Absorbent Composite with Adhered Resin Particles Preventing Gel Blocking
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Solution Overview
Problem
Current sanitary materials face challenges with gel blocking, uneven distribution, and reduced absorption performance due to high water-absorbent resin concentrations, leading to leakage and decreased comfort, while also environmental concerns arise from the use of pulp and other resources.
Innovation Solution
A thin, lightweight absorbent composite is developed with a base material and water-absorbent resin particles, where 50% or more of the resin particles adhere directly to the base material, maintaining their position and ensuring high absorption capacity and dispersibility, using a specific manufacturing method involving a rotating drum with dimples for adherence and controlled moisture supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the amount of water-absorbent resin is increased to reduce material usage and improve absorption capacity, then the absorption capacity improves, but gel blocking occurs which reduces absorption speed and dispersibility
Solution Approach 1:
The water-absorbent resin is divided into multiple small particles rather than using large chunks, increasing the surface area to volume ratio and preventing gel blocking while maintaining high absorption capacity
Solution Approach 2:
The resin particles are strategically positioned within the absorber structure, with higher concentration in regions where liquid contact is expected, optimizing both absorption capacity and preventing gel blocking in critical areas
2Weight of stationary object
If the proportion of hydrophilic fiber is reduced to make the absorber thinner and lighter, then the thickness and weight decrease, but the water-absorbent resin particles become unevenly distributed and move during use
Solution Approach 1:
The water-absorbent resin particles are pre-fixed to the base material before final assembly, ensuring they remain in predetermined positions and preventing uneven distribution or movement during use
Solution Approach 2:
A bonding agent or adhesive is introduced as an intermediary substance to securely attach the water-absorbent resin particles to the base material, maintaining positional stability while allowing the absorber to remain thin and lightweight
3Reliability
If pulp is used as the fiber material to maintain cleanliness and absorbent properties, then the absorption performance is maintained, but the burden on forest resources increases
Solution Approach 1:
The material composition is changed from natural pulp to synthetic or regenerated fibers, altering the material parameters while maintaining the necessary hydrophilic properties and absorption performance
Solution Approach 2:
A composite structure is created combining synthetic base material with water-absorbent resin particles, replacing traditional pulp-based materials while achieving similar or superior absorption performance with reduced environmental impact
4Length of stationary object
If the absorber is made thinner to improve comfort and reduce garbage disposal burden, then the comfort and disposability improve, but the absorption capacity and liquid holding capability decrease
Solution Approach 1:
The absorber structure incorporates porous materials with high surface area to volume ratio, enabling thin construction while maintaining high absorption capacity through increased internal surface area for liquid uptake
Solution Approach 2:
A composite structure combining base material with high-concentration water-absorbent resin particles creates a thin yet highly capable absorber, achieving both reduced thickness and maintained absorption capacity
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
The absorbent composite achieves high liquid dispersibility and holding capability, reducing material usage, conserving resources, and preventing gel blocking, resulting in unprecedented thin and lightweight sanitary products with improved absorption speed and stability.
Implementation Method 1
making the base material and/or the water-absorbent resin absorb water
Implementation Method 2
removing water from and drying the base material and the water-absorbent resin
Data Source
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AI summary
An absorbent composite comprising: a base material and water-absorbent resin particles; wherein the following conditions (1) to (4) are fulfilled: (1) the weight ratio of water-absorbent resin relative to the total weight of the base material and water-absorbent resin is 65 to 99 wt%, (2) the water-absorbent resin particles adhering directly to the base material constitute 50 wt% or more of the total water-absorbent resin particles; (3) the average absorption capacity of the water-absorbent resin particles is 50 g/g or more; and (4) the amount of residual monomers in the water-absorbent resin is 200 ppm or less.