Absorbent Body Manufacturing via Recessed Surface Mixing
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Solution Overview
Problem
Existing methods for manufacturing absorbent bodies for testing are not suitable due to their large scale and inability to easily modify the composition of absorbent fibers and water-absorbent resin, making them inappropriate for evaluating the properties of absorbent bodies.
Innovation Solution
A method for manufacturing absorbent bodies that involves dispersively disposing water-absorbent resin with absorbent fibers, allowing for varying blending ratios and introduction at different times, with configurations such as recesses and protrusions on surfaces to facilitate mixing and falling, enabling the production of absorbent bodies of specific sizes and properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large-scale apparatus is used to manufacture absorbent bodies, then the absorption capacity and gel strength are improved, but the device complexity and material consumption increase
Solution Approach 1:
The patent divides the manufacturing process into distinct stages: introducing absorbent fibers into a cavity, then separately introducing water-absorbent resin particles. This segmentation allows for controlled mixing in a confined space rather than requiring a large-scale continuous production apparatus, thereby reducing device complexity while maintaining product quality.
Solution Approach 2:
The water-absorbent resin particles are introduced into the cavity that already contains the absorbent fibers, creating a nested structure where one material is placed within the space occupied by another. This nesting approach enables efficient use of space and controlled blending without requiring additional large-scale equipment.
2Reliability
If a large-scale apparatus is used to manufacture absorbent bodies, then the gel strength is improved, but the loss of substance increases
Solution Approach 1:
The patent introduces the water-absorbent resin particles in a controlled manner into the cavity containing absorbent fibers, using only the necessary amount of each material for the test piece. This partial action approach avoids the excessive material consumption that would occur in large-scale continuous production, while still achieving sufficient gel strength for evaluation purposes.
3Manufacturing precision
If a fixed composition apparatus is used, then the manufacturing precision is improved, but the adaptability decreases
Solution Approach 1:
The patent employs a dynamic approach where the composition of absorbent fibers and water-absorbent resin can be adjusted by changing the amounts introduced into the cavity. This dynamic compositional adjustment allows the same apparatus to produce absorbent bodies with different blending ratios suitable for various evaluation purposes, thereby maintaining manufacturing precision while enhancing adaptability.
4Productivity
If absorbent bodies are manufactured for actual product production, then the productivity is improved, but the ease of operation decreases
Solution Approach 1:
The patent extracts the essential mixing function from large-scale continuous production and implements it in a simplified, discrete cavity-based system. By taking out only the necessary mixing and blending operations and performing them in a controlled cavity environment, the apparatus achieves ease of operation for composition adjustment while still producing sufficient quantity for evaluation, without the complexity of full-scale production equipment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method allows for the easy modification of absorbent fiber and water-absorbent resin composition, enabling the production of absorbent bodies suitable for testing, with uniform distribution and evaluation of properties like absorption capacity and permeation time.
Implementation Method 1
the water-absorbent resin is dispersively disposed in contact with the aggregate of the absorbent fibers
Implementation Method 2
the aggregate of the absorbent fibers and the water-absorbent resin are moved along the gap
Implementation Method 3
the absorbent fibers and the water-absorbent resin that were mixed can be caused to fall
Data Source
Figure 1
Figure 2
Figure 3(a)~3(b)
AI summary
A method for manufacturing an absorbent body according to the present invention includes a first step of successively introducing an aggregate of absorbent fibers and a water-absorbent resin into a gap that is formed between a first surface and a second surface and is smaller than a thickness of the aggregate of the absorbent fibers, recesses and protrusions being formed on at least one of the first surface and the second surface, a second step of applying a shearing force to the aggregate of the absorbent fibers by moving the first surface relative to and parallel to the second surface in order to mix the absorbent fibers and the water-absorbent resin, and a third step of causing the absorbent fibers and the water-absorbent resin that were mixed to fall, and stacking the absorbent fibers and the water-absorbent resin by suctioning the absorbent fibers and the water-absorbent resin into a recessed portion having a predetermined shape.