Hydroentangled Absorbent Pad Structure for Uniform Liquid Distribution
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Solution Overview
Problem
Current absorbent underpads for adult incontinence face challenges in maintaining uniform absorbency, mechanical stability, and preventing delamination, leading to inefficient liquid distribution and premature degradation under body stress.
Innovation Solution
A novel absorbent surface pad with a hydroentangled laminate structure comprising an absorbent pulp layer sandwiched between two liquid-permeable nonwoven layers, bonded strongly with a liquid impervious backsheet, enhancing integrity and liquid distribution capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional absorbent core layer made of cellulose fluff is used, then the pad can absorb liquids, but the fluff distribution becomes heterogeneous under body stress, leading to poor absorbency uniformity
Solution Approach 1:
The patent changes the physical state and bonding parameters of the absorbent material from loose cellulose fluff to hydroentangled fibers. This hydroentanglement process creates strong inter-fiber bonds that maintain uniform fiber distribution under body stress, preventing the heterogeneous settling that occurs with traditional fluff materials.
Solution Approach 2:
The patent creates a composite structure by combining the absorbent pulp layer with two liquid-permeable nonwoven layers through strong bonding. This composite laminate structure provides mechanical stability and maintains uniform absorbency distribution, preventing delamination and fiber displacement under body weight and movement.
2Reliability
If the pad structure is made with multiple layers bonded by glue strips, then liquid absorption is enabled, but delamination occurs under mechanical stress, reducing product life
Solution Approach 1:
The patent replaces the mechanical bonding system (glue strips) with a hydroentangled bonding system. The hydroentanglement process creates strong inter-fiber mechanical bonds throughout the entire laminate structure, providing uniform distribution of bonding forces that resist delamination under body stress and movement, thereby extending product life.
3Loss of substance
If the absorbent core layer is made thin to reduce waste, then material usage is reduced, but manufacturing precision and formation quality deteriorate
Solution Approach 1:
The patent changes the material parameters from traditional cellulose fluff to hydroentangled absorbent fibers. This material transformation enables the production of thin absorbent layers (reducing material waste) while maintaining high formation quality, because the hydroentangled structure provides inherent stability and uniformity even at reduced thicknesses.
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 improved mechanical stability, uniform absorbency, and extended product life by maintaining pulp fiber distribution and preventing delamination, ensuring effective liquid distribution across the pad surface.
Implementation Method 1
a hydroentangled laminate structure comprising an absorbent pulp layer sandwiched between two liquid-permeable nonwoven layers
Implementation Method 2
bonded strongly with a liquid impervious backsheet, enhancing integrity
Data Source
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AI summary
The liquid absorbent surface pad comprises a liquid absorbent laminate that is bonded with a liquid impervious backsheet and that comprises at least three layers bonded together: one pulp layer sandwiched between two liquid permeable nonwoven layers. At least one of the two liquid permeable nonwoven layers is a spunbonded nonwoven layer, and the other liquid permeable nonwoven is a spunbonded nonwoven layer or a carded nonwoven layer. The liquid absorbent surface pad is preferably a bed pad for protecting a bed mattress of adult incontinent against soilage.