Breast-Milk Pad Shape Retention via Segmented Absorber Folding
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Solution Overview
Problem
Conventional breast-milk pads suffer from poor shape retention, leading to leakage and discomfort, and have complex production processes that are inefficient and uncomfortable for users.
Innovation Solution
A breast-milk pad design featuring a back sheet, a liquid-permeable top sheet, and an absorber with cutout portions that narrow inwardly, where the top and back sheets are bonded only at the outer perimeter and inner folding line, eliminating the need for bonding the absorber directly and using an elastic body, thus maintaining shape and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the absorber is bonded directly to form a dome shape, then shape retention is improved, but the structure becomes complex and production becomes difficult
Solution Approach 1:
The absorber is divided into multiple sections by forming cutout portions at the outer peripheral part, which are then folded back to form the dome shape. This segmentation allows the absorber to maintain shape without requiring complex bonding structures throughout the entire dome surface.
Solution Approach 2:
The cutout portions are formed by removing material from the absorber at the outer peripheral part. This extraction of material creates the necessary structure for folding and forming the dome shape while simplifying the overall construction by eliminating the need for extensive bonding.
2Adaptability or versatility
If elastic body is applied to cutout portions to narrow them, then fitting properties are improved, but production becomes difficult and discomfort is caused
Solution Approach 1:
Instead of applying elastic body to narrow the cutout portions to achieve fitting, the invention inverts the approach by forming the dome shape through folding back the cutout portions themselves. This inversion eliminates the need for elastic body application, simplifying production while maintaining fitting properties through the geometric configuration of the folded structure.
3Ease of manufacture
If thin sheet is used instead of absorber, then production is simplified, but absorption capacity is insufficient and shape retention is poor
Solution Approach 1:
The absorber is designed with different thicknesses in different regions. The central part has greater thickness to provide adequate absorption capacity, while the outer peripheral part is thinner to facilitate folding and formation of the dome shape. This local variation in quality allows the thin sheet to function effectively as both absorber and structural element.
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 design enhances shape retention, prevents leakage, and simplifies production, providing a comfortable and effective breast-milk pad with improved fitting properties and ease of use.
Implementation Method 1
heat a circular material, which is formed flat on a top sheet on an outer surface by using polyethylene laminated paper or other thermal deformation material, and at the same time press the circular material against a dome mold to thermoform the abovementioned dome shape
Implementation Method 2
an absorber that is disposed between the back sheet and the top sheet to absorb and retain the liquid permeating the top sheet
Implementation Method 3
a liquid permeable top sheet that is disposed on each side contacting a body; and an absorber that is disposed between the back sheet and the top sheet to absorb and retain the liquid permeating the top sheet
Data Source
Figure 1~2(b)
Figure 3~4
Figure 5~6
AI summary
To provide a breast-milk pad, which can be produced relatively easily, reduces an uncomfortable sensation to the skin surface of a user, and has excellent shape retention properties, and a method for producing the breast-milk pad. The breast-milk pad comprises a material that is made up by stacking: a back sheet 11 that prevents permeation of liquid; a top sheet 13 that contacts the body; and an absorber 12 that is disposed between the back sheet 11 and the top sheet 13, wherein the top sheet and the back sheet are bonded to each other in an outer peripheral portion, cutout portions 22 obtained by cutting the absorber are formed in positions facing each other at the outer peripheral portion such that cutout width of each of the cutout portions gradually narrows down inwardly, the top sheet and the back sheet are bonded to each other on the inner side between the cutout portions, and the breast-milk pad further comprises bonding portions 21 for bonding inner surfaces of the top sheet together, which are superposed at each of cutout portions, in a state in which the product is folded up along a folding line 23 connecting the cutout portions facing each other so that the top sheet forms the inner surfaces.