Dryness Layer Laminate Channels for Absorbent Garments
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Solution Overview
Problem
Conventional absorbent garments, such as diapers and incontinence briefs, often experience long acquisition times and leakage due to poor liquid acquisition and retention, which can lead to discomfort for the wearer.
Innovation Solution
The introduction of a dryness layer in absorbent garments, comprising laminates with superabsorbent polymer (SAP) and substrate layers, along with channels defined between laminate strips or folded layers, enhances liquid acquisition and retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional absorbent garments use traditional absorbent cores without dryness layers, then the structure is simpler and manufacturing is easier, but liquid acquisition time is long and leakage occurs
Solution Approach 1:
The absorbent garment is divided into distinct functional layers: an absorbent core layer for bulk absorption and a dryness layer with channels for liquid distribution. This segmentation allows each layer to perform its specific function optimally, preventing leakage while maintaining structural complexity through functional specialization.
Solution Approach 2:
The dryness layer introduces localized channels with specific geometric properties (width, depth, spacing) that differ from the surrounding absorbent material. These channels provide targeted liquid pathways in critical areas, improving liquid retention at leakage-prone locations without requiring complete restructuring of the entire garment.
2Productivity
If conventional absorbent garments lack channels for liquid distribution, then manufacturing is simpler, but liquid acquisition time is prolonged and runoff occurs
Solution Approach 1:
The dryness layer with pre-formed channels is constructed and positioned within the absorbent core before final assembly. This preliminary construction of distribution pathways ensures that liquid is rapidly directed along predetermined routes upon contact, accelerating liquid acquisition without requiring complex post-manufacturing modifications.
Solution Approach 2:
The dryness layer combines multiple materials with different properties: hydrophilic materials for liquid wicking, structural materials for channel formation, and potentially superabsorbent polymers for retention. This composite construction enhances liquid acquisition speed by leveraging the complementary properties of each material, while the modular nature facilitates manufacturing through layer-by-layer assembly.
3Ease of operation
If the absorbent core alone handles liquid absorption, then the structure is simpler, but liquid distribution is poor and discomfort occurs at the wearer surface
Solution Approach 1:
The dryness layer acts as an intermediary between the absorbent core and the wearer's skin. It receives liquid from the core through its channel network and distributes it laterally, preventing direct contact between pooled liquid and the wearer surface. This intermediary function improves wearer comfort while adding a functional layer that justifies the increased structural complexity.
Solution Approach 2:
The dryness layer introduces a new dimensional aspect to liquid management by creating a three-dimensional channel network within the laminate structure. These channels provide vertical and lateral pathways that two-dimensional surface absorption cannot achieve, enabling liquid to be routed away from the wearer interface through depth and directionality, thereby improving comfort despite added complexity.
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 dryness layer effectively reduces runoff and improves liquid distribution to the absorbent core, enhancing comfort by minimizing leakage and maintaining dryness at the wearer's surface.
Implementation Method 1
The absorbent lamina comprises superabsorbent polymer (SAP) and has a basis weight between 40 and 140 grams per square meter (gsm).
Implementation Method 2
The absorbent core comprises fluff and superabsorbent polymer (SAP).
Implementation Method 3
channels defined between laminate strips or folded layers, enhances liquid acquisition and retention
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
The present disclosure relates to absorbent garments having a dryness layer that can comprise one or more laminates and one or more channels to facilitate liquid acquisition and retention. Laminate(s) can include an absorbent lamina disposed between substrate laminae, each comprising tissue and/or a nonwoven. Some dryness layers can have a folded laminate that defines a longitudinally-extending channel. Some dryness layers can have two or more laminate strips that are laterally spaced apart along a width of the dryness layer such that one or more longitudinally-extending channels are defined therebetween.