Curable Absorbent Films via UV Radiation Curing
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Solution Overview
Problem
Existing methods for producing absorbent film substrates with superabsorbent polymers are unsuitable for continuous manufacturing due to the need for thermal reactions and solvent removal, limiting manufacturing efficiency and product customization.
Innovation Solution
Development of radiation-curable compositions comprising acrylate monomers, oligomers, absorbent polymers, photo initiators, and solvents, which can be rapidly cured using UV radiation, enabling the production of absorbent films with customizable properties and high fluid absorption capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional coating, spinning, spraying or 3D printing techniques are used to prepare SAP containing substrates, then the substrates can be formed with desired shapes and structures, but thermal reaction and solvent removal are required prior to use, making them unsuitable for continuous manufacturing
Solution Approach 1:
The patent replaces thermal reaction and drying processes with UV radiation curing. The composition includes UV-curable components that undergo photopolymerization when exposed to UV light, eliminating the need for thermal heating and solvent evaporation steps, thereby enabling continuous manufacturing without time-consuming thermal processing
Solution Approach 2:
The UV-curable composition enables continuous manufacturing by allowing the film to be cured immediately after application without interruption for drying or thermal processing. The photopolymerization reaction occurs continuously during the coating process itself, eliminating idle time between manufacturing steps
2Productivity
If UV-curable composition is used to rapidly cure absorbent films, then manufacturing efficiency is improved, but the composition complexity increases due to multiple components required
Solution Approach 1:
The patent creates a multi-functional composition where a single formulation serves multiple purposes: it provides absorbency (via SAP), mechanical strength (via polymer matrix), UV curability (via photopolymerizable monomers and initiators), and processability (via solvent system). This consolidation of functions into one composition eliminates the need for separate layers or additives for each function
Solution Approach 2:
The patent employs a composite material system combining SAP particles dispersed in a UV-curable polymer matrix containing monomers, oligomers, and initiators. This composite structure integrates absorbent functionality with curable matrix properties, allowing rapid UV curing while maintaining the desired absorbent characteristics without requiring multiple separate materials
3Adaptability or versatility
If liquid or semi-solid precursor formulations are used, then high processability and customization capability are achieved, but the formulations require rapid curing to maintain manufacturing efficiency
Solution Approach 1:
The patent incorporates UV initiators and photopolymerizable components into the liquid or semi-solid precursor formulation before application. This preliminary preparation ensures that the material is ready for immediate UV curing upon contact with the substrate, allowing rapid transformation from liquid/semi-solid state to cured film without delaying the customization or formulation development process
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 solution allows for efficient and flexible production of absorbent films with improved mechanical properties and enhanced water absorption capacity, suitable for various applications, including personal care products.
Implementation Method 1
The compositions of the present invention can be cured using radiation, and more specifically UV radiation
Implementation Method 2
one or more absorbing polymers
Data Source
AI summary
The present invention relates to curable compositions useful in the manufacture of absorbent films or absorbent film products. Methods of using and manufacturing the compositions also disclosed.