Thin Flexible Absorbent Articles With Foam-SAP Core
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Solution Overview
Problem
Existing absorbent articles are either too thick and stiff to accommodate high fluid discharge volumes effectively, or too thin and flexible, leading to shape instability and reduced absorption rates under compressive forces, making them unsuitable for daily wear, especially during menstrual or incontinence incidents.
Innovation Solution
The development of absorbent articles with a caliper expansion of at least 275% measured at five minutes, incorporating a heterogeneous mass layer with open-cell foam pieces and superabsorbent polymers, which maintains shape and absorption efficiency even when loaded, achieved through specific structural design and material combinations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the absorbent article is made thinner and more flexible, then it provides better comfort and garment-like fit, but it loses shape stability and fluid storage capacity under compressive forces
Solution Approach 1:
The patent employs a composite absorbent core structure combining foam pieces with superabsorbent polymer particles embedded in a fibrous matrix. This composite material provides both flexibility for comfort and structural integrity for shape stability, resolving the contradiction between thin flexible design and compression resistance
Solution Approach 2:
The absorbent core features localized foam pieces distributed throughout the fibrous matrix, creating regions of different properties. The foam provides compressive strength and shape recovery in specific areas, while the overall structure remains thin and flexible, addressing the shape stability issue without sacrificing comfort
2Speed
If the absorbent article uses faster superabsorbent polymers to increase absorption rate, then it absorbs fluid more quickly, but it requires bulky acquisition volumes that increase article thickness
Solution Approach 1:
The patent utilizes foam pieces with porous structures that provide rapid fluid acquisition pathways. The porous foam allows quick fluid entry and transport to the superabsorbent polymers, achieving high absorption rates without requiring thick bulky structures, thus resolving the contradiction between speed and thickness
Solution Approach 2:
The foam acts as an intermediary acquisition layer between the fluid source and the superabsorbent polymer storage. It rapidly takes in fluid and transfers it to the SAP particles, enabling fast absorption while maintaining a thin profile, thereby solving the thickness-speed contradiction
3Quantity of substance
If the absorbent article is made thicker to accommodate larger discharge volumes, then it provides sufficient fluid storage capacity, but it creates noticeable bulges and sagging that cause embarrassment
Solution Approach 1:
The patent changes the structural parameters of the absorbent core by using foam pieces with specific density and porosity characteristics. This allows the core to compress to a thin profile when empty (no bulges) while expanding to accommodate large fluid volumes when loaded, resolving the contradiction between storage capacity and shape appearance
Solution Approach 2:
The absorbent core structure is designed to be dynamic, transitioning from a compressed thin state when empty to an expanded state when fluid-loaded. The foam pieces provide reversible compression and expansion, allowing the article to maintain a flat shape during wear while providing sufficient volume for large discharge incidents
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 solution provides a thin, flexible, and shape-stable absorbent article that maintains high absorption rates and fluid storage capacity under compressive forces, ensuring comfort and effectiveness during daily activities without noticeable bulges or sagging.
Implementation Method 1
an open cell foam piece or a plurality of open cell foam pieces, each foam piece having an average cell size of from 10 µm to 1000 µm
Implementation Method 2
superabsorbent polymers
Implementation Method 3
the absorbent article has a caliper expansion, measured at five minutes according to the dynamic caliper expansion test described herein, of at least 275%
Data Source
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AI summary
The present invention relates to an absorbent article, comprising a fluid permeable topsheet, a backsheet, an absorbent element disposed between the topsheet and the backsheet wherein the absorbent article has a caliper expansion measured at 5 minutes of at least 275%. The present invention also relates to an absorbent article, comprising a fluid permeable topsheet, a backsheet, an absorbent element disposed between the topsheet and the backsheet wherein the absorbent article has a dry caliper of 4.5 mm or less and wherein the absorbent article has a caliper expansion, measured at five minutes of at least 75%. The present invention also relates to an absorbent article, comprising a fluid permeable topsheet, a backsheet, an absorbent element disposed between the topsheet and the backsheet wherein a ratio of the caliper expansion measured at 5 minutes to the dry peak stiffness is at least 0.5%/N.