Heterogeneous Absorbent Mass With Integrated Foam Pieces
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Solution Overview
Problem
Current absorbent foam technologies in absorbent articles, such as diapers and sanitary napkins, are limited by the inability to create a heterogeneous mass with integrated discrete foam pieces and substrate elements, resulting in uniform foam with limited pore size variations and the need for adhesive cover layers.
Innovation Solution
A heterogeneous absorbent structure comprising discrete open cell foam pieces integrated with enrobeable elements, where the foam pieces enrobe the elements, creating a mass with varying pore sizes and allowing for enhanced absorbency and fluid retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If discrete foam pieces are placed into or onto another material, then absorbency can be improved, but the foam pieces require adhesive cover layers or binding mechanisms to hold them in place
Solution Approach 1:
The patent combines discrete foam pieces with substrate elements into a single integrated heterogeneous mass, eliminating the need for separate adhesive cover layers or binding mechanisms. The foam and substrate elements are merged at the molecular level through copolymerization, creating a unified structure where absorbent foam portions are distributed throughout the substrate.
Solution Approach 2:
The invention creates a composite material system consisting of hydrophilic foam portions and hydrophobic substrate elements within a single heterogeneous mass. This composite structure integrates materials with different properties (absorbent and non-absorbent) into one unified component that performs both functions without requiring additional fastening mechanisms.
2Ease of manufacture
If uniform foam is used in absorbent cores, then manufacturing is simplified, but pore size variation is limited reducing absorbency performance
Solution Approach 1:
The patent implements local quality by creating regions with different pore sizes and foam densities within the heterogeneous mass. The foam pieces vary in size, shape, and porosity throughout the substrate, with some regions having larger pores for rapid absorption and other regions having smaller pores for retention, optimizing performance at different locations.
Solution Approach 2:
The invention segments the foam structure into discrete pieces of varying sizes and pore characteristics distributed throughout the substrate. Rather than a single uniform foam structure, the absorbent core is divided into multiple foam portions with different properties, enabling both rapid absorption and fluid retention functions.
3Productivity
If foam is polymerized in continuous sheet or tubular form, then manufacturing efficiency is improved, but the foam cannot be integrated into substrate at discrete portions
Solution Approach 1:
The patent segments the continuous foam into discrete pieces that are then distributed throughout the substrate during the polymerization process. This segmentation allows the foam to be integrated at specific portions of the substrate while maintaining manufacturing efficiency through a single-step copolymerization process.
Solution Approach 2:
The invention performs preliminary action by pre-forming the heterogeneous mass structure with dispersed foam pieces before final polymerization. The foam pieces are positioned and distributed within the substrate matrix prior to complete polymerization, enabling integrated formation of both foam and substrate in one process step.
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 solution enables the creation of absorbent articles with improved absorbency and fluid retention capabilities, allowing for the integration of foam pieces with enrobeable elements, enhancing the overall performance of absorbent products.
Implementation Method 1
Open celled foams are used for their absorbent properties
Implementation Method 2
The heterogeneous mass has a depth, a width, and a height. The discrete portions of foam pieces enrobe one or more of the elements of the heterogeneous mass such that the two may be intertwined
Data Source
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AI summary
A heterogeneous mass comprising a longitudinal axis, a lateral axis, a vertical axis, one or more enrobeable elements and one or more discrete open cell foam pieces is disclosed. The open cell foam pieces comprise pores and vacuoles.