Clay-Crosslinked Superabsorbent Polymer via Spray-Stream Process
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing superabsorbent polymers in absorbent articles face challenges with high gel strength leading to gel blocking, reduced absorption speed, and inefficient hydrolysis processes, which hinder their commercial scalability and effectiveness in absorbent applications.
Innovation Solution
The development of clay-crosslinked superabsorbent polymers formed through a spray-stream polymerization process, where nano-sized or individual clay particles crosslink polymers during polymerization, creating uniform and high-performing superabsorbent materials with improved absorption speed and capacity, and avoiding the need for slow and energy-intensive hydrolysis steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If internal crosslinking or surface crosslinking is increased to improve gel strength and resistance against deformation, then the resistance of swollen gel against deformation increases, but the absorbent capacity of the gel is reduced undesirably
Solution Approach 1:
The patent uses a composite material system consisting of superabsorbent polymer particles combined with nanocellulose fibers. The nanocellulose acts as a separate reinforcing phase that provides mechanical strength and structural integrity to the gel network, allowing the polymer to maintain high absorbent capacity while the composite structure resists deformation. This composite approach enables both high gel strength and high absorbent capacity to coexist without the trade-off present in conventional crosslinked systems.
2Strength
If conventional crosslinking methods are used to improve gel strength, then the resistance against deformation improves, but the absorption speed decreases
Solution Approach 1:
The patent segments the reinforcing function from the absorbing function by using separate nanocellulose fiber elements distributed throughout the polymer matrix. The nanocellulose fibers provide structural support and gel strength without forming extensive crosslinks that would slow down fluid penetration. This segmentation allows the polymer chains to remain relatively free for rapid fluid absorption while the nanocellulose network provides mechanical reinforcement, thus achieving both high absorption speed and high gel strength simultaneously.
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 resulting superabsorbent materials exhibit enhanced absorption capacity, permeability, and resistance to deformation, addressing gel blocking issues while enabling faster absorption and reducing production costs through streamlined processing.
Implementation Method 1
whereby said clay particles crosslink said polymers during polymerization, forming individual clay particle crosslinks and/ or nano-size clay crosslinks
Implementation Method 2
polymerizing in a spray-stream, polymerizable compounds in the presence of a polymerization initiator system
Implementation Method 3
large amounts of bodily fluids, e.g. urine, can be absorbed by the article and locked away
Implementation Method 4
water-swellable polymers (also referred to as absorbent gelling material, AGM, or superabsorbent polymers, SAP's)
Data Source
AI summary
Superabsorbent material, comprising clay-crosslinked superabsorbent polymers, obtainable by polymerizing in a spray-stream, polymerizable compounds in the presence of a polymerization initiator system, and nano-sized or individual clay particles, which are all introduced into a vessel by a spraying step in the form of a said spray-stream thereof, whereby said clay particles crosslink said polymers during polymerization. The invention also relates to such a process and absorbent articles comprising such superabsorbent material.