Precise Disassembly and Technical Analysis of Adult Diaper Structure

I. Precise Disassembly of the Core Structure of Russian ПВТ-L Adult Diapers

1. Skin-Friendly Top Layer System (Direct Skin Contact Layer)

· Core Base Material: Full non-woven fabric surface layer system, split into front panel, back panel, and side guard non-woven fabrics, with additional non-woven inserts to achieve zoned skin-friendly performance and enhanced diversion.

· Core Leakage Prevention: Raised three-dimensional leak-proof barriers (Fecal Barrier, with a spelling error of Fecot Barrier in the original document), specially designed for fecal and urinary incontinence. Built-in independent elastomers can automatically stand up to form a closed leak-proof compartment.

· Core Technology: Ultrasonic welding process is used to replace traditional glue bonding, which integrally welds the surface layer, leak-proof barriers, non-woven inserts, front and back panels, reducing the risk of glue-induced sensitization. At the same time, it is matched with a three-layer embossing process to form three-dimensional diversion grooves, accelerating liquid infiltration and reducing the contact time between skin and urine.

2. Diversion and Diffusion System

· Exclusive Acquisition Distribution Layer (ADL): Located between the surface layer and the absorbent core, it is made of high-loft non-woven fabric. Its core function is to quickly receive and laterally diffuse urine, avoid local liquid absorption saturation, and solve the problems of side leakage and rewet caused by the large single urine output of adults.

3. Core Absorbent Core System

· Base Material Formula: Wood pulp (fluff pulp) + super absorbent polymer (SAP) composite core, which is the liquid absorption core of the product, adapting to the large-capacity liquid absorption demand of adults with severe incontinence.

· Structural Design: Adopts a 10-layer + 2-layer graded composite structure, matched with R50/R300/R20 multi-radian rounded corner cutting, which fits the ergonomic curve and avoids core delamination and clumping. At the same time, it is fixed by multi-proportion glue lines, which greatly improves the stability of the core when turning over and walking.

4. Leak-Proof Backsheet System

· Base Material: Breathable polyethylene (PE) backsheet, with a 2:1 ratio of breathable micropore design. While blocking urine leakage, it realizes moisture discharge, reducing the risk of bedsores and eczema in people who are bedridden for a long time.

· Auxiliary Design: The surface of the backsheet is coated with positioning glue to achieve firm bonding of each layer of structure, and a special urine indicator coating position is reserved.

5. Elastic Adaptation System

· Leg Leakage Prevention: Dual sets of leg elastics, matched with special elastic adhesive, achieve 360° fit around the leg circumference, adapt to different leg shapes, and eliminate side leakage when walking/turning over.

· Barrier Elasticity: The leak-proof barrier has a built-in independent elastomer to ensure that the barrier always maintains a three-dimensional state and forms an effective leak-proof barrier even in the lying position.

· Waist Circumference Adaptation: One-piece widened waistband design with a built-in elastic structure, which adapts to different waist sizes, improves wearing fit, and reduces gap leakage when turning over.

6. Functional Auxiliary System

· Urine Indicator Design: The backsheet has built-in urine indicator ink, which changes color after contact with urine to remind nursing staff to replace it in time, suitable for the nursing scene of disabled people.

· Pre-folding Design: The front and rear surface layers are pre-folded, which is suitable for automated packaging and convenient for nursing staff to quickly unfold and wear.

7. Bonding and Edge Sealing Technology

· Adopts zoned multi-proportion glue spraying process, which accurately controls the glue spraying amount in different areas, taking into account the bonding fastness and product softness.

· Ultrasonic edge sealing process fully encloses the edges of the surface layer and the core, eliminating burrs and side leakage, and improving product stability.

II. General Basic Structural Framework of Adult Diapers Worldwide

Regardless of the category, the mainstream adult diapers in the world follow the basic logic of the five-layer core structure, from the skin side to the outer side in the following order:

III. Structural Details of Mainstream Types of Adult Diapers in the Global Market

According to wearing methods, applicable scenarios, and degree of incontinence, adult diapers in the global market are divided into 4 major categories, with significant differences in structural details and regional preferences, as follows:

1. Tape-Type (Adhesive) Adult Diapers

· Core Positioning: The first choice for people with severe incontinence and bedridden disability, the mainstream category in European and American markets, Eastern European markets such as Russia, as well as the core model for hospitals and nursing homes.

· Core Structural Details:

1. Waistband Structure: Adopts a split design of front waistband + back waistband. The two sides of the back waistband are equipped with 2-3 sets of hook and loop fasteners, and the front waistband is a non-woven front waist landing zone that can be pasted repeatedly, adapting to the needs of lying down wearing and tightness adjustment for bedridden people; high-end models adopt a full elastic waistband to achieve 360° elastic wrapping.

2. Core Design: Full-size widened and lengthened core, with thickened treatment at the front and rear ends, especially the super thickening at the back end of the buttocks, which adapts to the urine flow direction of bedridden people in supine position and eliminates back leakage; European and American/Russian models generally use high gram weight fluff pulp + High-magnification SAP, with a liquid absorption capacity of generally 1500-3000ml, and the night model can reach more than 5000ml.

3. Leakage Prevention System: Standard equipped with double three-dimensional leak-proof barriers + double leg elastic rubber bands. High-end models are additionally equipped with a fecal leak-proof compartment (such as the Russian model mentioned above). The height of the barrier is generally 5-8cm, far exceeding other categories, and can form a closed leak-proof space even in the lying position.

4. Auxiliary Functions: The whole series is standard equipped with urine indicator design. High-end models are additionally equipped with anti-slip lines for turning over, bedsore protection pads, and activated carbon antibacterial and deodorant layer. European and American models generally reduce the amount of glue and give priority to ultrasonic welding process to reduce the risk of sensitization.

· Regional Differences: European and American/Russian models focus on large liquid absorption capacity, wide waistband and high barriers, adapting to large-weight people and long-term care scenarios; Japanese models focus on thinning, adopt composite core, take into account liquid absorption capacity and softness, and fit the body shape of Asian people.

2. Pull-On (Pant-Style) Adult Diapers

· Core Positioning: For people with mild to moderate incontinence and mobile active people, the mainstream category in Asia-Pacific markets such as Japan, China and South Korea, with an extremely fast growth rate in the European and American markets in recent years.

· Core Structural Details:

1. Waistband Structure: One-piece 360° full elastic waistband, which can be put on and taken off directly like underwear without lying down adjustment. The stretch ratio of the waistband is generally above 1:3, adapting to daily walking, exercise and sedentary scenarios without strangulation marks; high-end models are equipped with easy-tear openings on both sides for quick replacement without taking off shoes and pants.

2. Core Design: Medium-length ultra-thin composite core. The mainstream in Japan and South Korea is all-polymer dust-free paper core, with a thickness of only 2-3mm, which is not easy to delaminate and clump, adapting to daily activities; adopts gender-specific zoned thickening design, with the front side thickened for men's models and the middle and rear side thickened for women's models, fitting the physiological structure differences between men and women; the liquid absorption capacity is generally 800-2000ml, and the night enhanced model can reach 3000ml.

3. Leakage Prevention System: Standard equipped with double three-dimensional leak-proof barriers + leg Lycra elastics, with a barrier height of 3-5cm. The leg circumference adopts an ergonomic U-shaped design, which fits the root of the leg without friction and side leakage when walking.

4. Appearance Design: Adopts underwear-style traceless design, solid color/printed appearance, thin and close-fitting, no bulge when wearing pants outside, taking into account the user's privacy and weakening the medical sense.

· Regional Differences: Japanese models achieve extreme thinning, with leading core technology, precise zoned liquid absorption design, and the highest segmentation of women's special models in the world; European and American models focus on high elasticity and large size adaptation, suitable for large-weight and mild exercise people; Chinese models take into account thinness and liquid absorption capacity, with high cost performance, and the popularization rate of easy-tear opening design is extremely high.

3. Insert-Type Diaper Pads / Liners (Used with Mesh Pants)

· Core Positioning: For people with mild to moderate incontinence and economic demand, the mainstream category in developing countries and primary care scenarios, and the global cost-effective model.

· Core Structural Details:

1. Basic Structure: Simplified diaper structure, without waistband, waist paste, elastic system, only retaining four core structures: surface layer + diversion layer + absorbent core + backsheet. The shape is divided into straight strip type, gourd type and T type, adapting to different urine leakage scenarios.

2. Core Design: Gourd type / T type are mid-end models, with widened middle and narrowed front and rear, fitting the human body curve, with a liquid absorption capacity of 500-1500ml; straight strip type is an economic model, with simple structure and extremely low cost, only suitable for mild urine leakage.

3. Usage Method: It needs to be used with elastic mesh pants / fixed underwear. Insert the diaper pad into the mesh pants for fixation. Only the diaper pad needs to be replaced when changing, and the mesh pants can be reused, which greatly reduces the use cost.

· Regional Differences: It has a high penetration rate in Southeast Asia, Latin America, and China's sinking markets, focusing on cost performance; most European and American models are upgraded women's special panty liners, with additional antibacterial and ultra-thin design, suitable for mild stress urinary incontinence.

4. Special Functional Adult Diapers

Customized structure for special scenarios and special groups, with highly targeted core design, which is the core segmentation direction of the global high-end market:

1. Night Enhanced Type: Global general model, the core is an ultra-long and large-size core, with SAP content increased by more than 30%, the liquid absorption capacity is generally 3000-6000ml, which can achieve 8-12 hours of long-term liquid locking; additional multi-layer diversion layer is added, with full anti-rewet performance, widened waistband and heightened barriers to eliminate side leakage and back leakage when turning over.

2. Men's Special Type: The core is the front directional liquid absorption area, with thickened front side of the core, and a special men's leak-proof pocket, adapting to the scene of male standing urine leakage; divided into tape type, pull-on type and briefs type, with extremely high segmentation in the European and American markets, covering exclusive scenarios such as post-prostate surgery and severe incontinence.

3. Women's Special Type: The core is a mid-waist ergonomic core, which fits the female physiological curve and adapts to stress urinary incontinence after childbirth and menopause; subdivided into menstrual and urine leakage dual-purpose models, ultra-thin invisible models, with the most complete categories in the Japanese market, generally equipped with antibacterial and deodorant layers, adapting to women's private care needs.

4. Swimming Special Type: Mainstream niche high-end model in the European and American markets, the core is a waterproof backsheet + special SAP that does not swell when exposed to water, which does not swell when exposed to pool water and only absorbs body fluids; additionally equipped with high elastic sealed waistband and leg circumference to eliminate leakage and pollution of the swimming pool, suitable for swimming and water activities of incontinent people.

5. Special Type for Bedridden People with Fecal and Urinary Incontinence: Represented by special models for nursing homes in Russia and Europe and America, the core is a fecal leak-proof compartment + heightened three-dimensional barriers. The core is additionally equipped with a fecal fixation layer, which can absorb solid feces and realize rapid urine infiltration; an additional hip decompression layer is added to reduce the risk of bedsores.

6. Environmentally Friendly Biodegradable Type: Emerging category in Europe and America in recent years, the core is fully biodegradable materials, the surface layer adopts corn fiber non-woven fabric, the core adopts biodegradable SAP, the backsheet adopts PLA biodegradable film, no glue, full ultrasonic welding, adapting to environmental protection needs.

IV. Development Trend of Global Adult Diaper Structure Technology

1. Process Upgrade: Ultrasonic welding process is gradually replacing traditional glue bonding, reducing the risk of sensitization and improving skin-friendliness. It has been popularized in high-end models in Europe, America and Japan, and has begun to be applied on a large scale in Eastern European markets such as Russia.

2. Core Iteration: Upgrading from traditional fluff pulp + SAP to ultra-thin composite core and layered graded liquid absorption core, taking into account thinness, liquid absorption capacity, anti-rewet and anti-delamination, with Japan and South Korea's technology in the leading position in the world.

3. Extreme Segmentation: Targeted structural optimization according to gender, degree of incontinence and use scenarios, bidding farewell to "general-purpose models", with the highest segmentation in the European, American and Japanese markets in the world.

4. Health Attribute Enhancement: Antibacterial layer, deodorant layer and skin care layer (added with aloe vera, vitamin E) are generally added to reduce the risk of incontinence-associated dermatitis and bedsores, and the nursing attribute is continuously upgraded.

5. Environmental Protection: The structural application of degradable and recyclable materials has become the core development direction of the European and American markets.