Never-Dried Kraft Pulp Sheet for SAP Retention
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Solution Overview
Problem
Existing absorbent products face issues such as dust generation during manufacturing, SAP loss and migration, poor strength when wet, and the need for improved performance to meet evolving consumer demands.
Innovation Solution
A wet-laid cellulose pulp sheet formed from never-dried kraft pulp and fibrillatable fibers, with a specific composition and processing method that includes no binders, fillers, or surfactants, to create a porous sheet with improved dry and wet integrity when combined with superabsorbent polymers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If conventional dried pulp is used in absorbent product manufacturing, then material handling and storage are easier, but dust generation increases and SAP retention deteriorates
Solution Approach 1:
The patent changes the moisture content parameter of the pulp from dried state to never-dried state (wet pulp), which fundamentally alters the physical properties. This parameter change reduces dust generation during handling while improving SAP retention through enhanced fiber flexibility and bonding characteristics in the wet state
Solution Approach 2:
The patent creates a composite system by combining never-dried pulp with fibrillatable fibers and SAP particles. This composite approach leverages the unique properties of each component: the never-dried pulp provides dust-free handling and SAP retention, while the fibrillatable fibers enhance structural integrity and wicking properties
2Strength
If binders and fillers are added to improve product strength, then structural integrity improves, but product purity and simplicity deteriorate
Solution Approach 1:
The never-dried pulp and fibrillatable fibers inherently provide structural strength through their natural fiber-to-fiber bonding in the wet state, eliminating the need for external binders. The fibrillation process creates mechanical interlocking that strengthens the product without adding chemical substances
Solution Approach 2:
By maintaining the pulp in a never-dried state and controlling the fibrillation degree, the patent achieves optimal fiber bonding and structural strength without requiring fillers or binders. The physical state parameters of the fibers themselves provide the necessary mechanical properties
3Ease of manufacture
If conventional fiberization processes are used, then material processing is simpler, but material loss and dust hazards increase
Solution Approach 1:
The patent performs fibrillation of selected fibers before the main fiberization process. This preliminary action creates fibrillatable fibers that bond more effectively during subsequent processing, reducing material loss and improving SAP retention without complicating the overall manufacturing flow
Solution Approach 2:
The combination of never-dried pulp with specifically prepared fibrillatable fibers creates a composite system that processes efficiently while minimizing dust and material loss. The fibrillatable fibers act as binding agents during processing, reducing particulate loss
4Ease of manufacture
If SAP is loosely incorporated into the product, then manufacturing is easier, but SAP migration and product performance deteriorate
Solution Approach 1:
The patent merges SAP particles with never-dried pulp and fibrillatable fibers into a integrated composite structure. The SAP is not merely mixed but combined with the fibrillated fiber network, creating a unified structure where SAP particles are mechanically interlocked within the fiber matrix
Solution Approach 2:
The creation of a composite material system where SAP, never-dried pulp, and fibrillatable fibers form an integrated structure prevents SAP migration while maintaining manufacturing feasibility. The composite nature provides both ease of processing and reliable SAP retention
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 pulp sheet enhances the retention of superabsorbent polymers and improves the structural stability and wicking rate of absorbent products, reducing dust generation and maintaining integrity under wet conditions, as demonstrated by improved performance in rotap and hang tests.
Implementation Method 1
fibrillatable fibers
Implementation Method 2
porous sheet with improved dry and wet integrity
Data Source
AI summary
A cellulose pulp sheet is provided that is formed from never-dried kraft pulp and fibrillated fibers, such as lyocell. The pulp sheet provides several beneficial features as a result of both the use of fibrillated fibers and never-dried kraft pulp, particularly when the pulp sheet is used to form air-laid absorbent materials that include superabsorbent polymers.