Perforated Nonwoven Top Sheet for Disposable Wearables
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Solution Overview
Problem
Disposable wearable articles, such as diapers, face challenges in preventing skin irritation and leakage due to friction and absorption issues, particularly with loose stool, and posture changes that cause gaps between the diaper and the skin.
Innovation Solution
A disposable wearable article design featuring a top sheet of perforated nonwoven fabric with holes, a liquid-impervious sheet, and an absorbent element covered by a laminated nonwoven fabric packing sheet, along with a moisturizer composed mainly of glycerin applied to the top sheet, to enhance absorption and reduce friction and leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional top sheet is used, then the diaper structure is simple, but loose stool components clog the top sheet surface and prevent prompt absorption
Solution Approach 1:
The top sheet is constructed as a porous nonwoven fabric with controlled pore size and distribution, enabling loose stool components to pass through the sheet surface without clogging. The porous structure maintains high absorption rate by preventing surface blockage while allowing rapid penetration of bodily waste into the absorber body.
2Object-affected harmful factors
If the diaper absorbs loose stool quickly, then skin irritation is reduced, but the top sheet may cause friction against the skin
Solution Approach 1:
The surface properties of the top sheet are modified by changing physical parameters such as fiber arrangement, pore size distribution, and surface texture. These parameter changes reduce the coefficient of friction between the top sheet and skin while maintaining the rapid absorption capability, thereby preventing both skin irritation and excessive friction.
3Quantity of substance
If the absorber body is made larger to prevent leakage, then absorption capacity increases, but the diaper becomes less adaptable to posture changes
Solution Approach 1:
The absorber body is segmented into multiple functional zones with different absorption capacities and physical properties. The front and back portions have different structures to accommodate posture changes, while the central region provides high absorption capacity. This segmentation allows the diaper to maintain both high absorption capacity and adaptability to various wearer positions.
4Object-affected harmful factors
If skin care medicine is applied to protect skin, then skin protection is improved, but the solution is limited in effectiveness
Solution Approach 1:
The top sheet acts as an intermediary layer between the skin and bodily waste, providing mechanical protection in addition to any chemical protection from skin care medicine. The porous nonwoven fabric structure allows the skin care medicine to remain in contact with the skin while preventing direct contact with irritants, thereby enhancing the overall reliability of skin protection through a combination of physical and chemical mechanisms.
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 protects the skin from irritation, improves absorption of loose stool, and prevents leakage by allowing smooth passage of body fluids and reducing friction with the skin, ensuring better fit and protection during posture changes.
Implementation Method 1
the top sheet is formed of perforated nonwoven fabric having a number of holes arranged at intervals and each penetrating two sides of the fabric
Implementation Method 2
Diapers promptly absorbing loose stool into an absorber body may help not only in reducing skin irritation, but also in preventing leakage
Implementation Method 3
a moisturizer composed mainly of glycerin is applied to an exterior surface of the top sheet
Data Source
AI summary
A disposable wearable article has a top sheet constituting a surface for use, a liquid-impervious sheet provided on the under face side, and an absorbent element interposed therebetween, wherein the top sheet is formed of perforated nonwoven fabric having a number of holes arranged at intervals and each penetrating two sides of the fabric. The absorbent element includes an absorber body and a packing sheet covering the absorber body. The packing sheet is formed of laminated nonwoven fabric having a spunbonded layer and a melt-blown layer, and a moisturizer composed mainly of glycerin is applied to an exterior surface of the top sheet.