Multilayer Absorbent Core with Split-Level Compaction
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Solution Overview
Problem
Disposable absorbent articles, such as nursing pads, face issues with polymer water-absorption materials migrating and accumulating, leading to reduced absorbency, increased risk of skin damage, and insufficient tensile strength, resulting in frequent replacements and discomfort.
Innovation Solution
A multilayer absorbent core structure with a top layer of thin paper, a deflector layer of plant fibers, an absorbent layer of polymer water-absorption material, a reservoir layer of mixed plant fibers and polymer material, and a bottom layer of thin paper or non-woven fabric, compacted using a synchronized split-level process to prevent material migration and enhance tensile strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a polymer water-absorption material is used in the absorbent core, then the liquid absorption capacity is improved, but the polymer material migrates and accumulates on the surface causing skin damage and reducing absorbency
Solution Approach 1:
The absorbent core is divided into multiple functional layers: a top layer (cotton core) that contacts the user, a middle layer containing polymer material for absorption, and a bottom layer for support. This segmentation prevents polymer migration to the user-contact surface while maintaining high absorption capacity in the middle layer.
Solution Approach 2:
A cotton core layer serves as an intermediary between the user's skin and the polymer water-absorption material. This intermediary layer allows the polymer to perform its absorption function while preventing direct contact and migration to the skin surface, thereby eliminating skin irritation and maintaining absorbency.
2Ease of manufacture
If the absorbent core structure is simplified, then the manufacturing process is easier, but the tensile strength is insufficient causing tearing during use
Solution Approach 1:
The absorbent core uses a composite structure combining cotton fibers and polymer materials in distinct layers. The cotton top layer provides tensile strength and softness for user comfort, while the polymer middle layer provides absorption capacity. This composite approach achieves both ease of manufacture and sufficient tensile strength without complex processing.
3Ease of operation
If the nursing pad is frequently replaced to maintain absorbency, then the comfort level is maintained, but the workload of nurses increases and patient suffering increases
Solution Approach 1:
The absorbent core uses an excessive amount of polymer water-absorption material in the middle layer, beyond what a single layer would provide. This ensures that even after prolonged use and saturation of the top cotton layer, the polymer layer continues to absorb liquid effectively, extending the nursing pad's usable life and reducing replacement frequency.
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 achieves improved liquid absorption capacity, faster absorption speed, and increased tensile strength, preventing polymer material migration and maintaining comfort and effectiveness of the absorbent article.
Implementation Method 1
a polymer water-absorption material can easily be exposed to the surface of the nursing pad
Implementation Method 2
The polymer water-absorption material can agglomerate and ooze out of the surface of the nursing pad after it absorbs liquid
Data Source
AI summary
The invention provides a multilayer-structure absorbent core for a disposable absorbent article, and a method for preparing the absorbent core, wherein the absorbent core is compacted and formed by each layer; its surface presents a grid-shaped groove; the depth at the intersection point of the grid-shaped groove is bigger than that at the non-intersection point thereof. The invention adopts a new synchronous split-level process; that is, a linear grid-shaped trapezoid-shaped compaction mechanism, of which the height is smaller than that of a circular-platform structure, incompletely compacts the absorbent core and separates the absorbent core into numerous small convex spaces, while a circular-platform structure carries out the dot-shaped compaction for the absorbent core. Under the conditions that the liquid-absorption functions of a deflector layer and a reservoir layer are maintained, the movement of polymer water-absorption material is completely limited while the strength of a core body is enhanced. The invention adjusts the structure of the core body and a process of preparing it, thus facilitating the improved multilayer structure to have more liquid-absorption amount, faster liquid-absorption speed and increased strength.