Elastomeric Meltblown Composite Web for Superabsorbent Retention
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Solution Overview
Problem
Existing composite webs with meltblown fibers and discrete absorbent or superabsorbent particles face challenges in optimizing liquid absorption capacity without increasing the quantity of particles, leading to inefficiencies in liquid absorption and retention.
Innovation Solution
A composite web comprising meltblown fibers with an elastomer and hydrophilic additive, which are optimized in terms of fiber diameter, density, and elasticity, allowing better dispersion and adherence of superabsorbent particles, and optionally coupled with auxiliary webs, enhancing the web's ability to absorb and retain liquids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the quantity of discrete particles of superabsorbent material is increased to improve liquid absorption capacity, then the amount of liquid absorbed increases, but the quantity of material used increases and cost rises
Solution Approach 1:
The patent uses a composite web structure combining meltblown fibers with superabsorbent particles dispersed throughout the matrix. The fibers provide structural support and transport pathways while the particles provide absorption capacity, creating a synergistic composite material that improves liquid absorption efficiency per unit mass of particles used.
Solution Approach 2:
The superabsorbent particles are dispersed locally throughout the fiber matrix rather than concentrated in one area. This local distribution allows liquid to be absorbed at multiple points simultaneously as it penetrates the web, improving overall absorption capacity without requiring proportional increases in particle quantity.
2Reliability
If more superabsorbent particles are used to improve liquid retention, then retention capacity increases, but material quantity and cost increase
Solution Approach 1:
The meltblown fibers create a three-dimensional porous network with curved pathways that guide liquid flow and trap superabsorbent particles. The spherical or irregular shape of the particles themselves provides high surface area to volume ratio, enhancing their retention capacity within the fiber matrix.
Solution Approach 2:
The web structure is inherently porous due to the meltblown fiber construction, creating a network of voids and channels. These pores trap superabsorbent particles in place while allowing liquid to reach them, improving retention capacity without requiring additional particles.
3Loss of substance
If the quantity of superabsorbent particles is reduced to decrease material cost, then cost decreases, but liquid absorption capacity may be compromised
Solution Approach 1:
The meltblown fibers act as an intermediary medium between the liquid and the superabsorbent particles. The fibers transport liquid through capillary action to the particles, ensuring efficient delivery of liquid to the absorption sites and maximizing the utilization of each particle's capacity.
Solution Approach 2:
The invention transitions from a two-dimensional surface layer of particles to a three-dimensional dispersed distribution throughout the web volume. This volumetric distribution increases the effective surface area available for absorption without proportionally increasing particle quantity, improving absorption capacity per unit mass.
4Reliability
If discrete particles are trapped in the fiber matrix, then particle retention improves, but particle dispersion and accessibility to liquid may be reduced
Solution Approach 1:
The superabsorbent particles are dispersed and trapped within the fiber matrix during the web formation process itself, before the web is put into service. This preliminary distribution ensures uniform particle placement and guarantees that particles are accessible to liquid from multiple directions, maintaining both retention and accessibility.
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 improves liquid absorption capacity and retention, reducing the need for superabsorbent material while maintaining or exceeding traditional web performance, with enhanced wet and dry integrity and reduced particle loss.
Implementation Method 1
a hydrophilic additive melted and blown together with the first thermoplastic material to make the composite web hydrophilic. The hydrophilic property of the fibres allows the liquid that has to be absorbed by the web to effectively reach the absorbent or superabsorbent material
Implementation Method 2
The elastomer makes the fibres suitably elastic, that is to say, flexible enough to follow the SAP as it absorbs and expands, while at the same time holding it within the fibre matrix and stopping it from being lost
Implementation Method 3
particulate material, for example, an absorbent or superabsorbent polymer material. By absorbent (or superabsorbent) material is meant a material that is capable of retaining any liquid
Data Source
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AI summary
A composite web (1) comprises a mass (2) of meltblown fibres (3) comprising an elastomer and a hydrophilic additive, melted and blown together, and a particulate material (4) dispersed among the fibres and at least partly adherent thereto.