Absorbent Composites for Low Runoff and Rapid Fluid Intake
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Solution Overview
Problem
Current absorbent materials for surgical drapes and healthcare applications suffer from high runoff, slow absorption rates, and low absorption capacity, which can lead to fluid leakage and skin breakdown issues during surgical procedures and patient care.
Innovation Solution
A composite absorbent material comprising a nonwoven top layer with hydrophilic fibers and a through-air-bonded absorbent core layer, including continuous and staple multicomponent fibers, which is designed to provide rapid absorption, low runoff, and high absorbency, optionally sandwiched between the top layer and a film for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If cellulosic fibers (rayon, lyocell) in spunlaced or chemical bonded web are used, then absorption capacity is improved, but absorption time increases and run off increases
Solution Approach 1:
The absorbent material is divided into multiple layers with distinct functions: a top layer for rapid fluid intake and distribution, a middle absorbent layer for bulk absorption, and a bottom layer for containment. This segmentation allows each layer to be optimized for its specific function, achieving both fast absorption and high capacity.
Solution Approach 2:
The invention uses composite structures combining different fiber types and bonding methods. The top layer uses hydrophilic fibers (rayon, lyocell, cotton) for rapid wicking, while the bottom layer uses疏水性合成纤维 for containment. This composite approach reconciles the need for fast absorption with high capacity and low run off.
2Quantity of substance
If cellulosic fibers (rayon, lyocell) in spunlaced or chemical bonded web are used, then absorption capacity is improved, but run off increases
Solution Approach 1:
The absorbent material is divided into multiple layers with distinct functions: a top layer for rapid fluid intake and distribution, a middle absorbent layer for bulk absorption, and a bottom layer for containment. This segmentation allows each layer to be optimized for its specific function, achieving both fast absorption and high capacity.
Solution Approach 2:
The invention uses composite structures combining different fiber types and bonding methods. The top layer uses hydrophilic fibers (rayon, lyocell, cotton) for rapid wicking, while the bottom layer uses疏水性合成纤维 for containment. This composite approach reconciles the need for fast absorption with high capacity and low run off.
3Quantity of substance
If wood pulp is used to provide absorption, then absorption capacity is improved, but lint formation occurs
Solution Approach 1:
The invention changes the physical and chemical parameters of the absorbent materials by using chemically treated cellulose fibers and bonded synthetic fibers instead of raw wood pulp. This maintains high absorption capacity while eliminating lint formation through proper fiber selection and bonding processes.
4Object-generated harmful factors
If three-layer composite with spunbond cover, hydrophilic meltblown core, and backing film is used, then run off is reduced, but absorption capacity decreases
Solution Approach 1:
The invention changes the physical and chemical parameters of the absorbent materials by using chemically treated cellulose fibers and bonded synthetic fibers instead of raw wood pulp. This maintains high absorption capacity while eliminating lint formation through proper fiber selection and bonding processes.
5Quantity of substance
If hydrophilic spunbond laminated to film is used, then absorption capacity is improved, but run off increases and absorption rate decreases
Solution Approach 1:
The absorbent material is divided into multiple layers with distinct functions: a top layer for rapid fluid intake and distribution, a middle absorbent layer for bulk absorption, and a bottom layer for containment. This segmentation allows each layer to be optimized for its specific function, achieving both fast absorption and high capacity.
Solution Approach 2:
The invention uses composite structures combining different fiber types and bonding methods. The top layer uses hydrophilic fibers (rayon, lyocell, cotton) for rapid wicking, while the bottom layer uses疏水性合成纤维 for containment. This composite approach reconciles the need for fast absorption with high capacity and low run off.
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 composite material achieves a composite-run-off value of less than 50%, a composite-absorption capacity of at least 600%, and a rate of absorption of less than 10 seconds for a 5 ml liquid sample, effectively preventing fluid leakage and promoting skin health by reducing the risk of skin breakdown.
Implementation Method 1
The nonwoven top layer comprises a plurality of hydrophilic fibers... The nonwoven top layer comprises a generally open structure to allow relatively fast penetration by liquids
Implementation Method 2
the absorbent core layer comprises a through-air-bonded nonwoven, such as a high loft nonwoven including continuous and/or staple multicomponent fibers
Implementation Method 3
the fibers may be rendered hydrophilic via topical application of a hydrophilic additive and/or via addition of a hydrophilic additive to the polymer melt used to form at least some (or all) of the fibers
Data Source
Figure 1~2
Figure 3
AI summary
Absorbent composites are provided that include a nonwoven top layer having hydrophilic fibers and an absorbent core layer directly or indirectly attached to the nonwoven top layer, wherein the absorbent core layer comprises a through-air-bonded nonwoven. The absorbent composites may include a combination of (i) a composite-run-off value of less than 50% as determined by ISO 9073-11, (ii) a composite-absorption capacity of at least 600% as determined by ISO 9073, and (iii) a composite-rate of absorption of less than 10 seconds for a 5 ml liquid sample as determined by D824-94. The absorbent composites may include an optional film layer attached to the absorbent core layer.