Pleated Absorbent Core With Variable Stiffness Zones
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Solution Overview
Problem
Absorbent articles face challenges in preventing leakage of body exudates, particularly semi-solid fecal material, which can contaminate clothing and bedding, despite existing containment systems like elasticized flaps, as these systems still experience failures, especially in the waist regions.
Innovation Solution
Incorporating longitudinally extending pleats with varying stiffness and spacing into the absorbent articles, where the lower pleat portion is stiffer and bonded, and the upper portion is less stiff and un-bonded, to slow down the spread of exudates and enhance absorption by the absorbent core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elasticized containment flaps are used to provide gasketing around the wearer's legs, then leakage reduction is improved, but reliability is still insufficient as failures occur
Solution Approach 1:
The containment system is segmented into multiple functional zones: rigid containment flaps at the waist for structural barrier, elasticized leg cuffs for flexible sealing, and longitudinal pleats for flow control. Each segment addresses specific leakage pathways independently, improving overall reliability without requiring a single complex system
Solution Approach 2:
Different materials and structures are applied to different locations: rigid flaps at the waist region for containment, elasticized material at leg openings for flexibility, and pleated structures in the crotch area for flow management. This localized approach optimizes performance for each specific leakage risk zone
2Reliability
If containment flaps are added to reduce leakage, then leakage prevention is improved, but device complexity increases
Solution Approach 1:
Multiple containment functions are merged into integrated structures: the containment flaps are bonded to the bodyside liner and outer cover to form a unified waist containment system, while leg cuffs integrate elasticized material with the main body. This merging reduces the number of separate components while maintaining comprehensive leakage protection
3Productivity
If pleat height is increased to slow exudate spread, then absorption efficiency is improved, but device complexity increases
Solution Approach 1:
The pleat structure parameters are optimized with specific height ranges (2-15 mm) and spacing (2-15 mm) to achieve effective flow control. The pleats create tortuous paths that slow exudate migration without requiring excessive height or complexity, balancing absorption efficiency with structural simplicity
Data Source
AI summary
Absorbent articles comprising pleats and methods for forming pleated absorbent articles are disclosed. In one embodiment, an absorbent article extending in a longitudinal direction and a lateral direction may comprise a bodyside liner, an outer cover, an absorbent core disposed between the bodyside liner and the outer cover, and a pleat extending in the longitudinal direction and having a lower pleat portion and an upper pleat portion, the pleat having a pleat height, wherein the lower pleat portion has a greater stiffness than the upper pleat portion.