Multi-Layer Absorbent Core for Thin, Dry Menstrual Pads
Find Innovative SolutionsGenerate Solutions
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 the need for 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 has multiple strata, such as airlaid layers with super-absorbent materials, allowing for improved fluid distribution and reduced thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple components are used to improve absorption properties, then absorption capacity is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple functional layers (cover layer, transfer layer, absorbent core) into a single integrated absorbent article structure that can be manufactured as one unit. This merging of previously separate components reduces device complexity while maintaining the absorption capacity through the integrated multi-layer design.
Solution Approach 2:
The absorbent article is designed with multi-functional layers where each layer performs multiple functions. For example, the cover layer provides both fluid distribution and structural support, while the absorbent core handles both absorption and retention. This multi-functionality reduces the need for separate specialized components.
2Ease of operation
If thickness is reduced to improve flexibility and comfort, then ease of operation is improved, but absorption properties deteriorate
Solution Approach 1:
The patent changes the physical and chemical parameters of the materials used in each layer to achieve reduced thickness while maintaining absorption. This includes using highly absorbent materials with optimized pore structures, adjusting fiber compositions, and modifying layer densities to maximize absorption efficiency per unit thickness.
Solution Approach 2:
The absorbent core utilizes porous materials with optimized pore size distributions that enable rapid fluid uptake and retention in a compressed thickness. The porous structure allows for high surface area-to-volume ratio, enhancing absorption capacity without increasing overall product thickness.
3Reliability
If multiple components from different manufacturers are used to achieve desired properties, then product performance is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent integrates multiple functional components into a single manufacturable unit that can be produced by one manufacturer using a unified manufacturing process. This eliminates the need for assembly of components from different suppliers, simplifying the manufacturing process while maintaining product performance through carefully engineered material compositions.
4Volume of moving object
If thickness is reduced to create ultra-thin products, then volume is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent employs precise control of material parameters (fiber diameter, basis weight, layer density) and manufacturing parameters (forming pressure, bonding temperature, entanglement depth) to achieve consistent ultra-thin dimensions. These parameter optimizations enable reduced thickness while maintaining manufacturing precision through process control.
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, while maintaining flexibility and aesthetic appeal, and is up to 80% drier than existing products.
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
the absorbent core has multiple strata, such as airlaid layers with super-absorbent materials
Implementation Method 3
an absorbent core structure between the cover layer and the backsheet
Implementation Method 4
a backsheet that is generally hydrophobic thereby preventing moisture from travelling through the absorbent article
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.