Heterogeneous Mass Layer Absorbent Core Fluid Management
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Solution Overview
Problem
Existing absorbent articles face challenges in balancing comfort, flexibility, and fluid absorption, particularly in conforming to diverse body shapes and sizes while maintaining effective fluid connectivity and suction, as traditional methods often compromise between permeability, capillarity, and comfort, leading to issues with fluid retention and leakage.
Innovation Solution
An absorbent article with a structure comprising one or more layers of absorbent core and a topsheet, where open-cell foam pieces are integrated into a heterogeneous mass layer, enhancing fluid handling properties and maintaining comfort by allowing for dynamic conformation to body geometry without disrupting fluid connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional cellulose based thick products are used to provide high bulk volume for body coverage, then sufficient body coverage is available, but initial stiffness is high and products deform, bunch and degrade while wearing
Solution Approach 1:
The absorbent core uses a composite structure combining hydrophilic fibers (cellulose, rayon) with hydrophobic thermoplastic fibers (polyester, polypropylene) in a carded web. This composite material provides both bulk volume for body coverage and structural integrity to prevent deformation, bunching, and degradation during wear. The thermoplastic fibers act as binders while the hydrophilic fibers provide absorbency and softness.
2Shape
If airlaid absorbent materials are used to create thinner and more comfortable products, then comfort is improved, but initial stiffness is reduced and structural collapse occurs during wear
Solution Approach 1:
The carded web composite combines soft hydrophilic fibers for comfort with strong thermoplastic binder fibers that maintain structural integrity. The thermoplastic fibers are distributed throughout the hydrophilic fiber matrix, creating a structure that is both comfortable against the skin and resistant to collapse under load during wear.
Solution Approach 2:
The absorbent core structure has varying fiber distribution and density throughout its volume. The thermoplastic binder fibers are concentrated in regions requiring structural support while hydrophilic fibers dominate in regions requiring softness and absorbency, creating local quality variations that balance comfort and strength.
3Adaptability or versatility
If discrete absorbent elements are used to conform to complex body shapes, then fit to body is improved, but fluid continuity is broken and saturation at loading point increases
Solution Approach 1:
The absorbent core is divided into multiple layers with different functions: a top layer for rapid fluid acquisition and distribution, a middle layer for bulk absorption, and a bottom layer for containment. This segmentation allows each layer to be optimized for its specific function while maintaining overall fluid connectivity through controlled porosity and fiber orientation.
Solution Approach 2:
Different regions of the absorbent core have different fiber compositions and densities. The top surface has higher hydrophilic fiber content for rapid wicking, while deeper layers have more thermoplastic binder for structural support. This local quality variation enables conformation to body shapes while maintaining fluid pathways.
4Productivity
If a more permeable absorbent core is used to improve fluid absorption, then absorption rate is improved, but suction capability within the core is reduced
Solution Approach 1:
The absorbent core has spatially varying permeability and capillary pressure characteristics. The top layer has higher permeability for rapid fluid entry, while deeper layers have progressively lower permeability to generate capillary suction pressure. This gradient in local properties enables both high absorption rate and strong suction capability.
Solution Approach 2:
The composite fiber structure creates a hierarchy of pore sizes and capillary channels. Larger pores in the top layer facilitate rapid fluid entry, while smaller pores in deeper layers generate capillary suction. The thermoplastic binder fibers create a network that maintains both permeability and capillary pressure gradients.
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 effectively manages permeability and capillarity, ensuring efficient fluid absorption and retention while maintaining comfort and flexibility, capable of conforming to various body shapes and sizes, thereby reducing leakage and improving overall performance.
Implementation Method 1
manages permeability and capillarity, ensuring efficient fluid absorption and retention
Implementation Method 2
efficient fluid absorption and retention
Implementation Method 3
open-cell foam pieces are integrated into a heterogeneous mass layer, enhancing fluid handling properties and maintaining comfort by allowing for dynamic conformation to body geometry
Data Source
AI summary
An absorbent article and method of making the absorbent article are disclosed. The absorbent article having a topsheet, a backsheet, and an absorbent core structure having one or more layers wherein at least one layer is a heterogeneous mass layer, wherein the topsheet and the heterogeneous mass are integrated such that they reside in the same X-Y plane.