Absorbent Core Manufacturing via Suction and Embossing
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Solution Overview
Problem
Current methods for producing absorbent materials for hygiene pads either result in uneven distribution of wood pulp fibers and super absorbent polymers, leading to inconsistent liquid absorption and high production costs due to the need for separate manufacturing lines and pre-made absorbent paper, which increases waste and reduces quality.
Innovation Solution
A method and device that integrates the production of absorbent cores directly on the hygiene pad manufacturing line, ensuring even distribution of wood pulp fibers and super absorbent polymers through improved suction and distributing mechanisms, followed by compression and embossing to create a three-dimensional net-structured space that locks the polymers in place, allowing for consistent liquid absorption and increased polymer content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If absorbent paper is made using current technology, then the super absorbent polymers are evenly distributed and fixed tightly, but the production speed is low (50-70 meters/min)
Solution Approach 1:
The patent combines the manufacturing of absorbent material with the hygiene pad production line into a single integrated system. The absorbent material is produced in situ on the manufacturing line, eliminating the need for separate pre-making processes and enabling continuous production at speeds of 120-180 meters/min while maintaining uniform distribution of super absorbent polymers through controlled dispensing mechanisms.
Solution Approach 2:
The patent applies preliminary action by pre-distributing super absorbent polymers onto the base tissue before final assembly. The polymers are dispensed and positioned in advance on the moving web, allowing them to be evenly distributed and partially secured before the tissue is folded and sealed, ensuring uniform distribution even at high production speeds.
2Productivity
If absorbent material is made on the same manufacturing line, then the production speed is high (120-180 meters/min), but the wood pulp fibers and super absorbent polymers are not evenly distributed
Solution Approach 1:
The patent applies local quality by using targeted dispensing mechanisms that deliver super absorbent polymers to specific locations on the base tissue. The system controls the placement and distribution of polymers locally across the web, ensuring even distribution in high-speed production. The folding and sealing processes also apply local quality by securing polymers in specific zones to prevent migration.
Solution Approach 2:
The patent uses preliminary action by distributing super absorbent polymers onto the base tissue before the folding and sealing operations. This advance placement ensures that polymers are evenly distributed across the surface before the tissue is manipulated, preventing clumping and ensuring uniform distribution even at high production speeds of 120-180 meters/min.
3Quantity of substance
If a larger amount of super absorbent polymers is used, then the liquid-absorbing capability is improved, but the polymers move around and pile together inside the pad
Solution Approach 1:
The patent applies local quality by using folding and sealing mechanisms that secure super absorbent polymers in specific locations within the pad structure. The edges of the base tissue are folded over the polymer layer and sealed, creating localized containment zones that prevent polymer migration even when large amounts of polymers are used. This ensures both high polymer content and position stability.
Solution Approach 2:
The patent uses preliminary action by distributing and partially securing super absorbent polymers onto the base tissue before final assembly. The polymers are placed and preliminarily fixed in position before the tissue is folded and sealed, preventing them from moving around during subsequent handling and use. This preliminary positioning maintains stability even with increased polymer quantities.
4Manufacturing precision
If pre-made absorbent paper is used, then the quality is consistent, but additional packaging, storage and transportation are required which increases cost
Solution Approach 1:
The patent combines the manufacturing of absorbent material with the hygiene pad production line into a single integrated system. The absorbent material is produced in situ on the manufacturing line, eliminating the need for separate pre-making, packaging, storage, and transportation processes. This integration maintains quality consistency through controlled manufacturing while removing the complexity and costs associated with external supply chain operations.
Solution Approach 2:
The patent applies self-service by enabling the hygiene pad production line to produce its own absorbent material on-demand. The system includes integrated dispensing, distribution, and assembly mechanisms that allow the line to manufacture absorbent material with consistent quality without external intervention. This self-sufficiency eliminates packaging, storage, and transportation requirements while maintaining manufacturing precision.
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 approach enhances the liquid-absorbing capability of hygiene pads, reduces production costs by 12%-15%, and improves product quality by ensuring consistent absorption and increased tear strength while maintaining a soft and comfortable surface.
Implementation Method 1
a suction bed (1) having negative pressure on its surface; rolls of wood pulp (3) are shredded into wood pulp fibers by a wood pulp shredder (5), and the wood pulp fibers fall with the airflow in the wood pulp fiber container (4) and are sucked tightly on top of the base tissue (2) by the negative pressure on the surface of the suction bed (1)
Implementation Method 2
a bottom compressing roll (11.2) and a top compressing roll (11.1) compress on the edge-folded first compressed absorbent core for another time. Both the top compressing roll (11.1) and the bottom compressing roll (11.2) may have a smooth surface, and both may be used to reduce the required pressure from a top embossing roll (12.1) and a bottom embossing roll (12.2) and to preliminarily prevent the super absorbent polymers from moving inside the absorbent core
Data Source
AI summary
The invention relates to a method and a device for making absorbent cores used in disposable hygiene pads, the method or device comprising three steps: (A) suctioning of wood pulp fibers mixed with super absorbent polymers into a net structure on a base tissue to form an absorbent core; (B) compressing and embossing absorbent material; and (C) shaping of the absorbent core. The method of the current invention can be used for making different kinds of absorbent pad products. While increasing the tear strength of the product, the method realizes and simplifies the process of making both the absorbent material and the hygiene pad utilizing the absorbent material on the same manufacturing line, and reduces the cost of making the absorbent pads. The absorbent core made by applying the method of the current invention has a new structure formed by super absorbent polymers and wood pulp fibers, wherein the structure enables the super absorbent polymers to be evenly distributed in between the wood pulp fibers. Through the compressing and embossing process, the super absorbent polymers are prevented from sliding or piling together in the absorbent core, which increases the liquid-absorbing capacity of the hygiene pad products.