Layered Absorbent Core Structure for Thin, Fast-Drying Pads
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Solution Overview
Problem
Current absorbent products are bulky, lack flexibility, and have insufficient absorption properties, leading to discomfort and manufacturing challenges, and are often costly due to multiple components from different manufacturers.
Innovation Solution
An absorbent article with a reduced thickness and weight, featuring a cover layer, absorbent core, and backsheet, optionally including a transfer layer, where the cover layer is embossed with a honeycomb pattern and the absorbent core consists of multiple strata of pulp, bicomponent fibers, and super-absorbent polymer, bonded with dispersion binders, allowing for improved fluid distribution and reduced p-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current absorbent products use multiple components from different manufacturers, then absorption properties can be improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines multiple functional layers (acquire layer, transfer layer, storage layer) into a single integrated absorbent core structure manufactured by one manufacturer. This merging maintains the functional benefits of multiple components while simplifying manufacturing supply chain and reducing complexity.
Solution Approach 2:
The patent uses composite material structures within each layer, such as the acquire layer combining hydrophilic fibers with superabsorbent particles, and the transfer layer using bicomponent fibers with specific hydrophobic/hydrophilic ratios. These composite materials provide enhanced absorption properties while being manufacturable as integrated structures.
2Reliability
If absorbent product thickness is increased, then absorption capacity is improved, but flexibility and comfort deteriorate
Solution Approach 1:
The patent distributes absorption functionality across multiple specialized layers rather than using a single thick layer. The acquire layer (5-15 gsm) rapidly absorbs fluid at the surface, the transfer layer (20-40 gsm) distributes it laterally, and the storage layer provides bulk capacity. This layered approach with locally optimized properties achieves high absorption capacity while maintaining overall thinness and flexibility.
Solution Approach 2:
The absorbent core is segmented into distinct functional layers (acquire, transfer, storage) with specific thickness ranges for each. This segmentation allows each layer to be optimized for its specific function while contributing to overall product thinness, preventing the need for a single thick layer that would reduce flexibility.
3Weight of moving object
If absorbent product weight is reduced, then comfort is improved, but absorption properties may deteriorate
Solution Approach 1:
The patent optimizes the weight and composition parameters of each layer to achieve lightweight overall structure. The acquire layer uses low basis weight (5-15 gsm) materials, the transfer layer uses ultra-thin construction (20-40 gsm), and the storage layer uses high void fraction structures. These parameter optimizations maintain absorption properties while minimizing weight.
Solution Approach 2:
The patent employs porous materials throughout the absorbent core structure, particularly in the storage layer with high void fractions and the transfer layer with controlled porosity. These porous structures provide high absorption capacity per unit weight by increasing surface area and fluid pathways, achieving lightweight design without sacrificing absorption properties.
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 absorbent article achieves faster fluid penetration, reduced rewet, and improved dryness, with a simplified manufacturing process and cost-effectiveness, while maintaining flexibility and aesthetic appeal.
Implementation Method 1
The cover layer includes nonwoven fibers and/or synthetic fibers... The cover layer has a basis weight that is between about 20 gsm and about 50 gsm
Implementation Method 2
an absorbent core structure... The absorbent core consists of multiple strata of pulp, bicomponent fibers, and super-absorbent polymer
Implementation Method 3
super-absorbent polymer, bonded with dispersion binders, allowing for improved fluid distribution
Implementation Method 4
a backsheet that is generally hydrophobic thereby preventing moisture from travelling through the absorbent article and onto the underlying garment
Data Source
AI summary
An absorbent article for menstrual and/or incontinence purposes, having a unique two-layer acquisition and absorbent structure. The cover layer includes a nonwoven material. The absorbent core includes multiple strata including super absorbent, fiber material that is pulp and/or bicomponent fibers, and a binder material. The total thickness of the absorbent article is less than or equal to the thickness of absorbent articles of similar absorbent characteristics. The absorbent article includes various absorbent properties that are improved despite parity or reduction in overall thickness.