Cellulose-Free Absorbent Core with Sealed Wrap Sheets

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Solution Overview

Problem

Existing absorbent articles, such as diapers, face challenges in maintaining the immobilization of absorbent particulate polymer material in both dry and wet states, leading to potential bulkiness, reduced flexibility, and increased costs, while also risking the escape of super-absorbent materials, which can cause skin irritation.

Innovation Solution

A disposable absorbent article design featuring a cellulose-free absorbent core with a storage layer and two core wrap sheets, where the absorbent particulate polymer material is deposited on substrates and covered with thermoplastic adhesive material, ensuring continuous distribution and immobilization across the core area, and sealed with a traverse sealing zone to prevent material escape.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If absorbent particulate polymer material is immobilized using traditional technologies, then immobilization is achieved, but bulk and thickness increase

Engineering Contradiction:

Improveimmobilization effectivenessVSAvoidarticle thickness

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The absorbent core is divided into multiple layers including a first absorbent layer, a second absorbent layer, and a barrier layer. The polymer material is distributed across these segmented layers rather than concentrated in a single bulk layer, achieving immobilization while maintaining thinness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A thin barrier layer is introduced between the absorbent layers to prevent polymer material migration. This thin film approach provides effective immobilization without adding significant bulk to the article structure.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If absorbent particulate polymer material is immobilized using traditional technologies, then immobilization is achieved, but flexibility is reduced

Engineering Contradiction:

Improveimmobilization effectivenessVSAvoidarticle flexibility

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The core is segmented into thin layers separated by a barrier layer, allowing each layer to remain flexible while collectively providing immobilization. The segmented structure prevents polymer migration without sacrificing overall flexibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The barrier layer is designed as a thin flexible film rather than a rigid structure, enabling it to provide immobilization while conforming to body movements and maintaining article flexibility during use.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If absorbent particulate polymer material is immobilized using traditional technologies, then immobilization is achieved, but manufacturing cost increases

Engineering Contradiction:

Improveimmobilization effectivenessVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The segmented layer structure allows for efficient manufacturing processes where each layer can be produced and assembled separately. This modular approach reduces manufacturing complexity and cost compared to traditional bulk immobilization methods.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The thin barrier layer can be produced using cost-effective film formation techniques and integrated into the core structure during assembly, providing immobilization functionality at lower manufacturing cost than traditional methods.

Inventive Principle:

Principle #30Flexible shells and thin films

4Quantity of substance

If absorbent particulate polymer material is used, then absorbency is improved, but material escape and skin contact risk increase

Engineering Contradiction:

Improveabsorbency capacityVSAvoidskin irritation risk

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The absorbent core is segmented into multiple layers with a barrier layer positioned to contain the polymer material. This segmentation maintains high absorbency capacity while preventing polymer escape to the skin surface.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A barrier layer functions as a containment film within the absorbent core, preventing polymer material migration toward the skin-contacting surfaces while maintaining the article's flexibility and absorbency performance.

Inventive Principle:

Principle #30Flexible shells and thin films

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 provides a thin, flexible, and cost-effective absorbent article with enhanced immobilization of absorbent particulate polymer material in both dry and wet states, minimizing the risk of material escape and skin contact, thus enhancing comfort and performance.

Implementation Method 1

a thermoplastic adhesive material covers the absorbent particulate polymer material on the respective first and second substrates

Methodology Applied

Scientific EffectThermoplastic adhesive bonding: Adhesive

Implementation Method 2

Absorbent particulate polymer material absorbs liquid and swells

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Implementation Method 3

the first core wrap sheet being joined to the second core wrap sheet along at least one traverse sealing zone

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS9241845B2Disposable absorbent article with sealed absorbent core with substantially continuously distributed absorbent particulate polymer material

Publication Date: 2016.01.26 PROCTER & GAMBLE CO

AI summary

A disposable absorbent article includes a chassis and an absorbent core which is substantially cellulose free. The chassis may contain a topsheet and a backsheet. The absorbent core may be located between the topsheet and the backsheet and may include (i) a storage layer which comprises an absorbent particulate polymer material and has a wearer facing side and an opposed garment facing side, (ii) a first core wrap sheet covering the wearer facing side of the storage layer, and (iii) a second core wrap sheet covering the garment facing side of the storage layer, the first core wrap sheet being joined to the second core wrap sheet along at least one traverse sealing zone.