Disposable Worn Article Flap Stretchability and Core Stability
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Solution Overview
Problem
Disposable worn articles with high stretchability non-woven fabrics face manufacturing errors due to shrinkage in the vertical direction when stretched in the girth direction, and the high material cost of these fabrics increases product costs.
Innovation Solution
A disposable worn article design where stretchable non-woven fabrics are used only in the front and back flaps, not covering the entire absorbent core, allowing for controlled stretchability in the girth direction without vertical shrinkage, and manufacturing methods involve laminating and cutting techniques to minimize material usage and prevent errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a stretchable non-woven fabric is used in the girth portion to provide high stretchability, then the stretchability in the girth direction is improved, but the fabric shrinks in the vertical direction causing manufacturing errors
Solution Approach 1:
The patent divides the non-woven fabric into two distinct regions: a stretchable region in the girth direction and a non-stretchable region covering the absorbent core in the vertical direction. This segmentation allows each region to perform its specific function independently - the stretchable region provides elasticity for comfort while the non-stretchable region maintains dimensional stability during manufacturing, thereby resolving the contradiction between stretchability and manufacturing precision.
Solution Approach 2:
The patent applies different material properties to different parts of the worn article. The girth portion uses stretchable non-woven fabric to provide elasticity and comfort, while the crotch portion covering the absorbent core uses non-stretchable non-woven fabric to maintain dimensional stability. This local differentiation of material properties allows the article to have both stretchability where needed and manufacturing precision where required.
2Adaptability or versatility
If a stretchable non-woven fabric is used throughout the worn article to ensure high stretchability, then the comfort and fit are improved, but the material cost increases
Solution Approach 1:
The patent segments the worn article into regions requiring stretchability and regions where stretchability is unnecessary. By placing stretchable non-woven fabric only in the girth portion and using non-stretchable non-woven fabric in the crotch portion, the patent reduces the total quantity of expensive stretchable material used while maintaining the necessary comfort and fit, thereby resolving the contradiction between adaptability and material cost.
Solution Approach 2:
The patent applies stretchable material properties locally only where they are functionally necessary (girth portion for comfort and fit) rather than throughout the entire article. This localized application of expensive stretchable non-woven fabric reduces overall material costs while preserving the essential stretchability needed for wearer comfort.
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 design prevents manufacturing errors and reduces costs by limiting the area of stretchable non-woven fabric, ensuring the absorbent core's leg hole area does not shrink vertically and maintaining cost-effectiveness.
Implementation Method 1
a stretchable non-woven fabric that stretches in the girth direction
Implementation Method 2
an absorbent core which absorbs body fluid
Data Source
AI summary
The present invention relates to a disposable worn article, including: an absorbent body 2 including an absorbent core 24 which absorbs body fluid laminated between a liquid-permeable top sheet 26 and a liquid-impermeable back sheet 27; a pair of front flaps Ff extending in a girth direction X to be continuous with a front portion 20 of the absorbent body 2 that covers a front surface of a torso of a wearer; and a pair of back flaps Fb extending in the girth direction to be continuous with a back portion 21 of the absorbent body 2 that covers a back surface of the torso of the wearer, wherein: the front and back flaps Ff and Fb include a stretchable non-woven fabric 31 that stretches in the girth direction X; and an entire area of the absorbent core 24 is not essentially covered by the stretchable non-woven fabric 31.