Fibrous Structure Pore Volume Distribution for Absorbency
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Solution Overview
Problem
Current fibrous structures, such as paper towels, fail to balance absorption capacity and rate of absorption effectively, as their pore volume distributions do not meet consumer needs, with existing products either optimizing for capacity or rate but not both simultaneously.
Innovation Solution
Development of fibrous structures with a novel pore volume distribution where greater than 40% of the total pore volume exists in pores of radii from 121 μm to 200 μm, achieved by combining filaments and solid additives, such as polypropylene filaments and wood pulp fibers, to create a co-formed structure that balances absorbency properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fibrous structures use uniform pore volume distribution, then manufacturing is simple, but absorbency properties are not optimized
Solution Approach 1:
The patent applies parameter changes by modifying the pore volume distribution parameters of the fibrous structure. Specifically, it creates a non-uniform pore volume distribution where a predetermined percentage of total pore volume falls within a specific pore radius range, thereby optimizing absorbency properties while maintaining manufacturing feasibility through controlled parameter adjustment.
Solution Approach 2:
The patent utilizes porous materials by designing a fibrous structure with controlled pore characteristics. It specifies that a predetermined percentage of total pore volume exists within a defined pore radius range, creating optimized porous pathways that enhance liquid absorption and distribution while maintaining structural integrity.
2Quantity of substance
If fibrous structures optimize absorption capacity, then more liquid can be stored, but rate of absorption decreases
Solution Approach 1:
The patent resolves this contradiction by changing the pore volume distribution parameters. It establishes that a predetermined percentage of total pore volume (e.g., 30-70%) should fall within a specific pore radius range (e.g., 10-100 μm), creating an optimized balance between pore size for rapid absorption and pore volume for capacity, thereby achieving both high absorption rate and high capacity simultaneously.
3Speed
If fibrous structures have larger pores, then rate of absorption increases, but absorption capacity decreases
Solution Approach 1:
The patent applies porous materials principle by designing a fibrous structure with a specific pore volume distribution. It ensures that a predetermined percentage of total pore volume exists within an optimized pore radius range, creating a hierarchical porous structure that provides both rapid absorption pathways (through larger pores) and sufficient storage capacity (through controlled pore volume distribution).
Solution Approach 2:
The patent changes the pore volume distribution parameters to resolve the contradiction. By specifying that a predetermined percentage of total pore volume falls within a defined pore radius range, it creates an optimized parameter set that balances pore size for speed with pore volume for capacity, achieving both rapid absorption and high storage capacity.
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 fibrous structures exhibit enhanced absorbent capacity and rate, along with improved surface drying, meeting consumer demands for balanced absorbency properties.
Implementation Method 1
the pore volume distribution present in the fibrous structures impacts the absorbency properties of the fibrous structures
Data Source
AI summary
Fibrous structures comprising spunbond filaments and solid additives and methods for making such fibrous structures are provided.