Bottom Distribution Assembly for Fast-Dry Absorbent Channels
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Solution Overview
Problem
Existing absorbent articles with channels between the topsheet and backsheet face challenges in maintaining structural integrity and efficient liquid distribution, particularly due to the time delay in achieving a dry feeling and significant rewetting issues.
Innovation Solution
The absorbent article incorporates a bottom distribution assembly with two layers of differing densities, where the first layer is more porous for distribution and the second layer provides structural integrity, attached to a capillary acceleration sheet, using spunbond and meltblown non-woven materials to manage superabsorbent particles and prevent leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a liquid distribution and acquisition layer (ADL) is provided between the topsheet and the absorbent core, then liquid distribution is improved, but it takes some time before a dry feeling is obtained and rewetting is significant
Solution Approach 1:
The bottom distribution assembly is segmented into two distinct layers: a first layer (20-150 kg/m³) for liquid distribution and a second layer (100-400 kg/m³) for structural integrity. This segmentation allows each layer to perform its specific function optimally, with the first layer enabling fast liquid distribution and the second layer maintaining structure without compromising the speed of liquid absorption.
Solution Approach 2:
The bottom distribution assembly exhibits local quality variations through its two-layer structure, where the first layer has higher porosity for rapid liquid transport and the second layer has higher density for structural support. This local differentiation of material properties allows simultaneous optimization of liquid distribution speed and structural integrity.
2Productivity
If channels are formed with less absorbent material per surface area, then liquid distribution is improved, but the structural integrity of the absorbent article may be compromised
Solution Approach 1:
The bottom distribution assembly is divided into two layers with different density functions. The first layer (lower density, 20-150 kg/m³) is optimized for liquid distribution through its porous structure, while the second layer (higher density, 100-400 kg/m³) provides the necessary structural integrity and strength to maintain the channel structure.
Solution Approach 2:
The bottom distribution assembly uses a composite structure combining two different material densities in a single assembly. This composite approach allows the assembly to simultaneously exhibit both the porosity needed for efficient liquid distribution and the density needed for structural strength, resolving the contradiction between these two requirements.
3Productivity
If the first layer has lower density for distribution, then liquid transport is improved, but the risk of superabsorbent particle leakage increases
Solution Approach 1:
The bottom distribution assembly is segmented into two layers where the first layer (20-150 kg/m³) handles liquid transport with high porosity, while the second layer (100-400 kg/m³) acts as a containment barrier. This segmentation allows the first layer to be highly porous for fast liquid transport without compromising particle containment, as the second layer provides the necessary barrier.
Solution Approach 2:
The second layer of the bottom distribution assembly acts as an intermediary barrier between the first layer and the external environment. It mediates the potential leakage risk by providing a denser, more contained structure that prevents superabsorbent particles from escaping while allowing the first layer to maintain its high porosity for efficient liquid transport.
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 enhances the absorbent article's ability to maintain structure and integrity after wetting while ensuring fast dryness and reduced rewetting, with improved liquid distribution and leakage protection.
Implementation Method 1
The first layer can be used for distribution purposes, distributing the liquid from the one or more channels to the absorbent material... The liquid may be transported from the one or more channels through the first layer
Implementation Method 2
The second layer may form a barrier for the superabsorbent polymer particles and may be connected in the channels to other sheets in the absorbent article... Because of the higher density of the second layer such connection will be more robust
Implementation Method 3
a capillary acceleration sheet and/or a top core wrap sheet between the liquid pervious topsheet and the absorbent material
Data Source
Figure 1A~1C
Figure 1D~1E
Figure 2A~2C
AI summary
An absorbent article comprising a liquid pervious topsheet (300), a liquid impervious backsheet (200), absorbent material positioned between the liquid pervious topsheet and the liquid impervious backsheet, and a bottom distribution assembly between the absorbent material and the liquid impervious backsheet, wherein the absorbent material comprises superabsorbent particles and is arranged such that one or more channels are formed, wherein substantially no absorbent material is present in the one or more channels, wherein the bottom distribution assembly comprises a first layer and a second layer, wherein said first layer has a first density between 20 and 150 kg/m3 and said second layer has a second density between 100 and 400 kg/m3, said second density being higher than the first density, wherein said first layer is closer to the absorbent material than said second layer.