Honeycomb Absorber With Weak Bonds For Cell Coalescence
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Solution Overview
Problem
Conventional cell absorbers face challenges in easy coalescence of adjacent cells and insufficient increase in cell volume relative to the number of coalesced cells, leading to reduced absorption capacity and comfort issues due to swelling pressure and potential leakage of superabsorbent polymer particles.
Innovation Solution
The absorbent article features a honeycomb structure with same-sized regular hexagonal cells, where bonded portions are weak and can be peeled off by swelling pressure, allowing for smooth coalescence and efficient volume increase, along with strategic placement of strong and weak bonded portions to enhance liquid diffusibility and prevent leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the volume of superabsorbent polymer particles in saturated absorption state is sufficiently larger than the volume of the cell, then the absorption capacity is improved, but the absorption rate is lowered due to gel blocking and the comfort is deteriorated due to swelling pressure
Solution Approach 1:
The absorber is divided into multiple cells (first cells, second cells, third cells) with different configurations. First cells contain SAP particles with volume ratio 0.5-2.0, second cells have bonded portions at vertices only, and third cells have no bonded portions. This segmentation allows different regions to serve different functions: some for high absorption capacity, others for fast absorption rate, resolving the contradiction between capacity and rate.
2Quantity of substance
If the superabsorbent polymer particles swell in the cell, then the absorption capacity is improved, but the cell becomes hard due to swelling pressure and particles may leak from gaps among fibers
Solution Approach 1:
The absorber is divided into multiple cell types with different bonded portion configurations. Second cells with bonded portions only at vertices and third cells with no bonded portions provide pathways for swelling while containing particles. This segmentation allows the structure to accommodate particle swelling without becoming hard or causing leakage.
Solution Approach 2:
Different regions of the absorber have different bonding characteristics. First cells have continuous bonded portions for containment, second cells have vertex-only bonding for controlled expansion, and third cells have no bonding for maximum swelling freedom. This local quality variation allows different parts to optimize for either containment or swelling based on local requirements.
3Stability of the object's composition
If conventional cell absorbers use bonded portions to form cells, then the structure is maintained, but the coalescence of adjacent cells is difficult and the volume increase relative to number of coalesced cells is insufficient
Solution Approach 1:
The bonded portions are segmented into different types: continuous bonded portions in first cells for stability, and vertex-only bonded portions in second cells for easy coalescence. This segmentation allows the structure to maintain stability where needed while enabling easy coalescence where required, achieving both structural integrity and manufacturing ease.
Solution Approach 2:
Different bonded portion configurations are applied locally: continuous bonding in first cells provides structural stability, while vertex-only bonding in second cells facilitates easy coalescence. This local quality approach allows the absorber to have both stable and easily coalescible regions, resolving the contradiction between structure stability and ease of coalescence.
4Weight of stationary object
If the absorber is thinned and weight is reduced, then the comfort and wearability are improved, but the absorbable amount may be insufficient
Solution Approach 1:
The absorber is segmented into different cell types with optimized SAP content. First cells have SAP volume ratio of 0.5-2.0 for high absorption capacity, while the overall structure uses strategic placement of these high-capacity cells to achieve sufficient total absorbable amount in a thinned, lightweight configuration.
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 design enables easy coalescence of adjacent cells, significantly increasing the volume of the absorbent article while maintaining comfort and preventing superabsorbent polymer particle leakage, thereby improving absorption efficiency and wearability.
Implementation Method 1
the bonded portions positioned on at least one side of each cell are weak bonded portions which can be peeled off due to a swelling force of the superabsorbent polymer particles in the cells adjacent to the bonded portions
Data Source
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AI summary
An absorbent article includes an absorber (50) having a front surface side sheet (51), a back surface side sheet (52) disposed on the back surface side of the front surface side sheet, cells (55) each of which is surrounded by bonded portions (54) of the front surface side sheet (51) and the back surface side sheet (52) and inside each of which the front surface side sheet (51) and the back surface side sheet (52) are not bonded, and particulate materials which include superabsorbent polymer particles (53) and which are contained in each of the cells (55). The bonded portions (54) are arranged in continuous line shapes or dotted line shapes so as to form same-sized regular hexagons, which connect each other as unit shapes to be a honeycomb shape. All the cells (55) are the same-sized regular hexagonal cells (55) each of which is surrounded by the bonded portions (54). The bonded portions (54) positioned on at least one side of each cell (55) are weak bonded portions (54b) which can be peeled off due to swelling of the superabsorbent polymer particles (53) in the cells (55) adjacent to the bonded portions (54). [Representative Drawing] Fig. 7