Resilient Absorbent Laminates for Disposable Articles
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Solution Overview
Problem
Conventional absorbent cores in disposable absorbent articles, particularly those with predominantly superabsorbent polymer (SAP), face challenges such as lack of structural integrity after liquid absorption, high stiffness, and difficulty in providing sufficient void volume to handle liquid gushes without additional acquisition-distribution layers (ADLs).
Innovation Solution
The development of resilient absorbent laminates comprising a nonwoven substrate sandwiched between adhesive-supported SAP layers, which provide enhanced permeability and capillarity, allowing for absorption and distribution of liquids without a discrete ADL. These laminates are designed to maintain flexibility and physical integrity when wet, enabling them to function as both absorbent cores and patient-support articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional absorbent cores with predominantly superabsorbent polymer (SAP) are used, then liquid absorption capacity is improved, but structural integrity deteriorates after liquid absorption
Solution Approach 1:
The patent applies composite materials by combining SAP particles with a nonwoven substrate and adhesive layers to create a laminate structure. This composite construction allows the SAP to absorb liquid while the nonwoven substrate and adhesive maintain structural integrity, preventing the core from disintegrating after absorption.
Solution Approach 2:
The patent utilizes porous materials by incorporating a nonwoven substrate with controlled porosity that allows liquid penetration to reach the SAP particles while providing structural framework. The porous structure enables liquid absorption without compromising the overall structural stability of the core.
2Quantity of substance
If conventional absorbent cores with predominantly SAP are used, then absorbency is improved, but flexibility deteriorates due to high stiffness
Solution Approach 1:
The patent applies flexible shells and thin films by using a nonwoven substrate that provides flexibility to the overall laminate structure. This nonwoven layer acts as a flexible matrix that allows the SAP-containing laminate to bend and conform without breaking, maintaining ease of operation while preserving high absorbency.
3Quantity of substance
If conventional absorbent cores are used, then absorption capacity is improved, but device complexity increases due to need for additional acquisition-distribution layers
Solution Approach 1:
The patent applies merging by combining the functions of absorption and structural support into a single integrated laminate. The nonwoven substrate serves both as the structural framework and as the medium through which liquid is distributed to the SAP particles, eliminating the need for separate acquisition-distribution layers and reducing overall device complexity.
Solution Approach 2:
The patent applies universality by designing the nonwoven substrate to perform multiple functions simultaneously: providing structural integrity, enabling liquid distribution, and supporting the SAP particles. This multi-functional design reduces the number of separate components needed, simplifying the overall device structure while maintaining high absorption capacity.
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 resilient absorbent laminates effectively acquire and store body fluids, reducing internal runoff and leakage, while providing improved structural integrity and flexibility, allowing them to be used in various applications, including disposable absorbent articles and patient-support pads, without the need for additional ADLs.
Implementation Method 1
superabsorbent polymer (SAP) particles and an adhesive supporting the SAP particles in a porous matrix
Implementation Method 2
enhanced permeability and capillarity, allowing for absorption and distribution of liquids
Data Source
AI summary
Absorbent multi-layer laminates with SAP on both sides of a middle substrate that comprises wettable cellulosic fibers. Also absorbent cores including such absorbent laminates. Absorbent articles such as protective underwear, adult briefs, baby diapers and nursing pads including such absorbent cores, and patient-support pads such as underpads and sacral pads including such absorbent laminates and cores.