Multi-layer Folded Absorbent Core with Central Channel
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Solution Overview
Problem
Conventional absorbent cores with superabsorbent materials face challenges such as gel blocking, leading to leakage due to localized liquid transport and inadequate liquid distribution, which is exacerbated by the swelling and gelling of superabsorbent materials.
Innovation Solution
A multi-layer folded absorbent core design featuring a central channel and multiple liquid pathways, comprising an upper and lower laminate layer with a high percentage of superabsorbent polymer (SAP) in between, enhances liquid acquisition and distribution by creating a capillary network for improved permeability and absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If superabsorbent materials are used in conventional core designs, then liquid absorption capacity is improved, but gel blocking occurs leading to leakage due to localized liquid transport
Solution Approach 1:
The absorbent core is divided into multiple layers with different functions: an acquisition layer for rapid liquid uptake, a distribution layer for radial liquid transport, and a retention layer for liquid storage. This segmentation prevents gel blocking by distributing liquid absorption across multiple zones rather than allowing localized saturation in a single homogeneous core
Solution Approach 2:
A distribution layer composed of hydrophilic fibers acts as an intermediary between the acquisition layer and retention layer. This intermediate layer facilitates radial liquid transport through capillary action, preventing direct contact between large volumes of liquid and the superabsorbent materials, thereby avoiding gel blocking while maintaining high absorption capacity
2Quantity of substance
If superabsorbent materials swell and gel to retain liquid, then liquid retention is improved, but liquid transport pathways are blocked
Solution Approach 1:
The core is segmented into distinct functional layers where the distribution layer with hydrophilic fibers handles rapid liquid transport through capillary networks, while the retention layer with superabsorbent materials focuses on liquid storage. This spatial separation allows simultaneous optimization of both transport rate and retention capacity without mutual interference
Solution Approach 2:
The distribution layer utilizes porous hydrophilic fiber materials that create extensive capillary networks for rapid liquid wicking. These porous structures provide numerous narrow pathways that maintain high liquid transport rates even when the retention layer materials are swollen and gelled, as the transport function is performed by the porous distribution layer rather than the gel-forming retention layer
3Device complexity
If conventional radial liquid spreading is used, then liquid distribution is simple, but liquid acquisition is localized rather than dispersed
Solution Approach 1:
The acquisition function is segmented from the distribution function. The acquisition layer is designed with high porosity and hydrophilic properties to rapidly wick liquid across its entire surface area through capillary action, creating multiple simultaneous acquisition points rather than relying on radial spreading from a single impact zone. This segmented approach disperses liquid acquisition across the whole core surface
Solution Approach 2:
The invention transitions from two-dimensional radial spreading to three-dimensional liquid distribution by creating a multi-layered core structure with vertical stacking of functional layers. The acquisition layer captures liquid across the entire surface area, the distribution layer transports it radially and vertically through capillary networks, and the retention layer stores it. This adds the vertical dimension to liquid transport, enabling simultaneous acquisition and distribution throughout the core volume
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 achieves rapid liquid acquisition, high SAP efficiency, and reduced side leakage, allowing for the use of higher capacity SAPs with moderate permeability, while maintaining core stability and integrity.
Implementation Method 1
A multi-layer folded absorbent core design featuring a central channel and multiple liquid pathways, comprising an upper and lower laminate layer with a high percentage of superabsorbent polymer (SAP) in between, enhances liquid acquisition and distribution by creating a capillary network for improved permeability and absorption.
Implementation Method 2
Gel blocking refers to the blocking of liquid transport through the core by the swelling and gelling of the superabsorbent material as it absorbs and retains liquid and swells.
Data Source
AI summary
Absorbent laminates and multi-layer, folded absorbent cores comprising the absorbent laminates for use in absorbent articles are presented. Specifically, multi-layer, folded absorbent cores are presented that are formed from an absorbent laminate comprising an absorbent layer between two tissue layers, in which the absorbent core includes a central channel running longitudinally along the core and crenellations profiled along the thickness of the core and providing enhanced liquid distribution across the core surface area or profile and improved liquid absorption into the laminate.