Fluff Pulp Fiber Composition for High SAP-Loaded Absorbent Cores
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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 simple sugars to enhance SAP retention and core flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If fluff pulp is made thinner to reduce core caliper, then core thickness is reduced, but SAP retention deteriorates and fiber-fiber bonding increases
Solution Approach 1:
The patent changes the physical-chemical parameters of the fluff pulp by incorporating simple sugars (changing chemical composition) and controlling fiber morphology (changing physical structure). This allows thinner core caliper while maintaining SAP retention because the modified fiber structure prevents excessive fiber-fiber bonding that would otherwise occur in thinner cores.
Solution Approach 2:
The patent creates a composite material system combining fluff pulp fibers with simple sugars. This composite structure modifies the interfacial properties between fibers, reducing unwanted fiber-fiber bonding and improving SAP retention even when the core is made thinner, thus resolving the contradiction between reduced caliper and maintained reliability.
2Length of stationary object
If fluff pulp is made thinner to reduce core caliper, then core thickness is reduced, but fiber-fiber bonding increases
Solution Approach 1:
The patent modifies the physical-chemical parameters of the fluff pulp system by adding simple sugars and controlling fiber morphology. These parameter changes reduce the strength of fiber-fiber bonding interactions, allowing thinner cores without excessive bonding that would compromise flexibility and SAP distribution.
Solution Approach 2:
The simple sugars act as an intermediary substance between fibers, modifying the interfacial properties and reducing direct fiber-fiber bonding. This mediator allows the core to be thinner while preventing the harmful effect of excessive bonding, thus resolving the contradiction between reduced caliper and reduced fiber-fiber bonding.
3Reliability
If hardwood fiber content is increased to improve SAP retention, then SAP retention is improved, but shred energy increases
Solution Approach 1:
The patent changes the chemical composition parameter by introducing simple sugars into the fluff pulp system. This chemical modification improves SAP retention through enhanced interfacial properties while simultaneously reducing the mechanical energy required for shredding, thus resolving the contradiction between improved SAP retention and reduced shred energy.
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 process results in a thin, high SAP-loaded core with improved SAP retention, reduced shred energy, and maintained shred quality, enabling flexible and efficient absorbent products.
Implementation Method 1
The fluff pulp comprises softwood fibers and 3 to 35% by weight of hardwood fibers. In one embodiment, the short hardwood fibers limit the amount of fiber-fiber entanglement to make the core weaker when compressed to a very low caliper.
Implementation Method 2
In one embodiment, the sugar or sugar solution will help hold the SAP particles in the core due to the tacky or sticky properties of the sugar.
Implementation Method 3
contacting the furnish onto a moving wire, to form a web; and drying and optionally pressing the web, to form the fluff pulp
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.