Open Cell Foam Composite for Enhanced Fluid Retention
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Solution Overview
Problem
There is a need for an absorbent structure that combines the properties of a first open cell foam with a second open cell foam to enhance absorbency and fluid retention in absorbent articles, such as diapers and sanitary napkins, while avoiding the use of adhesives for association.
Innovation Solution
The absorbent structure comprises a first open cell foam with a cellular structure that contains a second open cell foam, where the association between the two foams can occur through entanglement, enrobing, direct contact, linking, or mechanical connection, without the use of adhesives, allowing for customizable chemical composition and physical properties to optimize absorbency and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a single homogeneous foam is used, then the structure is simple and easy to manufacture, but the absorbency and fluid retention capabilities are limited
Solution Approach 1:
The foam is divided into multiple distinct phases: a continuous foam phase and dispersed foam droplets, each with different properties. This segmentation allows each phase to contribute different absorbency characteristics, thereby increasing overall absorbency capacity without requiring a completely new complex structure
Solution Approach 2:
The invention creates a composite foam system where two different foam phases (continuous and dispersed) coexist. The continuous foam provides baseline absorbency while the dispersed foam droplets provide additional fluid retention capacity. This composite approach enables enhanced absorbency (10-200 g/g) by combining the advantages of different foam configurations in a single material system
2Reliability
If different foams are associated to serve different purposes, then absorbency and fluid retention are enhanced, but the manufacturing process becomes more complex
Solution Approach 1:
Multiple foam phases (continuous and dispersed) are merged into a single integrated foam structure. The dispersed foam droplets are incorporated within the continuous foam matrix during the foaming process, creating a unified material that provides both baseline absorbency and enhanced fluid retention without requiring separate assembly steps
Solution Approach 2:
The dispersed foam droplets are nested within the continuous foam phase, similar to nested dolls. This nesting approach allows the inner foam droplets to be contained within the outer continuous foam matrix, enabling enhanced fluid retention capabilities while maintaining a single integrated structure that can be manufactured in one process
3Stability of the object's composition
If adhesives are used to associate foams, then the association is strong and stable, but the chemical composition and physical properties become less customizable
Solution Approach 1:
The foam phases associate with each other through inherent physical mechanisms rather than requiring external adhesives. The dispersed foam droplets are stabilized within the continuous foam matrix through self-organization during the foaming process, allowing the foam itself to provide the association mechanism. This self-service approach maintains full customization of chemical composition and physical properties without being constrained by adhesive compatibility requirements
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
This configuration enhances the absorbency and fluid retention capabilities of the absorbent structure, achieving absorbency levels between 10 g/g to 200 g/g, with flexible and hydrophilic properties suitable for various applications, including sanitary napkins and diapers, by leveraging the unique properties of each foam type.
Implementation Method 1
Open celled foams are used for their absorbent properties
Implementation Method 2
The absorbent structure comprises a first open cell foam and a second open cell foam, wherein the first open cell foam provides a cellular structure comprising the second open cell foam
Data Source
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AI summary
An absorbent structure having a first open cell foam associated with a second open cell foam.