Structured Topsheet Channels for Rapid Fluid Intake and Leak Control
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Solution Overview
Problem
Current absorbent articles with nonwoven topsheets lack effective methods to impart three-dimensional structural features for rapid fluid acceptance and movement into the absorbent structure, while minimizing fluid retention and rewetting, and often result in fluid migration to the edges, leading to potential leakage.
Innovation Solution
The topsheet features continuous channel-forming structures symmetric about the central longitudinal axis, circumscribing the discharge locus, with attenuated regions of lower filament density and built-up regions of higher density, designed to guide fluid into the absorbent structure and prevent lateral migration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If nonwoven web material is used for topsheets, then cost effectiveness and wearer comfort are improved, but three-dimensional structural features and rapid fluid movement capability are insufficient
Solution Approach 1:
The nonwoven web is segmented into regions of different filament densities - built-up regions with higher density and attenuated regions with lower density. This segmentation creates three-dimensional structural features that facilitate rapid fluid movement while maintaining cost-effectiveness using standard nonwoven manufacturing processes
Solution Approach 2:
Different regions of the topsheet are given different local qualities through varying filament density. The built-up regions provide structural support and fluid distribution, while the attenuated regions enable rapid fluid penetration. This local differentiation achieves rapid fluid movement without requiring complete restructuring of the nonwoven material
2Device complexity
If conventional nonwoven topsheets are used, then manufacturing simplicity is maintained, but fluid retention and rewetting occur due to lack of structural features
Solution Approach 1:
The nonwoven web is formed with built-up and attenuated regions before the fluid absorption process occurs. This preliminary structuring ensures that fluid is immediately directed into the absorbent core through the attenuated regions, preventing fluid retention on the surface and subsequent rewetting
Solution Approach 2:
The attenuated regions create porous pathways through the nonwoven structure, allowing fluid to move rapidly from the wearer-facing surface into the absorbent core. These porous channels prevent fluid accumulation and rewetting while maintaining manufacturing simplicity
3Productivity
If standard nonwoven topsheets are used, then production efficiency is maintained, but fluid migration to edges occurs leading to potential leakage
Solution Approach 1:
The channel-forming structures are positioned asymmetrically with respect to the discharge locus, creating a symmetric pattern about the central longitudinal axis. This asymmetric arrangement within a symmetric framework guides fluid away from the edges toward the center, preventing fluid migration and leakage while maintaining production efficiency
Solution Approach 2:
The built-up regions act as intermediary structures that intercept and redirect fluid flow. These raised regions serve as barriers that guide fluid through the attenuated regions into the absorbent core, preventing fluid from reaching the edges and causing leakage
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 structured topsheet enhances fluid distribution to the absorbent core, reduces fluid retention on the surface, and minimizes leakage by channeling fluids effectively into the absorbent structure, providing both aesthetic appeal and functional efficiency.
Implementation Method 1
the topsheet is adapted to be liquid permeable such that liquid body exudates may pass therethrough
Implementation Method 2
be absorbed and retained by the absorbent material until the time the article is removed and discarded
Data Source
AI summary
A disposable absorbent article includes a topsheet, a backsheet, and an absorbent structure positioned intermediate the topsheet and the backsheet. The topsheet includes an elongate central portion and two wing portions opposingly laterally extending from the elongate central portion. The topsheet forms a wearer-facing surface in the two wing portions. The topsheet includes one or more continuous channel-forming structures following one or a plurality of paths. The one or plurality of paths is substantially symmetric about a central longitudinal axis of the topsheet and predominately circumscribes a discharge locus on the central longitudinal axis of the topsheet. The one or more continuous channel-forming structures extends across a central lateral axis of the topsheet. The topsheet includes a continuous hinge forming structure following a path extending generally longitudinally along one of the wing portions and extending across the central lateral axis of the topsheet.