Fluff pulp and high SAP loaded core
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Solution Overview
Problem
Current methods for producing fluff pulp struggle to create a thin, high-SAP loaded core with improved SAP retention, shred quality, and reduced shred energy, while maintaining flexibility and preventing fiber-fiber bonding.
Innovation Solution
A process involving a mixture of softwood and hardwood fibers, with 3 to 35% hardwood fibers by weight, is used to create a fluff pulp that is then dried and optionally pressed, allowing for the incorporation of superabsorbent polymers and additives to enhance SAP retention and core properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hardwood fiber content is increased to improve SAP retention and reduce shred energy, then core flexibility and thinness are improved, but fiber-fiber bonding and entanglement increase making the core weaker when compressed
Solution Approach 1:
The patent applies parameter changes by precisely controlling the hardwood fiber content within 3-35% by weight of total fibers. This optimized ratio balances the competing requirements: enough hardwood to improve SAP retention and reduce shred energy, but not so much that excessive fiber-fiber bonding weakens the core under compression. The parameter optimization resolves the contradiction by finding the optimal point in the composition space.
Solution Approach 2:
The patent uses composite materials by combining softwood and hardwood fibers in a specific ratio (3-35% hardwood). This composite approach leverages the complementary properties of each fiber type: softwood provides structural integrity and strength, while hardwood improves SAP retention and reduces shred energy. The composite material strategy allows the core to simultaneously achieve flexibility, thinness, and adequate compression strength.
2Use of energy by moving object
If hardwood fiber content is increased to reduce shred energy, then energy consumption during shredding is reduced, but fiber-fiber entanglement increases affecting core flexibility
Solution Approach 1:
The patent applies parameter changes by optimizing the hardwood fiber content to 3-35% by weight. This controlled parameter adjustment reduces shred energy consumption while preventing excessive fiber-fiber entanglement that would compromise core flexibility. The specific range balances energy efficiency with operational flexibility.
3Length of moving object
If the core is made thinner to improve flexibility and SAP loading density, then product performance is enhanced, but SAP retention becomes more difficult to maintain
Solution Approach 1:
The patent uses composite materials (3-35% hardwood with softwood) to create a fluff pulp with optimized physical properties. This composite structure enables the formation of thinner cores while maintaining SAP retention, as the controlled fiber composition provides adequate fiber-fiber bonding and structural integrity even at reduced thickness.
Solution Approach 2:
The patent applies parameter changes by controlling hardwood content at 3-35% to optimize the fluff pulp properties for thin core formation. This parameter optimization allows the core to be made thinner while maintaining sufficient SAP retention through improved fiber characteristics and reduced shred energy.
Data Source
AI summary
A fluff pulp is provided, which comprises softwood fibers; and 3 to 35% by weight of hardwood fibers. A fluff is also provided, which comprises the fiberized or shredded fluff pulp. A core is also provided, which comprises the fluff and at least an SAP. Processes for making and using the fluff pulp, fluff, and core are provided, and products made thereby.