Hybrid Absorbent Sheet Structure for Precise SAP Channel Alignment
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Solution Overview
Problem
Existing methods for manufacturing absorbent bodies with a water-absorbing material and stacked fiber layers face challenges in maintaining precise shape and position stability, particularly with superabsorbent polymers (SAP) shifting during conveyance.
Innovation Solution
The manufacturing apparatus and method involve forming an absorbent sheet with defined spraying and channel areas for SAP, and using suction conveyance to stabilize the SAP, while stacking fibers on the sheet to create a hybrid structure with precise channel and fiber parts, ensuring the SAP remains fixed and evenly distributed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If SAP is disposed between base material sheets and conveyed by suction, then the absorbent body can be manufactured with hybrid structure, but the SAP is likely to move and shift positions reducing manufacturing precision
Solution Approach 1:
The SAP is sprayed and deposited onto the first sheet before conveyance begins, forming a stable absorbent sheet structure. This preliminary formation ensures the SAP is fixed in position before any movement occurs, preventing shifting during the manufacturing process
Solution Approach 2:
The first sheet and second sheet serve as intermediary carriers that hold the SAP in place during conveyance. By sandwiching the SAP between these sheets, the system prevents direct contact and potential shifting of the SAP particles during suction conveyance
2Quantity of substance
If water-absorbing material is sprayed uniformly across the sheet, then absorption capacity is maximized, but fluid diffusion channels are reduced
Solution Approach 1:
The water-absorbing material is selectively sprayed in specific areas (spraying areas) while leaving other areas (channel areas) free of material. This creates local variations in material distribution, with high absorption zones and fluid diffusion channels coexisting in the same absorbent sheet
Solution Approach 2:
The absorbent sheet is segmented into distinct functional zones: spraying areas for absorption and channel areas for fluid diffusion. This segmentation allows the single sheet to perform multiple functions simultaneously, balancing absorption capacity with fluid transport capability
3Quantity of substance
If fibers are stacked densely to form absorbent fluff, then absorption capacity increases, but channel formation for fluid diffusion becomes difficult
Solution Approach 1:
The fiber stacking is performed locally in specific areas while leaving channel areas free of fibers. This creates a heterogeneous structure where dense fiber regions provide absorption capacity and fiber-free regions provide fluid diffusion pathways
Solution Approach 2:
The absorbent fluff is segmented into stacked fiber parts for absorption and channel parts for fluid diffusion. This segmentation ensures that the fiber stacking process does not compromise the formation of essential fluid diffusion channels
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
This approach allows for the production of absorbent bodies with high precision in shape and improved fluid diffusion, enhancing the absorption of bodily fluids by suppressing SAP movement and maintaining the desired structure.
Implementation Method 1
The first suction conveyer includes a first conveying surface having a suction function, and is configured to convey the first sheet while suctioning the first sheet on the first conveying surface
Implementation Method 2
The fiber-stacking drum has a suction function and is configured to cause the fibers supplied by the fiber supplier to be stacked on a peripheral surface of the fiber-stacking drum to form the absorbent fluff
Data Source
Figure 1~2B
Figure 3A
Figure 3B
AI summary
Provided are a device and method for manufacturing an absorbent body, with which a hybrid structure absorbent body having a desired shape can be manufactured with high precision. A manufacturing device (1000A) includes an absorbent sheet formation unit (100) that forms an absorbent sheet (Sa) in which a SAP is sprayed between a first sheet (S1) and a second sheet (S2), and presses the absorbent sheet using a press; and a fiber-stacking unit (300) that stacks fibers to form an absorbent fluff (Fa) and stacks the absorbent fluff on the absorbent sheet. When stacking the absorbent fluff on the absorbent sheet, the fiber-stacking unit lays a channel part of the absorbent fluff, where the fibers are not disposed, over a channel area of the absorbent sheet, where the SAP is not sprayed.