Low-Basis-Weight Absorbent Laminate with High Void Volume
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Solution Overview
Problem
Existing absorbent structures, such as disposable paper towels and wipes, face challenges in achieving high absorbency while maintaining low basis weight, which is essential for cost-effectiveness and environmental sustainability.
Innovation Solution
A laminate of at least two plies with specific structural features, including a Valley Volume greater than 11 microns and a Pit Density of greater than 25 pockets per square centimeter, is produced using a wet laid structured tissue process, incorporating cellulosic-based and synthetic fibers, and adhered with a water-soluble adhesive, enhancing absorbency without increasing basis weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional water-laid or air-laid technologies are used to produce absorbent structures, then manufacturing ease and production speed are improved, but absorbency is reduced due to web compaction during pressing
Solution Approach 1:
The patent creates a porous, non-compacted web structure by eliminating the traditional pressing step in the water-laid process. The web is formed on a moving belt and dried without mechanical compression, maintaining high porosity and void volume that enable superior absorbency while allowing continuous high-speed production.
Solution Approach 2:
The patent changes the drying parameters by using a moving belt system with controlled drying conditions instead of traditional pressing. The web is dried while moving, allowing moisture removal without mechanical compression, thus maintaining web thickness and absorbency while achieving high production rates.
2Quantity of substance
If more material is used to increase absorbency, then absorbency is improved, but basis weight increases leading to higher costs and reduced environmental sustainability
Solution Approach 1:
The patent uses a porous, non-compacted web structure that maximizes void volume and surface area available for liquid absorption. This allows the web to absorb more liquid relative to its weight, achieving high absorbency without increasing basis weight, thus reducing material consumption and improving environmental sustainability.
Solution Approach 2:
The patent changes the physical state and structure of the web by preventing compaction during manufacturing. The resulting high-bulk, low-density structure provides greater absorbency per unit weight, allowing reduction of basis weight while maintaining or improving absorbency performance.
3Use of energy by stationary object
If web pressing is applied to remove moisture efficiently, then energy consumption is reduced, but web thickness and absorbency are lowered
Solution Approach 1:
The patent maintains a porous, non-compacted web structure throughout the drying process by eliminating pressing. The porous structure allows efficient moisture vapor removal through the web, enabling effective drying without mechanical compression, thus preserving web thickness and absorbency while managing energy consumption.
Solution Approach 2:
The patent changes the moisture removal mechanism from mechanical pressing to evaporative drying in a moving belt system. This allows moisture removal without compression, maintaining web thickness and absorbency while achieving efficient energy use through continuous drying during belt movement.
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 achieves high absorbency of greater than 16 grams of water per gram of fiber at a basis weight of less than 43 grams per square meter, effectively conserving natural resources and reducing production costs while maintaining product performance.
Implementation Method 1
adhered with a water-soluble adhesive
Implementation Method 2
high absorbency of greater than 16 grams of water per gram of fiber
Data Source
AI summary
Absorbent product including a laminate of at least two plies, wherein the absorbent product has a measured Valley Volume parameter greater than 11 microns and a Pit Density of greater than 25 pockets per sq. cm.