Absorbent Core 3D Mesh Network for High SAP Content
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Solution Overview
Problem
Current absorbent cores with high superabsorbent material content face challenges in achieving optimal liquid uptake, retention, and leakage prevention while maintaining a dry feel for the wearer, as they often require a balance between absorbency and flexibility.
Innovation Solution
The absorbent structure comprises a lofty nonwoven reinforcing material with superabsorbent particles intermixed with adhesive filaments, forming a three-dimensional mesh network that immobilizes the superabsorbent particles, allowing for high superabsorbent content (≥90% by weight) with minimal adhesive content (<4.5% by weight), enhancing absorbency and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If absorbent cores contain mostly superabsorbent material with minimal other absorbent material, then the absorbent core can be made thinner and more flexible, but the liquid uptake and retention performance may be compromised
Solution Approach 1:
The patent combines superabsorbent particles with adhesive filaments to form a composite absorbent material. The adhesive filaments create a three-dimensional mesh network that immobilizes the superabsorbent particles, allowing the core to maintain high flexibility and thinness while achieving optimal liquid uptake and retention through the synergistic interaction between the two materials.
2Quantity of substance
If superabsorbent material content is increased to ≥90% by weight, then absorbency is enhanced, but the structural integrity and flexibility may deteriorate
Solution Approach 1:
Adhesive filaments serve as an intermediary material that binds superabsorbent particles together, providing structural integrity to the absorbent core. The filaments form a mesh network that holds the high-content superabsorbent particles in place, enabling the core to maintain both high absorbency (≥90% superabsorbent material) and adequate structural strength for flexibility and handling.
3Loss of substance
If adhesive content is minimized to <4.5% by weight, then material usage is reduced and cost is lowered, but the binding effectiveness may be insufficient
Solution Approach 1:
The patent changes the physical form and distribution parameters of the adhesive from traditional bulk application to thin filament formation. The adhesive filaments are distributed throughout the absorbent core in a three-dimensional mesh network, maximizing surface area and binding sites while minimizing total adhesive content to <4.5% by weight. This parameter change enables effective binding of superabsorbent particles with minimal adhesive material.
4Adaptability or versatility
If absorbent core is made thinner, then flexibility is improved, but leakage prevention capability may be reduced
Solution Approach 1:
The patent applies local quality by creating regions of high superabsorbent particle concentration within the thin absorbent core structure. The adhesive filaments form a mesh network that locally immobilizes clusters of superabsorbent particles, creating zones of enhanced absorbency and containment. This localized optimization allows the thin core to maintain flexibility while preventing leakage through strategically distributed absorbent zones.
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 configuration improves liquid intake, retention, and rewet performance, while maintaining thinness and flexibility, reducing overall material usage and minimizing superabsorbent penetration into the reinforcing material, thus preventing leakage and ensuring a dry feel for the wearer.
Implementation Method 1
adhesive filaments forming a three-dimensional mesh network comprising network adhesive filaments with the superabsorbent particles immobilized within the mesh network
Implementation Method 2
superabsorbent material may be able retain more liquid per particle than pulp fluff
Implementation Method 3
pulp fluff or other fibrous absorbent material may absorb liquid more quickly than superabsorbent material
Data Source
AI summary
Absorbent structures and methods of forming absorbent structures are disclosed. An absorbent structure may comprise a body side liner (28), an outer cover (26), and an absorbent structure. The absorbent structure may comprise a top material, a bottom material, a lofty nonwoven reinforcing material between the top material and the bottom material, and an absorbent layer of superabsorbent particles (318) and adhesive filaments (316) between the top material and the lofty nonwoven. The superabsorbent particles (318) may be present at greater than 90% by weight of absorbent material, and the adhesive filaments (316) may form a three-dimensional mesh network comprising network adhesive filaments (316) with the superabsorbent particles (318) immobilized within the mesh network, the network adhesive filaments (316) and superabsorbent particles (318) extending throughout a three-dimensional space defined by the network adhesive filaments (316) and the superabsorbent particles (318), with the network adhesive filaments (316) extending in random orientations throughout the three-dimensional space.