Leg and Flap Elastic Composite for Absorbent Article
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Solution Overview
Problem
Current training pants face issues with irregular waistband gathers, curling lateral edges, limited leg elastic effectiveness, interference with shaped absorbent assemblies, inconsistent flap tackdown adhesive, and manufacturing challenges such as 'tunnels' and reduced containment bucket volume.
Innovation Solution
The design incorporates leg and flap elastic composites with deadened portions, extending beyond the outer cover for a cuff-like appearance, and a manufacturing method that attaches these composites to a body-side liner and outer cover, allowing for a uniform waistband bond pattern and eliminating the need for flap tackdown adhesive, ensuring effective gasket formation and improved fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If leg elastics are disposed between the outer cover and the liner adjacent the longitudinal side edges of the absorbent assembly, then the absorbent assembly is held in place, but the spacing is very narrow which limits the ability of the leg elastics to form an effective gasket
Solution Approach 1:
The leg elastic is repositioned from a lateral placement adjacent to the absorbent assembly to a longitudinal placement along the side edges of the outer cover. This dimensional repositioning allows the elastic to extend further in the longitudinal direction, creating a longer gasket interface with the leg while maintaining secure attachment through the side edges of the outer cover.
2Reliability
If the waistband material is adhesively applied and pressure bonded at lateral edges, then secure attachment is ensured, but the resulting gathers are often irregular and detract from aesthetic appearance
Solution Approach 1:
The bond pattern is designed with varying bond densities at different locations. The lateral edges have sufficient bond density for secure attachment and curl prevention, while the central portion has optimized bond spacing to create uniform gathers. This localized differentiation of bond quality achieves both secure attachment and aesthetic uniformity simultaneously.
3Device complexity
If the waistband bond pattern terminates before the lateral edges, then the bond pattern is simplified, but the lateral edges curl, expose adhesive, and cause training pants to stick together
Solution Approach 1:
The bond pattern is extended to include the lateral edges of the waistband material before the garment is assembled and worn. This preliminary bonding action at the edges prevents curling and sticking issues from developing during use, while the bond pattern is designed to taper off smoothly toward the center to maintain simplicity.
4Reliability
If leg elastics are placed to gather the crotch and enable flap elastics to contact the body, then the absorbent assembly is secured, but the effective MD length of the leg elastics is limited by stress on the waistband
Solution Approach 1:
The leg elastic is segmented into distinct functional zones: a first portion that contacts the absorbent assembly for securing, and a second portion that extends along the side edges of the outer cover to form a gasket. This segmentation allows each portion to perform its specific function optimally without being constrained by the other, effectively increasing the total functional length of the elastic.
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
This solution provides a training pant with a uniformly gathered waistband, enhanced leg elastic functionality, improved aesthetics, and manufacturing efficiency, reducing leakage risks and maintaining product quality.
Implementation Method 1
leg and flap elastic composites with each leg and flap elastic composite including a containment flap portion and a gasket portion
Implementation Method 2
each of the leg and flap elastic composites have a deadened portion in at least one of the front waist region and the back waist region
Data Source
AI summary
An absorbent article having a front waist region, a back waist region, and a crotch region extending between and interconnecting the front and back waist regions. The article comprises an outer cover, a body-side liner, an absorbent assembly between the outer cover and the body-side liner, and leg and flap elastic composites including a containment flap portion and a gasket portion. Each of the composites are attached to the liner such that one of the composites is disposed adjacent one side edge of the liner and the other composite is disposed adjacent the other side edge of the liner, each of the composites extend longitudinally from the front waist region to the back waist region, and each of the composites have a deadened portion in the front waist region or the back waist region. The article further includes a waist elastic member extending longitudinally between the deadened portions.