Heterogeneous mass containing foam
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Solution Overview
Problem
Current absorbent structures for products like diapers and sanitary napkins typically require multiple processes to achieve dual pore-size ranges, either using different compositions or systems, which is inefficient and limits the creation of absorbent structures with more than two pore-size ranges.
Innovation Solution
A heterogeneous mass with three or more pore-size ranges is developed, where at least two of these ranges are within discrete open-cell foam pieces made from High Internal Phase Emulsion (HIPE) polymerization, allowing for the integration of enrobeable elements and open-cell foam pieces that exhibit distinct pore-size ranges optimized for absorption and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple processes are used to create dual pore-size ranges in absorbent structures, then the pore size optimization is achieved, but the manufacturing complexity and process time increase
Solution Approach 1:
The patent combines multiple pore-size ranges (at least three distinct ranges) into a single foam structure created through one polymerization process. This merges what would traditionally require multiple separate processes into a single integrated manufacturing step, reducing complexity while maintaining precise pore size optimization for different absorbent functions.
Solution Approach 2:
The invention creates a composite foam structure with heterogeneous pore-size ranges within a single polymerized matrix. By forming a High Internal Phase Emulsion (HIPE) with multiple domain sizes before polymerization, the process produces a composite material with distinct pore regions (ranging from micrometers to millimeters) that perform different absorbent functions, eliminating the need for multiple manufacturing processes.
2Reliability
If different compositions or systems are used to achieve dual pore-size ranges, then the absorbent performance is improved, but the material complexity and processing difficulty increase
Solution Approach 1:
The patent applies local quality by creating regions with different pore-size characteristics within a single foam structure. The HIPE formulation includes domains of at least three distinct size ranges, where each region provides locally optimized absorbent properties (acquisition, transport, storage) while being part of an integrated structure processed in one manufacturing step.
Solution Approach 2:
The invention changes physical parameters during a single polymerization process to achieve multiple pore-size ranges. By controlling the HIPE domain size distribution before polymerization (through emulsification conditions, surfactant selection, and phase ratio), the process produces a foam with heterogeneous pore structures ranging from micrometers to millimeters without requiring multiple processing steps or different material compositions.
3Productivity
If traditional continuous sheet or tubular foam polymerization is used, then the manufacturing efficiency is maintained, but the ability to create varied pore-size ranges within the same foam is limited
Solution Approach 1:
The patent applies preliminary action by pre-forming the HIPE with the desired multi-domain pore structure before polymerization. The emulsion is prepared with at least three distinct domain size ranges through controlled emulsification and phase separation, establishing the pore-size distribution in advance. This preliminary structuring allows the subsequent single-step polymerization to produce a foam with heterogeneous pore sizes, combining manufacturing efficiency with pore size versatility.
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 approach enables the creation of absorbent structures with enhanced absorbency and fluid management capabilities, allowing for the simultaneous optimization of multiple pore sizes within a single foam structure, improving the performance and efficiency of absorbent articles.
Implementation Method 1
The open-cell foam is a thermoset polymeric foam made from polymerization of a High Internal Phase Emulsion (HIPE) formed by combining an aqueous phase and an oil phase
Implementation Method 2
a High Internal Phase Emulsion (HIPE) formed by combining an aqueous phase and an oil phase in a ratio between about 8:1 and 140:1
Implementation Method 3
Open celled foams are used for their absorbent properties
Implementation Method 4
One pore size may be optimized for acquisition while the other pore size may be optimized for storage
Data Source
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Figure 4
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 heterogeneous mass comprises three or more pore-size ranges. At least two of the pore-size ranges are in the foam pieces.