Absorbent Resin Composition for Faster Under-Load Liquid Uptake
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Solution Overview
Problem
Absorbent articles such as paper diapers using existing water-absorbing resins are slow to absorb aqueous liquids and prone to exuding, and adding liquid permeability enhancers can cause dusting and filter clogging during production.
Innovation Solution
A method for producing a surface-crosslinked particulate poly(meth)acrylic acid (salt)-based water-absorbing resin by adding water-soluble polyalkylene glycol with a weight average molecular weight of not more than 2000 during polymerization, followed by gel-crushing, drying, and surface-crosslinking, to achieve improved initial water absorption speed under load without a liquid permeability enhancer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If water-absorbing resin is mixed with other granular materials and granulated together, then manufacturing process is simplified, but resin aggregates fail to granulate properly and production becomes unstable
Solution Approach 1:
The water-absorbing resin is granulated separately before mixing with other granular materials. This preliminary granulation action ensures the resin is in the correct form for subsequent mixing and processing, preventing aggregation issues while maintaining production stability.
Solution Approach 2:
The granulation process is divided into separate stages: first granulating the water-absorbing resin alone, then mixing with other materials, and finally granulating the mixture if needed. This segmentation prevents the resin from aggregating during the mixing process while still achieving the desired final granule structure.
2Reliability
If water-absorbing resin is granulated separately and then mixed with other granular materials, then production stability is improved, but manufacturing process complexity increases
Solution Approach 1:
The separately granulated water-absorbing resin is mixed with other granular materials in a simple mixing operation. If final granule characteristics are not achieved, a second granulation step is applied. This merging approach maintains production stability while using straightforward, common equipment for mixing and optional granulation.
3Ease of manufacture
If excessive water is used during granulation of water-absorbing resin, then granulation process is easier, but resin aggregates form and cannot be dispersed
Solution Approach 1:
Water is added to the water-absorbing resin in periodic, controlled amounts during granulation rather than all at once. This periodic addition allows the resin to absorb water gradually, preventing excessive moisture that would cause aggregation, while still achieving proper granulation. The process may involve multiple passes of water addition and mixing.
4Quantity of substance
If water-absorbing resin particles are small, then product performance is improved, but resin aggregates form during granulation and cannot be dispersed even with long mixing times
Solution Approach 1:
The water-absorbing resin is granulated separately before mixing with other materials. This preliminary granulation creates uniformly sized small particles that will not aggregate during subsequent mixing, eliminating the need for extended mixing times to disperse aggregates.
Solution Approach 2:
The water-absorbing resin is treated differently from other granular materials by granulating it separately first. This local quality approach ensures the resin has the correct particle size and moisture content before mixing, preventing aggregation issues that would otherwise require long mixing times to resolve.
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 a water-absorbing resin with enhanced initial water absorption speed, reducing exuding and preventing dusting and filter clogging, while maintaining excellent liquid permeability and safety, and improving the absorption speed of the absorbent articles.
Implementation Method 1
water-absorbing resin... granulated in the presence of water... granules having a water content of not less than 3 wt% and not more than 20 wt%
Data Source
AI summary
Provided is a method for producing an absorbent article comprising a water-absorbing resin having an excellent initial water absorption speed under load even substantially without adding a liquid permeability enhancer. The method steps for producing the water-absorbing resin includes the step of polymerizing a monomer while adding certain polyalkylene glycol thereto so as to generate, during or after the polymerization, a crosslinked hydrogel polymer containing the polyalkylene glycol of a specific molecular weight, wherein the crosslinked hydrogel polymer has a centrifuge retention capacity within a given range and a final water-absorbing resin to be obtained has various physical properties (CRC, AAP, SFC, FSR) being within given ranges.