Fiber-SAP Composite Particles for Absorbent Core Immobilization
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Solution Overview
Problem
Existing absorbent cores in disposable absorbent articles, such as diapers, face challenges in fluid handling capabilities, including liquid absorption rates, distribution properties, and immobilization of superabsorbent particles (SAP).
Innovation Solution
A method involving the partial drying of a liquid suspension of fibers and mixing them with superabsorbent particles (SAP) to form fiber-SAP particles, where the fibers attach to the SAP, enhancing absorption and distribution properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a typical absorbent core is made of high or super absorbent polymer (SAP) stabilized by a bulky absorbent matrix, then the SAP is immobilized within the absorbent core, but the liquid absorption rates and distribution properties are reduced due to the bulky matrix
Solution Approach 1:
The patent removes the bulky absorbent matrix from the traditional absorbent core structure, extracting only the essential SAP particles and replacing the matrix with a minimal amount of fibers that provide structural support without impeding liquid absorption. This extraction eliminates the harmful bulkiness while preserving SAP immobilization through fiber networking.
Solution Approach 2:
The patent employs a fiber network structure that creates porous pathways throughout the absorbent core, allowing liquid to flow freely and rapidly reach SAP particles. The porous structure formed by interconnected fibers provides both mechanical support for SAP immobilization and efficient liquid distribution channels, eliminating the need for bulky matrix materials.
2Reliability
If a bulky absorbent matrix is used to stabilize SAP, then SAP immobilization is achieved, but the liquid distribution properties are worsened
Solution Approach 1:
The fiber network creates a three-dimensional porous structure with interconnected voids that facilitate rapid liquid distribution throughout the absorbent core. The porous architecture allows liquid to penetrate uniformly and reach multiple SAP particles simultaneously, improving distribution properties while the fiber interconnections maintain SAP immobilization.
Solution Approach 2:
The patent creates a composite structure combining SAP particles with a minimal fiber network, where the fibers provide structural framework and the SAP particles provide absorption function. This composite approach eliminates the need for bulky matrix materials while achieving both SAP immobilization and superior liquid distribution through the optimized fiber-SAP interface.
3Reliability
If de-fiberized wood pulp or similar material is used as absorbent matrix, then SAP is stabilized, but the overall bulkiness increases relative to topsheet and backsheet
Solution Approach 1:
The patent extracts and eliminates the bulky wood pulp matrix from the absorbent core formulation, retaining only the essential SAP particles and introducing a minimal amount of fibers for stabilization. This extraction reduces the absorbent core volume to be comparable to or smaller than the topsheet and backsheet while maintaining SAP stability through the efficient fiber network.
Solution Approach 2:
The patent develops a new composite material system replacing traditional wood pulp matrix with a fiber-SAP composite where fibers and SAP particles are intimately associated. This composite structure achieves SAP stabilization with minimal material volume, creating a compact absorbent core that does not exceed the bulkiness of other article components.
4Reliability
If traditional absorbent matrix is used, then SAP is immobilized, but integration of SAP and fiber network formation into manufacturing systems is lacking
Solution Approach 1:
The patent merges the SAP particle distribution and fiber network formation processes into a single integrated manufacturing step. By combining these functions, the invention simplifies the manufacturing system while achieving both SAP immobilization and fiber network creation simultaneously, reducing device complexity compared to multi-step traditional processes.
Solution Approach 2:
The patent designs a manufacturing system where a single apparatus performs multiple functions: distributing SAP particles, forming the fiber network, and stabilizing the absorbent core structure. This multi-functional approach eliminates the need for separate processing steps for each function, reducing overall system complexity while maintaining SAP immobilization effectiveness.
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 formation of fiber-SAP particles improves liquid absorption rates, distribution, and immobilization within the absorbent core, leading to enhanced performance in absorbent articles.
Implementation Method 1
an atomizer at the inlet positioned to direct atomized fiber-liquid suspension into the drying chamber
Implementation Method 2
Partial dried fibers and liquid are received in the chamber
Implementation Method 3
mixing the partially dried fibers with superabsorbent particles (SAP) such that at least some of the fibers attach to at least some of the SAP
Data Source
AI summary
A fiber-SAP particle includes a superabsorbent core particle (SAP core particle) and a plurality of fibers attached to the SAP core particle and extending therefrom. The fiber-SAP particles may be formed in a fluidized bed chamber using a spray drying process. The fiber-SAP particles may be incorporated into absorbent cores and articles, such as in disposable diapers.