Absorbent Material Needlepunch Fiber Integration
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Solution Overview
Problem
Lofty, resilient non-woven webs used in disposable sanitary products have low absorbency and poor rewet properties due to their low density and loft, which leads to fluid release under external pressure.
Innovation Solution
A method involving a needlepunch process to impregnate absorbent fibers within a fibrous matrix, maintaining high loft while enhancing fluid handling capabilities by selecting fibers with specific diameters and using a needlepunch apparatus with tailored barb depth to integrate absorbent fibers without compromising the material's structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If lofty, resilient non-woven webs are used to provide comfort and conformability, then comfort and conformability are improved, but absorbency deteriorates due to low density
Solution Approach 1:
The patent combines two different fiber types with complementary properties: lofty, resilient fibers (e.g., polyester) that provide comfort and conformability, and highly absorbent fibers (e.g., rayon, cotton, or cellulosic fibers) that provide fluid absorption. This composite structure allows the material to simultaneously achieve comfort and high absorbency by leveraging the strengths of each fiber type.
Solution Approach 2:
The patent creates regions with different fiber compositions and densities within the non-woven web. Specifically, it incorporates a higher concentration of absorbent fibers in certain zones while maintaining lofty, resilient fibers in other areas. This local variation in quality allows different regions to perform different functions: comfort/conformability in some areas and fluid absorption in others.
2Ease of operation
If lofty, resilient non-woven webs are used to maintain high loft, then comfort is improved, but rewet properties deteriorate due to fluid release under pressure
Solution Approach 1:
The composite structure combines resilient fibers that maintain loft and comfort with absorbent fibers that have superior rewet resistance. The absorbent fibers (particularly cellulosic types) capture and hold fluid more effectively, preventing rewetting even when the material is compressed, thus improving reliability while maintaining comfort.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the fiber composition, including fiber diameter, length, and material type. By selecting specific fiber parameters (e.g., using shorter, finer absorbent fibers mixed with longer resilient fibers), the material achieves both comfort and improved rewet properties through optimized fiber characteristics.
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 results in an absorbent material that retains high loft properties while significantly improving fluid handling capabilities, ensuring superior absorbency and reduced fluid release, making it suitable for use in sanitary products.
Implementation Method 1
impregnated within the fiber matrix by means of a needlepunch process
Data Source
Figure 1
Figure 2
Figure 3~3a
AI summary
An absorbent material including a fibrous material having a plurality of individual fibers forming a fiber matrix, a plurality of absorbent fibers, wherein the plurality of absorbent fibers are impregnated within the fiber matrix by means of a needlepunch process.