Composite Absorbent Tape With Adhesive-Free Particle Embedding
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Solution Overview
Problem
Existing absorbent structures in hygiene products require complex production processes, involve the use of adhesives that complicate recycling and increase ecological footprint, and often result in poor particle containment and reduced production flexibility.
Innovation Solution
A composite tape is developed with continuous microfilaments mixed with particles, formed within the pores of a high thickness tape, eliminating the need for adhesives and enhancing particle containment and production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If particles are incorporated into the pores of a preformed tape using adhesives, then particle containment is improved, but the ecological footprint increases and recycling becomes more difficult
Solution Approach 1:
The invention extracts and eliminates the adhesive component from the particle incorporation process. Instead of using adhesives to fix particles to the tape, the patent employs a calendering process that mechanically embeds particles into the pores of the foam tape through heat and pressure, completely removing the harmful adhesive substance from the system.
Solution Approach 2:
The invention replaces the chemical bonding mechanism (adhesives) with a mechanical-thermal process (calendering). The calendering process uses heated rollers to melt and reshape the foam tape surface, allowing particles to be mechanically embedded into the pores through controlled deformation and cooling, substituting chemical adhesion with physical entrapment.
2Reliability
If adhesives are used to fix particles in absorbent structures, then particle containment is improved, but production costs and energy consumption increase
Solution Approach 1:
The invention extracts and eliminates the adhesive component from the particle incorporation process. Instead of using adhesives to fix particles to the tape, the patent employs a calendering process that mechanically embeds particles into the pores of the foam tape through heat and pressure, completely removing the harmful adhesive substance from the system.
Solution Approach 2:
The invention replaces the chemical bonding mechanism (adhesives) with a mechanical-thermal process (calendering). The calendering process uses heated rollers to melt and reshape the foam tape surface, allowing particles to be mechanically embedded into the pores through controlled deformation and cooling, substituting chemical adhesion with physical entrapment.
3Reliability
If complex production processes are used to form absorbent cores in-line, then particle containment is improved, but production flexibility and volume are reduced
Solution Approach 1:
The invention applies preliminary action by pre-forming the foam tape with embedded particles off-line using calendering before the tape reaches the conversion line. This preliminary particle incorporation allows the tape to be produced in large volumes independently, then simply unwound and joined at the conversion line, eliminating the need for complex in-line particle handling systems.
Solution Approach 2:
The invention segments the production process into two independent stages: (1) off-line foam tape production with particle embedding via calendering, and (2) in-line assembly at the conversion line. This segmentation allows each stage to be optimized independently, enabling high-volume tape production without compromising particle containment.
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 simplifies recycling by avoiding adhesives, while maintaining high production volumes.
Implementation Method 1
The tape is then calendered, in order to embed the particles into the pores of the foam tape
Implementation Method 2
embed the particles into the pores of the foam tape
Implementation Method 3
the mixture then penetrates, at least in part, into the pores of the high thickness tape
Data Source
AI summary
A composite tape (1) is provided comprising at least a first layer (3) comprising a plurality of first continuous polymer filaments (32) defining a development axis (32a) and at least in part a plurality of mutually identical outlines (33) arranged in succession along said development axis (32a); a second layer (4) of second continuous polymer filaments (40) forming a surface layer of tape (1) and placed in contact with the first layer (3); 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.