted by durable hydrophilic fibers and non-durable hydrophilic fibers.