Absorbent Body Duct Partitioning for Uniform Polymer Dispersion
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Solution Overview
Problem
The uniform dispersion of superabsorbent polymer in absorbent bodies is impaired due to outside air intrusion into the duct, causing turbulence and non-uniform distribution during the manufacturing process of absorbent articles like disposable diapers.
Innovation Solution
An apparatus with a duct-inner-wall section is used to restrict outside air from entering the duct, maintaining a lower air pressure inside and preventing turbulence by dividing the gas flow path into end-side and center-side paths, ensuring stable gas flow and uniform distribution of superabsorbent polymer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If gas is sucked through air intake holes in the form die to form the absorbent body, then the absorbent body can be formed by stacking fluid absorbent fibers and superabsorbent polymer, but outside air intrudes into the duct causing turbulence and non-uniform distribution of superabsorbent polymer
Solution Approach 1:
A partition wall is introduced as an intermediary structure inside the duct to separate the gas flow path into a center-side flow path and an end-side flow path. This partition wall acts as a mediator that prevents outside air from mixing with the center gas flow, thereby eliminating turbulence while maintaining the suction-forming function. The partition wall allows the harmful outside air to be directed away from the critical center area where superabsorbent polymer is casted.
Solution Approach 2:
The duct's gas flow path is segmented into distinct regions by the partition wall - a center-side flow path for the main gas flow carrying superabsorbent polymer, and an end-side flow path for outside air intrusion. This segmentation isolates the harmful turbulent flow from the critical formation area, allowing uniform distribution of superabsorbent polymer while accommodating the inevitable outside air entry.
2Ease of manufacture
If the duct operates with negative pressure to enable gas suction through the form die, then absorbent body formation is enabled, but outside air enters through gaps in the rotating drum and duct interface
Solution Approach 1:
Instead of attempting to completely seal against outside air intrusion (which would complicate the rotating drum-duct interface), the invention accepts the negative pressure condition and outside air entry as inherent to the suction-forming process. The partition wall converts the harmful effect of outside air intrusion into a controlled separate flow path, directing it away from the critical center area. This approach maintains the beneficial negative pressure suction-forming capability while neutralizing the harmful turbulence effect.
3Manufacturing precision
If superabsorbent polymer is casted toward the center area of the distribution opening, then uniform dispersion is desired, but turbulence from outside air prevents uniform distribution
Solution Approach 1:
The partition wall serves as a protective intermediary that shields the center-side flow path (where superabsorbent polymer is casted) from the destabilizing influence of outside air intrusion. By physically separating the two flow paths, the partition wall ensures that the gas flow stability in the center area is maintained, allowing uniform dispersion of superabsorbent polymer to occur without turbulence interference.
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 solution effectively reduces the impact of outside air on the uniform dispersion of superabsorbent polymer, achieving stable gas flow and uniform stack distribution of fluid absorbent fibers, resulting in improved absorbent body formation with a three-layer structure.
Implementation Method 1
a duct (31) disposed in a predetermined position in the moving path, discharging a gas (3) including fluid absorbent fibers (2) from an opening section (31a) toward the predetermined face
Implementation Method 2
by the gas (3) being sucked through air intake holes in a bottom section of the form die
Data Source
AI summary
An apparatus for manufacturing an absorbent body, including a recessed form die formed on a predetermined face of a predetermined member, moving in one direction along a moving path along the predetermined face; a duct disposed in a predetermined position in the moving path, discharging a gas including fluid absorbent fibers from an opening section toward the predetermined face; and a polymer casting member disposed inside the duct, casting a superabsorbent polymer from a casting opening toward a center area of the opening section in a direction along the moving path, wherein in the case of the form die passing the duct position, by the gas being sucked through air intake holes in a bottom section of the form die, the fluid absorbent fibers and the superabsorbent polymer in the gas are stacked in the form die to form an absorbent body, wherein an air pressure inside the duct is made lower than the air pressure outside the duct because of the gas being sucked through the bottom section of the form die, wherein a duct-inner-wall section is inside the duct and is disposed facing an inner wall face of a wall section of the duct with a spacing therebetween, the wall section having a gap between the predetermined face and the opening section of the duct, and an outside air intrudes into the duct along the moving path through the gap, and the duct-inner-wall section restricts the outside air intruding into the duct through the gap flowing into the center area of the duct.