Secondary Topsheet with Larger Pores for Rapid Fluid Transfer
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Solution Overview
Problem
Absorbent articles with natural fiber topsheets face challenges in fluid transfer efficiency due to the inherent properties of cotton, which can lead to fluid retention and discomfort, necessitating the development of materials with higher capillary suction without compromising natural fiber experience.
Innovation Solution
The design of an absorbent article featuring a liquid permeable topsheet, a liquid impermeable backsheet, and a secondary topsheet with a first layer having a larger mean pore size than the topsheet, optimized to facilitate rapid fluid transfer from the topsheet to the absorbent core, utilizing a combination of thermoplastic fibers and cellulose-based materials in the secondary topsheet layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a topsheet made of natural fibers (cotton) is used, then the natural and gentle skin experience is improved, but the fluid transfer speed and absorption efficiency deteriorate due to fluid retention on the topsheet
Solution Approach 1:
A secondary topsheet layer is introduced as an intermediary between the natural fiber topsheet and the absorbent core. This intermediate layer acts as a mediator that accelerates fluid transfer from the topsheet to the core through capillary action, resolving the contradiction between maintaining natural fiber comfort and achieving fast fluid transfer.
Solution Approach 2:
The secondary topsheet is designed with specific porosity and pore size characteristics to enhance capillary suction. The porous structure enables rapid fluid wicking and transfer, compensating for the fluid retention properties of natural fiber topsheets while preserving their skin-friendly characteristics.
2Object-affected harmful factors
If a topsheet made of natural fibers (cotton) is used, then the natural and gentle skin experience is improved, but the amount of fluid remaining on the topsheet increases causing wetness discomfort
Solution Approach 1:
The secondary topsheet serves as an intermediary that actively draws fluid away from the natural fiber topsheet through capillary action. This prevents fluid accumulation on the topsheet surface, reducing wetness discomfort while allowing the use of comfortable natural fibers.
Solution Approach 2:
The secondary topsheet's physical parameters (porosity, pore size, fiber composition) are optimized to create strong capillary forces that actively remove fluid from the topsheet. This parameter optimization ensures minimal fluid retention on the topsheet while maintaining natural fiber benefits.
3Speed
If the layer underneath the topsheet has high capillary suction, then the fluid transfer speed is improved, but it becomes challenging to find material layers with higher capillary suction than 100% cotton topsheet
Solution Approach 1:
The secondary topsheet utilizes composite material construction, combining different fiber types and structures to achieve superior capillary suction properties. This composite approach enables the layer to outperform 100% cotton topsheets in fluid transfer while remaining manufacturable with available materials.
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 configuration enhances fluid acquisition time and reduces fluid left on the topsheet, providing a natural fiber experience while ensuring efficient fluid transfer and comfort, as demonstrated by improved acquisition time and reduced rewet measurements.
Implementation Method 1
the layer underneath topsheet has high capillary suction than that for topsheet
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The absorbent article (10) comprising a liquid permeable topsheet (1), a liquid impermeable sheet (3), an absorbent core (5) disposed between the topsheet (1) and the backsheet (3), and a secondary topsheet (4) disposed between the topsheet (1) and the absorbent core (5), wherein the secondary topsheet (4) comprises a first layer (42) and a second layer (44), the first layer (42) being located between the topsheet (1) and the second layer (44), wherein a mean pore size of the first layer (42) is larger than a mean pore size of the topsheet (1).