Layered Diaper Topsheet Projections for Fluid Overflow Prevention
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Solution Overview
Problem
Conventional absorbent articles face issues where excessive body fluid discharge can lead to overflow from storage portions, causing stickiness and sweating due to fluid adherence to the skin.
Innovation Solution
The absorbent article features a topsheet with a layered structure comprising a first sheet and a second sheet, where the first sheet protrudes to form projections that surround second projections, creating regions for fluid storage and facilitating smooth transfer to an absorbent member, reducing skin contact and enhancing dryness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a single-layer topsheet with embossed projections is used to create storage portions, then fluid storage capacity is improved, but fluid transfer efficiency deteriorates when large amounts of body fluid are discharged
Solution Approach 1:
The topsheet is divided into multiple layers (first sheet and second sheet) with distinct functions. The first sheet provides fluid storage capacity through projections, while the second sheet facilitates efficient fluid transfer. This segmentation allows each layer to optimize its specific function without compromising the other.
Solution Approach 2:
The invention transitions from a single-layer two-dimensional structure to a multi-layer three-dimensional structure. The layered configuration with projections extending in the thickness direction creates additional spatial dimensions for fluid storage and transfer pathways, enabling simultaneous optimization of both storage capacity and transfer efficiency.
2Object-affected harmful factors
If projections are formed on the topsheet to create temporal storage portions, then dryness is enhanced by preventing fluid adherence to skin, but fluid overflow occurs when large amounts of body fluid are discharged
Solution Approach 1:
The topsheet is segmented into multiple functional layers that work together to manage fluid. The first sheet with projections provides initial storage and skin protection, while the second sheet ensures reliable fluid containment and prevents overflow, thereby maintaining both dryness and reliability simultaneously.
Solution Approach 2:
The layered structure with projections creates a cushioning effect that anticipates and accommodates large amounts of body fluid discharge. The projections and interlayer spaces provide buffer capacity before overflow can occur, preventing fluid from reaching the skin even under high fluid load conditions.
3Productivity
If a layered body structure with projections is used, then fluid transfer to absorbent member is improved, but device complexity increases
Solution Approach 1:
The topsheet is segmented into two functional layers with distinct roles: the first sheet for fluid storage and the second sheet for fluid transfer. This segmentation achieves improved fluid transfer efficiency through the second sheet's structure while keeping each individual layer relatively simple in design and manufacturing.
Data Source
AI summary
Provided is a disposable diaper (1) which includes an absorbent member (4) and a topsheet (2). The topsheet (2) includes a first sheet (20) and a second sheet (21). Both sheets (20) and (21) are partially joined to form a plurality of joined regions (22), and the first sheet (20) has a plurality of projections (23) which protrude from the second sheet (21) toward the wearer's skin side at a portion other than the joined regions (22). The projections (23) include first projections (23A) and second projections (23B) and, when the topsheet (2) is viewed in a plan view, a second projection region (23R) is formed which includes the second projections (23B) surrounded by the plurality of first projections (23A). When the topsheet (2) is viewed in a plan view, the joined regions (22) include an inner joined region (22A1) in the second projection region (23R).