Disposable absorbent surface protection mat
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Solution Overview
Problem
Existing absorbent surface protection mats face challenges in achieving good liquid transport and retention while maintaining air permeability and stability, often resulting in an unfavorable microclimate due to the use of film barrier layers that can lead to clamminess and limited exchange with the ambient climate.
Innovation Solution
A disposable absorbent surface protection mat made of non-woven material without a film barrier layer, featuring a base layer of staple fibers including absorbent cellulosic and hydrophilic synthetic fibers, and fusible bonding fibers, with a partial coating on the underside to enhance liquid absorption and air permeability, providing improved liquid retention and air exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a film barrier layer is provided on the absorbent mat, then liquid retention is improved, but air permeability deteriorates and an unfavorable microclimate is created
Solution Approach 1:
The patent removes the film barrier layer from the absorbent mat structure. The invention describes an absorbent mat consisting of an absorbent base layer and a fleece cover layer, explicitly without a film barrier layer. This extraction eliminates the harmful effect of the film on air permeability and microclimate while maintaining liquid retention through the absorbent properties of the base layer and fleece layer combination.
Solution Approach 2:
The patent uses a composite structure combining an absorbent base layer (made of absorbent fibers) and a fleece cover layer (made of staple fibers). This composite material approach provides liquid retention through the absorbent base layer while the fleece cover layer maintains air permeability and prevents the formation of an unfavorable microclimate, achieving both functions without a film barrier.
2Reliability
If a film barrier layer is used, then liquid transport is improved, but material costs and device complexity increase
Solution Approach 1:
The patent eliminates the film barrier layer from the mat structure, reducing device complexity from a multi-layer construction (base layer + fleece layer + film barrier) to a simpler two-layer construction (base layer + fleece layer). Liquid transport is maintained through the intrinsic properties of the absorbent base layer and the capillary action within the fleece layer fibers.
Solution Approach 2:
The patent employs a disposable absorbent mat made from relatively inexpensive natural and synthetic fibers. By eliminating the film barrier layer and using a simple two-layer construction of absorbent and fleece layers, the overall material cost is reduced while maintaining adequate liquid transport performance for single-use applications.
3Reliability
If staple fibers with fusible bonding fibers are used, then liquid absorption is improved, but structural stability may deteriorate
Solution Approach 1:
The patent utilizes fusible bonding fibers that melt at elevated temperatures to bond the staple fibers together. The fusible fibers undergo a phase transition from solid to molten state during heat treatment, forming bonding points that stabilize the fleece layer structure while maintaining the liquid absorption capabilities of the staple fibers.
Solution Approach 2:
The fleece cover layer is constructed as a composite material containing both staple fibers (for liquid absorption) and fusible bonding fibers (for structural stability). This composite approach allows the two components to perform their respective functions: the staple fibers absorb liquid while the fusible bonding fibers provide structural integrity when melted and bonded.
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 allows for effective liquid absorption and retention, maintains air permeability, and creates a positive microclimate by allowing air exchange, while also providing slip resistance and cost savings by eliminating the need for a full film barrier layer.
Implementation Method 1
a fiber material made of staple fibers that includes fusible bonding fibers enables a partial connection of the staple fibers so that cavities, i.e. gaps, are formed and thus a certain channel structure and compartmentalization structure is achieved within the fiber material. In this way, the transfer of liquid from the outside of the fleece material, and thus also from the surface to be covered, into the surface protection mat can be improved.
Implementation Method 2
Absorbent cellulosic fibers and/or hydrophilic synthetic fibers... the liquid attraction and binding properties of the nonwoven material can be adjusted
Implementation Method 3
the staple fibers a.) absorbent cellulosic fibers and/or hydrophilic synthetic fibers and b.) melt-binding fibers, in particular bi- or multi-component fibers
Implementation Method 4
a fiber material made of staple fibers that includes fusible bonding fibers enables a partial connection of the staple fibers
Implementation Method 5
the execution of the partial, area-wise, not full-area coating on the underside of the non-woven material can give the non-woven material slip resistance
Implementation Method 6
with the height of the coating being at least 0.1 mm, a spacer can be created between the liquid-absorbing non-woven material and the surface to be covered
Implementation Method 7
In combination with absorbent cellulosic fibers and/or hydrophilic synthetic fibers, the liquid attraction and binding properties of the nonwoven material can be adjusted. Overall, this advantageously contributes to a dry appearance of the surfaces of the surface protection mat.
Data Source
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AI summary
The present invention relates to a disposable absorbent surface protection mat (100) made of a nonwoven material (102) with a bottom (104) and a top (106), wherein the nonwoven material (102) comprises an absorbent base layer (108) and the base layer (108). Fibrous material made of staple fibers, the staple fibers a.) comprising absorbent cellulosic fibers (150) and/or hydrophilic synthetic fibers (152) and b.) melt-binding fibers (154), in particular bi- or multi-component fibers, and the underside (104) of the fleece material (102) is provided with a region-wise, not full-area coating (112) and the coating (112) has a height (113) of at least 0.1 mm.