Diapers with next-to-skin moisture-adaptive embossment for improved comfort

[Display omitted] •Diapers with moisture-adaptive embossment reduce skin wet and cold discomfort.•Designed embossments increase height by 92% after absorbing urine.•Peak heat flux of designed diapers decreases up to 44% than control group.•New diapers improve the urine absorption speeds by 12.5% to 42.8%.•Moisture-adaptive embossment can be extended to other absorbent hygiene products. Diapers are essential living consumables to infants and elderly. Thermal and tactile comfort of diapers are critical to the well-being of those who use them daily. Prolonged contact with moisture and fecal matter has been identified as a primary factor contributing to diaper dermatitis. The embossing patterns on the diaper’s next-to-skin surface can reduce the contact area and decrease the risk of dermatitis. Current surface embossing designs of baby diapers have limitations in addressing issues related to prolonged usage, lack of support under body pressure, and insufficient reduction of skin contact with the surface layer. This paper reports on the development of a novel moisture-adaptive embossed surface layer through the embedment of a moisture absorbing hydrogel [viz. acrylic acid-co-sodium acrylate (AA-co-SA)] in the embossing structure. The incorporation of tailored AA-co-SA hydrogel dots within the diapers’ inner surface layer resulted in superior thermal and moisture comfort in comparison with existing commercial products. The designed embossments proved effective in reducing the contact area and maintaining an air gap between the skin and the diaper under heavy compression.