Composite Absorbent Tape for Adhesive-Free Particle Containment
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Solution Overview
Problem
Existing absorbent structures in hygienic articles require complex production processes, involve the use of adhesives that complicate recycling and increase ecological footprint, and often result in reduced production speed and flexibility.
Innovation Solution
A composite tape is developed with continuous microfilaments and particles mixed within high thickness tape pores, eliminating the need for adhesives and allowing high production volumes without compromising particle containment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If particles are incorporated into preformed tapes by wrapping in coating materials, then particle containment is improved, but device complexity and production cost increase
Solution Approach 1:
The patent applies preliminary action by forming the particles and binder mixture into a cohesive mass before incorporation into the tape structure. The binder is applied to particles in advance, creating a pre-assembled composite that can be directly integrated into the absorbent core without requiring subsequent wrapping or coating operations.
Solution Approach 2:
The patent extracts the particle containment function from the tape structure itself rather than relying on external wrapping materials. The binder material is integrated directly with the particles and tape matrix, eliminating the need for separate coating layers while maintaining particle containment.
2Reliability
If adhesives are used to bind particles in absorbent structures, then particle containment is improved, but ease of manufacture and environmental impact worsen due to recycling complexity
Solution Approach 1:
The patent changes the fundamental parameter of binding mechanism from chemical adhesion (adhesives) to physical entanglement and absorption. The binder material operates through capillary action and physical bonding within the porous matrix, eliminating the need for separate adhesive layers and simplifying both manufacturing and recycling processes.
Solution Approach 2:
The patent creates a homogeneous distribution of binder material throughout the particle-tape composite structure. The binder is integrated uniformly with both particles and tape matrix, forming a single-phase composite material that is easier to manufacture and recycle compared to multi-layer adhesive constructions.
3Manufacturing precision
If complex handling systems are used for adding particles and joining preformed tapes, then particle distribution is improved, but productivity decreases
Solution Approach 1:
The patent merges multiple manufacturing operations into a single integrated process. Particle-binder mixing, tape formation, and particle incorporation are combined into one continuous operation, eliminating the need for separate handling, unwinding, and joining systems while maintaining uniform particle distribution throughout the absorbent core.
Solution Approach 2:
The patent performs preliminary mixing of particles and binder material before tape formation, creating a pre-distributed composite that can be directly incorporated into the absorbent core structure. This eliminates the need for complex in-line particle addition systems and enables high-speed continuous production.
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 composite tape achieves efficient particle containment during production and use, reduces production costs, and facilitates recycling by avoiding the use of adhesives, thus improving economic feasibility and environmental impact.
Implementation Method 1
the mixture penetrates into the pores of the high thickness web
Implementation Method 2
penetrates into the pores
Implementation Method 3
at least in part adhering to the filaments due to the adhesiveness of the latter
Implementation Method 4
absorbent structures composed of super-absorbent polymer (SAP) particles... which are designed to absorb and contain body exudates
Implementation Method 5
where the particles remove contaminants with an adsorption mechanism
Data Source
Figure 1~2
Figure 3~4
Figure 5~6b
AI summary
A composite tape (1) is provided comprising one or more matrices (2) of high thickness polymeric fibres comprising pores; at least one first layer (3) in contact with the matrix (2) and including a mixture (30) at least in part penetrating the pores, and comprising, mutually mixed together, a plurality of cellulose particles (31), and a plurality of continuous first polymer filaments (32) defining, before being mixed with the particles (31), a development axis (32a) and defining at least in part a plurality of mutually identical outlines (33) arranged in succession along the development axis (32a); a second layer (4) of continuous second polymer filaments (40) forming a surface layer of the tape (1) and placed in contact with the matrix (2) and/or the first layer (3) without penetrating the pores; wherein the outline (33) is determined on a section plane (32b) normal to the development axis (32a), defining a first extension area on the section plane (32b) and being inscribable in a circle determined on the section plane (32b) and defining a second extension area on the section plane (32b); and wherein the first extension area is less than 90% of the second extension area.