Absorbent Member Density Profile for Liquid Handling
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Solution Overview
Problem
Current absorbent core materials in disposable absorbent articles, such as airfelt, have limitations including low integrity, tendency to bunch and rope when wet, and inability to provide a density gradient, leading to suboptimal liquid acquisition and retention capabilities.
Innovation Solution
The development of absorbent members with a controlled density profile achieved through mechanical deformation processes, utilizing cellulose fibers to create layers with varying densities, allowing for improved liquid handling and retention without the need for additional binder materials or complex processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If airfelt is used as absorbent core material, then the material can be easily manufactured, but the integrity is low and it bunches and ropes when wet
Solution Approach 1:
The patent applies parameter changes by controlling the density profile through the thickness of the absorbent member. By creating a gradient density structure with higher density at the bottom and lower density at the top, the material achieves improved integrity and wet strength while maintaining ease of manufacture through the papermaking process. This resolves the contradiction by modifying the density parameter spatially rather than uniformly.
Solution Approach 2:
The patent implements local quality by creating different density zones within the absorbent member. The bottom portion has higher density for structural integrity and wet strength, while the top portion has lower density for liquid acquisition. This spatial variation in local properties resolves the contradiction between ease of manufacture and reliability by optimizing different regions for different functions.
2Device complexity
If airfelt is used as absorbent core material, then the manufacturing process is simple, but the material has low density and cannot provide sufficient capillary work potential
Solution Approach 1:
The patent changes the density parameter by creating a gradient structure during the papermaking process. By controlling drainage and pressing conditions, the material achieves varying density through its thickness without adding process complexity. This resolves the contradiction by implementing parameter changes within the existing manufacturing framework.
3Ease of operation
If airfelt is used as absorbent core material, then the material structure is uniform, but it cannot provide zones with different properties for optimized liquid handling
Solution Approach 1:
The patent implements local quality by creating different density zones within the absorbent member. The bottom portion has higher density for structural integrity and wet strength, while the top portion has lower density for liquid acquisition. This spatial variation in local properties resolves the contradiction between ease of operation and adaptability by optimizing different regions for different functions.
4Manufacturing precision
If airlaid structures with density gradient are used, then the density gradient can be achieved, but the process and materials are more expensive and the supply chain is more complex
Solution Approach 1:
The patent merges the density gradient creation with the existing papermaking process. By implementing density control during the conventional wetlaid papermaking operation, the patent eliminates the need for separate airlaid processing steps. This resolves the contradiction between manufacturing precision and device complexity by combining multiple functions into a single integrated process.
Solution Approach 2:
The patent applies self-service by enabling the papermaking process itself to create the density gradient without requiring external airlaid equipment or additional processing steps. The conventional papermaking machinery and operations automatically produce the gradient structure through controlled drainage and pressing, making the system self-sufficient and reducing supply chain complexity.
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 absorbent members exhibit enhanced liquid acquisition, flexibility, and fluid retention capabilities while reducing costs and complexity in manufacturing, providing improved performance and integrity compared to traditional materials.
Implementation Method 1
subjecting a precursor material to at least one cycle through a mechanical deformation process
Implementation Method 2
provide as much capillary work potential as a higher density material
Data Source
AI summary
Absorbent members and methods of making the same are disclosed. In one embodiment, the absorbent member is a unitary absorbent fibrous web having a density profile through its thickness. In such an embodiment, the density profile may be relatively centered through the thickness of the web and the maximum density of the web is located between about 35% and about 65% of the distance through the thickness of the web.