Surge Layer Barriers Block Linear Fluid Flow in Diapers

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional disposable absorbent articles face challenges in absorbing liquid insults without pooling or leakage, as the rate of liquid deposition can exceed the absorption capacity, leading to fluid accumulation and leakage.

Innovation Solution

The introduction of a surge layer with barriers extending through the surge material in the Z-direction, configured to block linear longitudinal fluid flow paths while allowing non-linear fluid flow paths, helps to manage fluid distribution and absorption within the absorbent article.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the inner layer is made liquid permeable to permit body waste to pass through for absorption, then the absorption function is improved, but liquid can pool in the lowest parts of the article leading to leakage when the rate of liquid deposition exceeds the absorption rate

Engineering Contradiction:

Improveabsorption rateVSAvoidleakage resistance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The surge layer is segmented into multiple zones with different barrier configurations. First barrier zones are positioned to intercept linear longitudinal flow paths, while second barrier zones are positioned to intercept non-linear longitudinal flow paths. This segmentation allows the system to handle both rapid linear flow and distributed non-linear flow, preventing pooling and leakage while maintaining high absorption capacity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The surge layer acts as an intermediary between the liquid permeable inner layer and the absorbent body. It receives liquid waste from the inner layer and distributes it to the absorbent body through controlled flow paths. The barriers within the surge layer mediate the flow distribution, ensuring liquid is directed to areas with available absorption capacity rather than pooling in lowest parts.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If barriers are added to block linear longitudinal fluid flow paths, then fluid distribution is improved and pooling is reduced, but the structure becomes more complex

Engineering Contradiction:

Improvefluid distribution controlVSAvoidsurge layer structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple barrier functions are merged into a single integrated surge layer structure. The first and second barrier zones are combined in one layer rather than using separate layers or components. This merging reduces structural complexity while maintaining the ability to block both linear and non-linear longitudinal flow paths, achieving effective fluid distribution control without proportionally increasing complexity.

Inventive Principle:

Principle #5Merging (Combining)

3Quantity of substance

If the surge layer allows non-linear fluid flow paths, then fluid can be distributed more evenly throughout the absorbent body, but linear flow paths may still allow rapid fluid accumulation

Engineering Contradiction:

Improvefluid distribution evennessVSAvoidrapid fluid absorption capacity

Core Design Contradiction:

Quantity of substanceVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

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 the absorbent article's ability to absorb and distribute liquid evenly, reducing the likelihood of pooling and leakage, and optimizing the utilization of the absorbent material already present in the article.

Implementation Method 1

a barrier extending substantially through the surge material in the Z-direction, wherein the barrier is configured to block at least one linear longitudinal fluid flow path

Methodology Applied

Scientific EffectPhysical barrier blocking:

Implementation Method 2

a surge layer disposed between the bodyside liner and the absorbent body

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Implementation Method 3

the surge layer having an X-Y plane, a Z-direction, and a longitudinal direction

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 4

an absorbent body disposed between the bodyside liner and the outer cover

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Data Source

PatentUS12263072B2Disposable absorbent article with surge layer including at least one barrier

Publication Date: 2025.04.01 KIMBERLY CLARK WORLDWIDE INC

AI summary

A disposable absorbent article includes a bodyside liner, an outer cover, an absorbent body disposed between the bodyside liner and the outer cover, and a surge layer disposed between the bodyside liner and the absorbent body, the surge layer having an X-Y plane, a Z-direction, and a longitudinal direction, and a barrier extending substantially through the surge material in the Z-direction, wherein the barrier is configured to block at least one linear longitudinal fluid flow path. The surge layer can alternatively have a plurality of barriers extending substantially through the surge material in the Z-direction, wherein the plurality of barriers is configured to block a plurality of linear longitudinal fluid flow paths or all linear longitudinal fluid flow paths while allowing non-linear fluid flow paths in the longitudinal direction.