Absorbent Structure Dual-Adhesive Intermixing for Wet Pad Integrity
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Solution Overview
Problem
Current absorbent cores in personal care articles face challenges in achieving high superabsorbent material content while maintaining effective liquid retention and leakage prevention.
Innovation Solution
A method of manufacturing absorbent structures involves directing superabsorbent particles toward a substrate with adhesive application on both sides, ensuring intermixing before deposition, and subsequent layering to achieve high superabsorbent particle distribution and adhesive content, enhancing Wet Pad Integrity values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the superabsorbent material content in absorbent cores is increased to improve liquid retention capacity, then the liquid retention performance is improved, but the structural integrity and leakage prevention capability deteriorate
Solution Approach 1:
The patent employs a composite adhesive system combining a water-soluble adhesive (first adhesive) and a water-insoluble adhesive (second adhesive). The water-soluble adhesive provides initial binding and allows for processing, while the water-insoluble adhesive maintains structural integrity during wet conditions. This composite approach enables high superabsorbent material content (50-95% by weight) to be incorporated while maintaining pad integrity and leakage prevention, as the dual-adhesive system compensates for the structural weakness that would otherwise result from such high particulate content.
Solution Approach 2:
The patent applies parameter changes by controlling the ratio and properties of the two adhesives, as well as adjusting processing parameters such as drying conditions and adhesive application amounts. Specifically, the water-soluble adhesive is selected to have solubility between 10-50 g/100 mL water, and the water-insoluble adhesive is applied at specific ratios (0.1-10 parts by weight relative to 100 parts water-soluble adhesive). These parameter adjustments optimize the balance between maintaining structural integrity with high superabsorbent content and ensuring proper adhesion and leakage prevention.
2Quantity of substance
If the superabsorbent material content is increased to enhance absorbency, then the liquid absorption capacity is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-mixing the two adhesives in specific ratios before application to the superabsorbent material stream. The adhesives are combined and adjusted to optimal concentrations in advance, then applied uniformly to the particle stream. This preliminary preparation simplifies the manufacturing process compared to applying multiple adhesive layers separately, as the dual-adhesive system is established in a single mixing and application step, reducing equipment complexity while enabling high superabsorbent material content (500-1000 gsm).
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 method produces absorbent structures with improved Wet Pad Integrity values, ensuring effective liquid retention and reduced leakage, even with high superabsorbent material content.
Implementation Method 1
spraying, with a first adhesive applicator having a first adhesive nozzle, the first side of the first stream of superabsorbent particles with a first adhesive, the first adhesive contacting the first stream of superabsorbent particles and intermixing with the superabsorbent particles of the first stream of superabsorbent particles prior to said superabsorbent particles depositing onto the first substrate material layer
Data Source
AI summary
Absorbent structures and methods of manufacture are disclosed. In one embodiment, a method of manufacturing an absorbent structure may comprise directing a stream of particles toward a material layer, spraying the stream with a first adhesive, the first adhesive contacting the stream at a first contact point, spraying the stream with a second adhesive, the second adhesive contacting the stream at a second contact point, depositing the particles, first adhesive, and second adhesive onto the material layer, and separating the mixture of the particles, adhesive, and the material layer into individual absorbent structures, each absorbent structure produced having particles disposed in an amount equal to 500 gsm and adhesive disposed in an amount equal to 7% by weight, of the weight of the superabsorbent particles, and having Wet Pad Integrity values greater than or equal to 20, according to the Wet Pad Integrity Test Method.