Modular Absorbent Articles for Multi-Size Fit and Fast Changeovers
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Solution Overview
Problem
Current absorbent articles suffer from improper fit, leading to skin irritation, leakage, and inefficiencies in manufacturing due to multiple sizes and complex design, which contribute to increased costs and environmental impact.
Innovation Solution
A chassis with a rectangular shape and adjustable securement portions that accommodate various body sizes, using a single chassis width and length with interchangeable securement portion widths to fit a range of users, combined with embossed cores for improved fluid management and a lamination layer for comfort and reduced leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple sizes are produced to accommodate different body proportions, then fit and comfort are improved, but manufacturing complexity and machine downtime increase
Solution Approach 1:
The absorbent article is divided into modular components: a universal chassis and interchangeable size-specific components (ears, leg cutouts, crotch chaises). This segmentation allows the base structure to remain constant while only replacing specific modules for different sizes, reducing manufacturing complexity compared to completely reconfiguring the entire article for each size.
Solution Approach 2:
The chassis is designed as a universal base structure that can accommodate multiple sizes through interchangeable components. The same chassis platform serves all size variations, eliminating the need for multiple dedicated manufacturing lines and reducing machine downtime while maintaining adaptability to different body proportions.
2Adaptability or versatility
If multiple sizes are produced with different components, then various body sizes are accommodated, but manufacturing time and converting costs increase
Solution Approach 1:
Size-specific components (ears, leg cutouts, crotch chaises) are pre-manufactured and stored ready for quick interchange. This preliminary preparation allows rapid changeovers without requiring time-consuming on-machine adjustments or recalibrations, significantly reducing machine downtime between size productions.
Solution Approach 2:
The manufacturing system is designed to be dynamically reconfigurable through quick-change component interchange rather than static, fixed configurations. This dynamic approach allows the production line to adapt between sizes rapidly by simply swapping modular components rather than retooling entire sections.
3Ease of manufacture
If oversized garments are used to accommodate all body types, then manufacturing is simplified, but fit, comfort and dignity are reduced
Solution Approach 1:
Different portions of the absorbent article are optimized for their specific functions: the chassis provides a universal base, while interchangeable ears, leg cutouts, and crotch chaises provide size-specific local adaptations. This allows proper fit in critical areas (waist, thighs, crotch) without requiring the entire garment to be oversized.
4Adaptability or versatility
If stretch material is added to accommodate larger waists, then size adaptability is improved, but skin irritation and breakdown increase
Solution Approach 1:
The waist securement portions incorporate elastic materials that dynamically adapt to different waist sizes through elastic deformation. This dynamic adjustment provides accommodation for larger waists without requiring excessive stretching that would cause skin irritation, as the elastic material naturally conforms to the wearer's anatomy within safe strain limits.
Data Source
AI summary
An absorbent article includes a chassis having a substantially rectangular shape a first portion, a second portion and a crotch portion extending between the first and second portion, a portion of the chassis being configured to absorb fluids. The absorbent article includes a first securement portion operatively coupled to the first portion of the chassis. The absorbent article includes a second securement portion operatively coupled to the second portion of the chassis and configured to releasably attach to the first securement portion. The chassis is configured to include one of a first chassis length or a second chassis length. When the chassis includes the first length, the chassis includes a first width and the first securement portion includes a second width, and when the chassis includes the second length, the chassis includes the first width and the first securement portion includes a third width, greater than the second width.