Hierarchical multilayer conformal diaper architecture for improved comfort through fluid routing and thermal regulation

Overview

This research program develops a hierarchical multilayer diaper architecture that combines fluid management with active thermal regulation to improve comfort in wearable absorbent products. The design works within conventional diaper layers—topsheet, acquisition-distribution layers (ADL), absorbent core, and backsheet—but adds engineered structures that move liquid away from the skin, suppress rewet, spread localized heat, and allow moisture vapor to escape. The intended result is a diaper that maintains absorbency and fit while reducing skin heat, humidity, and rewet, particularly during wet, warm, or clothed conditions.

The value proposition is relevant to manufacturers of baby diapers, adult incontinence products, and related absorbent hygiene goods seeking differentiation on comfort and skin health. Because the architecture is built on familiar converting processes and material classes, it is designed to be manufacturable and compatible with existing production lines.

Technical specifications

The proposed diaper system integrates five functional elements:

• A skin-compatible topsheet providing rapid liquid uptake, vapor transport, and low thermal resistance.
• Acquisition-distribution layers with directional capillary channels, capillary burst valves that suppress backflow, wicking networks, and conductive pathways for heat spreading.
• An absorbent core combining superabsorbent polymers (SAP) with encapsulated phase-change material (PCM) for fluid retention and latent-heat buffering.
• A breathable microporous backsheet with ventilation pathways to enhance vapor and heat rejection.
• A conformal layer architecture that preserves softness, fit, leakage control, and breathability.

Development is supported by multiphysics modeling to optimize layer thickness, capillary-channel geometry, burst-valve design, directional wicking, heat-spreading paths, PCM loading, and ventilation. Candidate materials will be screened for thermal properties, vapor transport, liquid uptake, rewet, flexibility, and converting compatibility. Prototype validation uses CTherm thermal-property measurements, infrared thermography, gravimetric absorption tests, differential scanning calorimetry, humidity and moisture sensors, and heated or sweating manikin tests under dry, wet, humid, and clothed conditions.

Technology readiness level

The concept is currently at the research and feasibility stage. The project plan defines four stages: material screening, multiphysics design optimization, prototype fabrication and testing, and performance validation against commercial diapers. The final stage includes repeatability, compression/storage, leakage, rewet, breathability, safety screening, manufacturability, and preliminary cost assessment. Successful completion is intended to establish a technology readiness level (TRL) 4 laboratory validation and produce a scale-up plan.