Multi-layer Unitary Absorbent Structure for Fluid Management
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Solution Overview
Problem
Existing absorbent materials for consumer products like diapers and hygiene products require multiple layers for fluid acquisition and retention, leading to increased complexity and cost, while there is a need for simpler constructions that provide thinness, comfort, and effective liquid management.
Innovation Solution
A multi-layer unitary absorbent structure composed of specific layered constructions using bicomponent fibers with varying dtex and lengths, optionally including spunbond fibers and a cellulosic fiber layer, and potentially an absorbent core with superabsorbent polymer, to enhance fluid acquisition and retention characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple distinct components (topsheet, absorbent core, backsheet) are used to achieve fluid acquisition and retention, then liquid management performance is improved, but device complexity and material cost increase
Solution Approach 1:
The patent combines multiple distinct components (topsheet, absorbent core, backsheet) into a single unitary nonwoven structure. The multi-layer construction integrates liquid pervious, liquid impervious, and absorbent functions within one continuous material system, eliminating the need for separate bonded components while maintaining fluid acquisition and retention performance.
Solution Approach 2:
The unitary nonwoven structure performs multiple functions simultaneously: the first layer provides liquid distribution and acquisition, the second layer provides fluid retention and barrier properties, and the integrated structure eliminates the need for separate topsheet, core, and backsheet components, reducing overall construction complexity.
2Reliability
If traditional multi-layer construction is used, then fluid retention is achieved, but thinness and comfort are compromised
Solution Approach 1:
The patent applies different fiber types and structures to specific layers: the first layer uses hydrophilic fibers for liquid acquisition, the second layer uses hydrophobic or mixed fibers for fluid barrier properties. This localized functional differentiation achieves effective fluid retention while maintaining overall structure thinness through optimized layer-specific properties.
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 multi-layer structure achieves improved fluid acquisition and retention performance with a simpler construction, reducing material costs and enhancing comfort and efficiency in absorbent articles such as diapers and hygiene products.
Implementation Method 1
a multi-layer unitary absorbent structure comprising a first layer comprising a first bicomponent fiber and having a basis weight from about 5 gsm to about 50 gsm and a second layer, adjacent to the first layer, comprising a second bicomponent fiber and having a basis weight from about 5 gsm to about 50 gsm
Implementation Method 2
the multi-layer unitary absorbent structure can further include a cellulosic fiber layer adjacent to the second layer
Data Source
AI summary
The presently disclosed subject matter relates to multi-layer unitary absorbent structures and their use in absorbent articles. More particularly, the presently disclosed subject matter relates to unitary layered structures having a particular fibrous content that have improved fluid acquisition and retention characteristics.