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Channel cores are an innovative approach to disposable diaper designs that arose out of the pursuit of improved core performance and the preference for thinner cores. Although mostly seen in baby care products, it is beginning to cross over into adult incontinence articles for personal use. Compared to a more traditional core, the channel core has longitudinal zones (channels) that are free of any absorbent material. These channels are formed by laminating the upper and lower core wrap materials together with adhesive, which can be done through the use of a modified drum with elevated ridges. Typically, the channels are limited to the crotch area, where the absorbent materials are contained in tubular zones formed by these channels.

Benefits attributed to the channel core can include: 

  • Better core integrity and reduced risk of core cracking 
  • Better fluid circulation, for better core utilisation
  • Better air circulation, for improved dryness and skin wellness  
  • Less bulking and sagging

Most diaper manufacturers have designed their channel cores to remain intact after insult. To achieve this, a designated channel core adhesive is recommended to create this unique core design. As the superabsorbent polymer (SAP), and in some designs a mix of SAP and fluff, within the tubes absorbs liquid, it expands, and puts extra pressure on the adhesive. To remain sealed, the channel adhesive must have a higher static peel.

A number of manufacturers have added channel core diapers to their product lines. However, there are variations in design. The channels may be straight or curved. There may be two, three, or even four channels.

If you are considering introducing channel cores into your product line, we recommend involving core adhesive experts like Bostik in the early stages of new core development. We can choose the right nonwoven adhesive solutions to meet your design and performance needs. 

Discover More about Absorbent Core Trends

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