Design and development of a gusset for a leakproof menstrual underwear with enhanced absorption

Abstract

Reusable menstrual underwear is an undergarment designed to absorb and retain blood during the menstrual cycle. It is generally made with multiple layers of wicking and absorbing fabrics, including an additional barrier layer for leak-proofing [1]. An ideal menstrual underwear should possess adequate absorbency, mobility, leakage prevention, and environmental sustainability [2]. However, current commercially available products have the major limitations of limited absorbency despite their high bulkiness [3], insufficient gusset coverage, and limited durability [4]. The primary function of the skin-contact or wicking layer is to promptly wick the fluids into the subsequent absorbent layers [5]. Additionally, consumer reviews highlighted the need to minimize the spread of fluid and prevent rewetting of the skin contact surface [6]. The absorbent layer's role is to retain the menstrual fluid within the gusset, while the barrier layer prevents fluid leakage [7]. Despite existing research on menstrual underwear, a limited number of them focus on the design and development aspect [3]. Most studies and patents lack specific technical details of each layer but follow the common three-layer gusset layout consisting of wicking, absorbent, and barrier layers. The wicking layer’s requirements for one-way fluid transfer and maximum fluid spread in its outer surface can be achieved with fabrics that have less hydrophilic yarns, lower yarn counts, and higher filament counts on the skin-contact surface compared to the outer surface [8]. Weft-knitted spacer fabrics can satisfy this requirement, and they also possess the advantages of low bulk density, layered structure capability, good absorbent capacity, and design flexibility [9]. However, the use of spacer fabrics for enhanced wicking and absorbency in menstrual underwear has not been explored in published literature. Electrospun nanofibrous mats have the potential to significantly improve absorbency levels while using sustainable and non-toxic raw materials such as Sodium alginate and Chitosan [10]. Thus, it could further enhance the absorbency of the gusset. This study aims to address the major limitations of existing reusable menstrual underwear by designing and developing an effective gusset with enhanced absorbency, wicking, coverage, and leak-proofing. It also seeks to address the scarcity of published literature on reusable menstrual underwear design and development, focusing on Sodium alginate-based electrospun mats and spacer fabrics to enhance absorbency and wicking.