Lower Acquisition Layer for Faster Absorbent Article Liquid Distribution
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Solution Overview
Problem
Existing absorbent articles face issues with liquid distribution, leading to a cold and damp feel on the garment-facing surface due to vapor penetration through the backsheet, increased visibility of stains, and slow absorption of high gush volumes, especially when using superabsorbent polymers.
Innovation Solution
Incorporation of a lower acquisition and distribution system (ADS) between the absorbent material and the backsheet to temporarily hold and absorb liquid away from the garment-facing surface, utilizing nonwoven layers to manage liquid distribution and minimize liquid presence near the backsheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If superabsorbent polymer material is used in the absorbent core, then absorption capacity is improved, but absorption speed deteriorates especially when the material has not been previously wetted
Solution Approach 1:
The absorbent core is segmented into multiple functional layers: a first portion containing superabsorbent polymer particles for high absorption capacity, and a second portion containing fast-absorbing material (cellulose fibers or hydrophilic polymer particles) for rapid initial absorption. This segmentation allows each layer to perform its specialized function, resolving the contradiction between capacity and speed.
Solution Approach 2:
The second portion of the absorbent core acts as an intermediary layer between the topsheet and the superabsorbent polymer. It rapidly absorbs liquid first and then transfers it to the superabsorbent polymer, enabling the slow-absorbing material to still achieve its full capacity while maintaining overall fast absorption performance.
2Reliability
If liquid is absorbed quickly into the absorbent core, then leakage prevention is improved, but liquid may pool between the absorbent core and backsheet causing vapor penetration
Solution Approach 1:
The backsheet is designed with localized breathable regions that allow vapor to escape from specific areas where liquid pooling occurs, while other regions maintain liquid impermeability for leakage prevention. This local differentiation resolves the contradiction between preventing leakage and allowing vapor escape.
Solution Approach 2:
The liquid pooling between the absorbent core and backsheet, which was previously a harmful effect causing vapor penetration and discomfort, is converted into a beneficial feature by incorporating breathable regions in the backsheet. These regions allow the pooled liquid to evaporate and release vapor outward, transforming the harmful pooling effect into a controlled vapor management system.
3Object-affected harmful factors
If a breathable backsheet is used, then vapor penetration is improved, but damp feel and cold feel on garment-facing surface worsen
Solution Approach 1:
The backsheet is segmented into breathable regions and non-breathable regions. The breathable regions allow vapor escape to prevent pooling-related discomfort, while the non-breathable regions maintain a dry and warm feel on the garment-facing surface. This spatial segmentation resolves the contradiction between vapor management and thermal comfort.
Solution Approach 2:
Different regions of the backsheet have different permeability properties tailored to their specific functions. Breathable regions are positioned where vapor management is critical, while non-breathable regions are positioned where maintaining warmth and dryness is prioritized, creating local quality variations that satisfy both requirements.
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 reduces liquid adjacent to the backsheet, maintaining a dry wearer-facing surface and preventing vapor penetration, thus enhancing user comfort and reducing stain visibility.
Implementation Method 1
a lower acquisition and distribution system with at least one woven layer or, preferably, at least one nonwoven layer, the lower acquisition and distribution system being interposed between the layer of absorbent material and the backsheet
Implementation Method 2
the lower acquisition and distribution system is free of superabsorbent polymer... to temporarily hold and absorb liquid away from the garment-facing surface
Implementation Method 3
the layer of absorbent material comprises superabsorbent polymer... absorption of liquid into the superabsorbent polymer material
Implementation Method 4
moisture or vapor of liquid that pools between the absorbent core and the backsheet may nevertheless penetrate the backsheet
Data Source
Figure 1
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Figure 2B
AI summary
An absorbent article comprising a topsheet, a backsheet, and a layer of absorbent material interposed between the topsheet and the backsheet, wherein the layer of absorbent material (28) comprises superabsorbent polymer. The absorbent article further comprises a lower acquisition and distribution system with at least one nonwoven or woven layer, the lower acquisition and distribution system being interposed between the layer of absorbent material and the backsheet. The absorbent article has a first zone corresponding to 800 µm starting from and including the topsheet and extending towards the backsheet, and a second zone corresponding to 800 µm starting from and including the backsheet and extending towards the topsheet. The amount of liquid in the first and second zone is very small as measured by the NMR test method set out herein.