Zonal Absorbent Cover Balancing Breathability and Leakage
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Solution Overview
Problem
Reusable outer covers for absorbent articles face challenges in balancing competing properties such as containment, wearer comfort, skin condition, and aesthetic appeal, often compromising on durability or leakage protection for enhanced breathability and comfort.
Innovation Solution
A reusable outer cover with zones of varying properties, including a rear zone with high extension and unload force, a crotch zone with high WVTR and fluid penetration resistance, and zones with specific static coefficients of friction to accommodate anatomical contours and body movements, while maintaining durability and leakage protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If enhanced breathability is implemented in the outer cover, then wearer comfort and skin condition are improved, but leakage protection and containment are reduced
Solution Approach 1:
The outer cover is divided into multiple zones with different material properties: the crotch zone uses highly breathable material (WVTR ≥1200 g/m2/24hrs) for comfort, while the waistband and leg opening zones use less breathable material with higher fluid penetration resistance (≥5 mbar) for containment. This zonal differentiation allows simultaneous optimization of comfort and leakage protection.
2Object-affected harmful factors
If softer and more flexible materials are used to improve comfort and conforming, then wearer comfort is enhanced, but durability over multiple use cycles is reduced
Solution Approach 1:
Different zones of the outer cover use materials with different softness and flexibility characteristics. The crotch zone uses softer, more flexible material for comfort, while the waistband and leg openings use more durable, structured materials to maintain shape and integrity through multiple wash cycles.
Solution Approach 2:
The outer cover employs composite material construction combining different fabric types and weights in different zones. The crotch zone may use lighter, softer knitted fabrics while the waistband uses heavier, more structured woven fabrics with elastic properties, creating a composite structure that balances comfort and durability.
3Ease of operation
If the rear zone has high extension to accommodate body movements, then wearer comfort and fit are improved, but the front zone requires different extension characteristics for proper containment
Solution Approach 1:
The outer cover features zonal differentiation in extension properties: the rear zone has high extension capability (≥50% at 5N force) to accommodate buttock movement and sitting positions, while the front zone has lower extension (≥15% at 5N force) to maintain containment effectiveness and prevent leakage during normal activities.
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 solution provides improved containment, wearer comfort, and aesthetic appeal by optimizing stretch characteristics, breathability, and friction properties across different zones, enhancing the overall performance and longevity of the outer cover.
Implementation Method 1
The crotch zone may have a higher WVTR than the front and rear zones. The crotch zone may have a WVTR of at least 1200 g/m2/24 hrs, or at least 3000 g/m2/24 hrs.
Implementation Method 2
the rear zone has a greater percent extension than the front zone in the Whole Product Back Extension test. The rear zone may extend at least 50% under an applied force of 5N and may have an unload force of at least 1.0N at 25% extension.
Implementation Method 3
The crotch zone may have a higher fluid penetration resistance than the front and rear zones. The crotch zone may have a fluid penetration resistance of at least 5 mbar.
Implementation Method 4
The side, rear, and front zones may have a higher static coefficient of friction relative to skin than the crotch zone. The side, rear, and front zones may have a static coefficient of friction relative to skin greater than 0.5.
Implementation Method 5
The second layer may be more hydrophobic than the first layer. The second layer may be more hydrophobic than the front and rear zones.
Data Source
AI summary
An absorbent article having a reusable outer cover and, optionally, an absorbent insert. The reusable outer cover has zones of varying properties. The properties of the different zones are varied to provide different performance features in different parts of the outer cover. The outer cover with zones of varying properties may provide competing or contradictory functionalities for improved comfort, fit, leakage protection, and aesthetic appeal.