Pleated Absorbent Core Manufacturing for Flexibility and Leakage Control
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Solution Overview
Problem
Existing absorbent cores in disposable hygiene articles face challenges in maximizing absorption capacity while maintaining flexibility and preventing leakage, particularly due to limited expansion room for swelling absorbent materials.
Innovation Solution
The method involves pleating the first core cover web to reduce stress and improve conformability, applying absorbent material in a mat-forming process with channel-forming elements, and sandwiching the material between core cover webs to form channels and stabilize the core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large amount of superabsorbent material is used to increase absorption capacity, then absorption capacity is improved, but the article becomes bulky and loses flexibility
Solution Approach 1:
The absorbent core is divided into multiple layers with different functions: a first core cover layer, a second core cover layer, and an absorbent material layer containing superabsorbent particles. This segmentation allows the core to achieve high absorption capacity while maintaining flexibility through the distributed structure of multiple layers rather than a single bulky mass.
Solution Approach 2:
Different regions of the absorbent core are given different properties. The core cover layers provide structural integrity and flexibility, while the absorbent material layer provides absorption capacity. This local differentiation allows the article to be bulky only where needed for absorption while remaining flexible in the core cover layers that contact the wearer.
2Quantity of substance
If the absorbent core is made thick to provide sufficient absorption capacity, then absorption capacity is improved, but the article becomes stiff and uncomfortable
Solution Approach 1:
The thick absorbent core is segmented into multiple thin layers (first core cover layer, second core cover layer, and absorbent material layer) rather than a single thick mass. This segmentation reduces stiffness while maintaining overall thickness and absorption capacity, as each thin layer remains flexible while the combination provides sufficient absorption volume.
Solution Approach 2:
The absorbent core uses a composite structure combining different materials: core cover material for flexibility and structural integrity, and absorbent material containing superabsorbent particles for absorption capacity. This composite approach allows the core to achieve both thickness for absorption and flexibility for comfort.
3Quantity of substance
If superabsorbent material absorbs liquid and swells, then absorption capacity is improved, but the article loses flexibility and becomes stiff
Solution Approach 1:
The swollen absorbent material is segmented and distributed within a multi-layer structure rather than forming a single swollen mass. The first and second core cover layers constrain and distribute the swelling, allowing the superabsorbent particles to expand while maintaining overall flexibility through the distributed multi-layer architecture.
Solution Approach 2:
The flexibility is maintained locally in the core cover layers that remain relatively unaffected by swelling, while the absorbent material layer swells to provide absorption capacity. This local differentiation allows the article to be swollen and absorptive in the absorbent layer while remaining flexible in the core cover layers.
4Ease of operation
If channels are created in the absorbent core to improve liquid distribution, then liquid distribution is improved, but the structural integrity may be compromised
Solution Approach 1:
Channels are created locally within the absorbent material layer through the mat-forming process using channel-forming elements, while the first and second core cover layers remain intact to provide structural integrity. This local channel creation in the absorbent layer improves liquid distribution without compromising the overall structural strength provided by the core cover layers.
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
This approach enhances the absorbent core's ability to utilize its absorption capacity effectively, maintains flexibility, and reduces the risk of tearing during the manufacturing process, thereby improving wearer comfort and leakage security.
Implementation Method 1
Superabsorbents can absorb many times their own weight of fluid upon swelling and formation of a hydrogel
Implementation Method 2
Superabsorbents can absorb many times their own weight of fluid upon swelling and formation of a hydrogel
Implementation Method 3
bringing the pleated first core cover web into conformance with the recess and the at least one channel-forming element on the bottom surface of the recess, with the second surface of the first core cover web facing the bottom surface of the recess and causing the pleat in the first core cover web to at least partially unfold at the at least one channel-forming element
Implementation Method 4
applying an adhesive on the first surface of the second core cover web; applying the second core cover web to the first core cover web and to the absorbent material arranged on the first core cover web
Data Source
AI summary
A method of manufacturing an absorbent core for a disposable absorbent hygiene article includes providing a first core cover web and at least one pleat in the first core cover web; applying an adhesive to the pleated first core cover web; bringing the pleated first core cover web into conformance with a recess, the recess including at least one channel-forming element arranged on a bottom surface of the recess and causing the pleat to at least partially unfold at the channel-forming element; applying absorbent material on the first core cover web in the recess; applying an adhesive on a second core cover web; applying the second core cover web to the first core cover web; forming an absorbent laminate by pressing together the second and first core cover webs; and forming individual absorbent cores by severing the absorbent laminate. An absorbent core and an absorbent article including the absorbent core are also disclosed.