Pull-on Diaper Chassis with Segmented Waist and W-Shaped Core
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Solution Overview
Problem
Conventional pull-on disposable wearing articles face issues with elastic waist regions causing discomfort, irregular gathers leading to appearance problems and potential damage, and absorbent layers with stiff side edges that do not reliably maintain a predetermined shape, resulting in discomfort and inadequate fluid containment.
Innovation Solution
A pull-on disposable wearing article design featuring a chassis with a thermoplastic fibrous nonwoven fabric for waist regions and a crotch area, where the waist regions are elastically extensible only in the transverse direction, and the crotch region is not extensible in the longitudinal direction, with crotch side sheets that are elastically extensible to form gathers and guide the absorbent core into a W-shaped configuration for improved fit and fluid containment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If elastic members are used in front and rear waist regions to provide elastic extensibility, then good fitness of the article is improved, but irregular gathers are formed on the outer surfaces causing appearance problems and potential damage
Solution Approach 1:
The waist regions are segmented into an inner sheet layer and an outer sheet layer. The elastic members are positioned between these layers, with the inner sheet forming gathers that are concealed by the outer sheet. This segmentation allows the elastic function to be preserved while hiding the irregular gathers from view and preventing them from contacting external objects.
Solution Approach 2:
The elastic members are nested between the inner sheet and outer sheet layers. The inner sheet with its gathered structure is nested within the outer sheet, which provides a smooth outer surface. This nested arrangement allows the elastic contraction to occur while the outer sheet maintains a neat appearance and protects the gathered inner sheet from damage.
2Reliability
If the absorbent layer is deformed into a W-shaped cross-section with side edges bent downward, then fluid containment is improved, but the stiff side edges cause discomfort to the wearer
Solution Approach 1:
The crotch region is designed with different material properties from the rest of the absorbent layer. A crotch-side sheet made of soft, flexible material is applied to the side edges of the absorbent layer, providing local softness at the contact points with the wearer's thighs while maintaining the W-shaped deformation for fluid containment in the central region.
Solution Approach 2:
The crotch region combines the absorbent layer with a crotch-side sheet made of different material characteristics. The composite structure integrates the stiff absorbent material needed for W-shaped formation with the soft crotch-side sheet material that provides comfort against the wearer's skin, achieving both fluid containment and comfort.
3Device complexity
If relatively wide elastic members are attached to the crotch region, then the structure is simplified, but no specific technical significance or absorbing effect is achieved
Solution Approach 1:
The elastic function is extracted from the crotch region entirely. Instead of attaching elastic members to the crotch, the patent positions the crotch-side sheet to extend into the leg holes, allowing the crotch region to maintain its natural conformability to the wearer's body without elastic components, thereby preserving the absorbing effect of the absorbent layer.
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 ensures a comfortable fit without irregular gathers, prevents fluid leakage by maintaining the W-shaped cross-section of the absorbent core, and allows for smooth donning and secure contact with the wearer's skin, enhancing both comfort and absorbency.
Implementation Method 1
a front waist band member adapted to be elastically extensible in a direction defined by the transverse axis but substantially not elastically extensible in a direction defined by the longitudinal axis
Implementation Method 2
a pair of crotch side sheets... adapted to be elastically extensible... so that, when the article is put on the wearer's body, the crotch side sheets are formed with gathers
Data Source
AI summary
A pull-on disposable wearing article is provided with a chassis and an absorbent batt structure extending on the inner surface of the chassis. The chassis has a front waist region, a rear waist region and a crotch region and is composed of a base sheet which is substantially not elastically extensible/contractible, and first and second outer sheets stretched in a transverse direction and bonded in such a stretched state to outer surfaces of the base sheet in the front and rear waist regions, respectively, and being elastically extendible/contractible in the transverse direction. An absorbent batt structure is laid inside the chassis. The base sheet defining an inner surface of the chassis is formed with gathers as the first and second outer sheets contract.