Double-Bowl Absorbent Core with Acquisition Layer
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Solution Overview
Problem
Existing absorbent articles struggle to effectively manage and store large amounts of bodily waste while maintaining a predetermined shape, which is essential for improved fit and leakage prevention.
Innovation Solution
The absorbent core is designed with a double-bowl shape that forms under pressure, comprising an upper and lower core with an acquisition layer, where the upper core has a greater extension in the width direction, and an opening that overlies both the acquisition layer and the lower core, along with a resilient forming element to maintain the shape and enhance liquid distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If absorbent articles are designed to adopt a predetermined shape in use, then improved fit and leakage prevention are achieved, but the ability to effectively manage and store large amounts of bodily waste is compromised
Solution Approach 1:
The absorbent core is divided into multiple layers including a first absorbent layer, a second absorbent layer, and an acquisition layer positioned between them. This segmentation allows different regions to perform different functions: the acquisition layer rapidly absorbs incoming waste, while the upper and lower layers provide structural shape and additional absorption capacity, resolving the contradiction between maintaining shape and managing large waste volumes.
Solution Approach 2:
The invention introduces a vertical dimension by stacking absorbent layers in three dimensions rather than using a single planar layer. The acquisition layer is positioned between upper and lower absorbent layers, creating a multi-level structure that maintains the predetermined shape while providing increased volume for waste management through vertical space utilization.
2Shape
If absorbent articles are designed to adopt a predetermined shape in use, then improved fit is achieved, but the ability to rapidly distribute and store large amounts of bodily waste is compromised
Solution Approach 1:
The acquisition layer is strategically positioned in specific regions where rapid waste absorption is most needed, typically in the central and front portions of the absorbent core. This layer has enhanced absorption properties compared to other layers, creating local quality variations that optimize the overall distribution and storage rate while preserving the predetermined shape.
Solution Approach 2:
The acquisition layer is pre-positioned between the upper and lower absorbent layers during manufacturing, ready to immediately intercept and distribute incoming waste. This preliminary positioning ensures rapid initial absorption and distribution action as soon as waste contact occurs, improving productivity without compromising the predetermined shape.
3Shape
If absorbent articles are designed to adopt a predetermined shape in use, then improved fit and leakage protection are achieved, but manufacturing complexity increases
Solution Approach 1:
The absorbent core is manufactured as segmented layers that can be produced separately and then assembled. The acquisition layer is positioned between upper and lower absorbent layers, allowing each layer to be optimized and manufactured independently using standard web-forming and bonding techniques, thereby maintaining manufacturing simplicity while achieving the predetermined shape.
Solution Approach 2:
Multiple absorbent layers are combined in a single integrated core structure where the acquisition layer is bonded between the upper and lower absorbent layers. This merging of layers creates the predetermined shape through their collective geometry rather than requiring complex post-manufacturing shaping operations, simplifying the overall manufacturing process.
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 configuration allows for efficient receipt, distribution, and storage of large amounts of bodily waste, providing improved fit and leakage protection by adopting a predetermined shape that effectively handles rapid insults.
Implementation Method 1
The structure of the absorbent core allows it to adopt a 'double-bowl' shape when subject to compression in the width (X) direction
Data Source
AI summary
An absorbent core for an absorbent article includes an upper absorbent core and a lower absorbent core. An acquisition layer is located between the upper and said lower absorbent cores in the thickness (Z) direction of the core. The upper absorbent core includes an opening and fold indications. The relative dimensions and positioning of the core components allows it to adopt a double-bowl shape. Further, an absorbent article includes the absorbent core.