Porous Absorbent Structure Using SAP-Coated Particle Networks
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Solution Overview
Problem
There is a need for absorbent articles that are both effective and easily manufactured in all regions, as traditional methods are costly and require complex manufacturing processes, and existing alternatives lack sufficient absorbency and integrity.
Innovation Solution
A porous absorbent structure formed by mixing superabsorbent polymer material with absorbent particles, where the ratio of superabsorbent polymer to absorbent particles is optimized, and the mixture is sprayed onto a form to create a structure that can be dried and used as an absorbent article, with the superabsorbent polymer coating and connecting the particles into a network for enhanced absorbency and integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional disposable absorbent articles are manufactured using complex manufacturing processes, then absorbency and integrity are improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent combines superabsorbent polymer particles with conventional absorbent particles (such as cellulose or starch) to create a composite absorbent core. This composite structure leverages the high absorbency of superabsorbent polymers while using cost-effective conventional materials for bulk absorption, achieving both high performance and manufacturing simplicity
Solution Approach 2:
The patent optimizes parameters such as the ratio of superabsorbent polymer to conventional absorbent material, particle size distribution, and cross-linking degree to achieve maximum absorbency with minimal manufacturing complexity. By carefully controlling these parameters, the patent achieves high reliability without requiring complex manufacturing processes
2Quantity of substance
If traditional disposable absorbent articles are manufactured with multiple layers and components, then absorbent capacity and integrity are improved, but manufacturing cost increases
Solution Approach 1:
The patent merges the functions of multiple traditional layers (topsheet, absorbent core, backsheets) into a single integrated porous structure. This monolithic structure maintains all necessary absorbent functions while eliminating the need for separate manufacturing and assembly of multiple components, thereby reducing manufacturing cost while preserving absorbent capacity
Solution Approach 2:
The patent uses composite materials that provide both structural integrity and absorbent capacity within a single layer, eliminating the need for multiple separate layers. The composite formulation includes superabsorbent polymers combined with conventional absorbents, creating a material that simultaneously provides structural support and high absorbency
3Ease of manufacture
If absorbent articles are made with simpler manufacturing processes, then ease of manufacture is improved, but absorbency and integrity deteriorate
Solution Approach 1:
The patent employs a porous polymer network that forms a flexible yet structurally sound matrix. This network structure provides mechanical integrity while allowing simple manufacturing processes, as the porous structure can be formed through straightforward techniques such as spray application or dip-coating followed by drying
Solution Approach 2:
The composite material formulation includes superabsorbent polymers cross-linked to form a robust three-dimensional network that maintains structural integrity. This network structure provides mechanical strength and shape retention even when manufactured using simple processes, ensuring reliability without requiring complex manufacturing
4Reliability
If superabsorbent polymer material is used to form porous absorbent structure, then absorbency is improved, but viscosity control becomes critical for spray application
Solution Approach 1:
The patent carefully controls the viscosity of the superabsorbent polymer solution by adjusting parameters such as polymer concentration, molecular weight, and solvent composition. This optimization ensures the solution has the appropriate flow characteristics for spray application while maintaining high absorbency in the final product
Solution Approach 2:
The patent applies the superabsorbent polymer solution in a controlled manner, ensuring uniform distribution and appropriate thickness during spray application. This local control of application quality ensures consistent absorbency performance while managing viscosity 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
The resulting porous absorbent structure demonstrates improved absorbency, integrity, and flexibility, capable of maintaining shape and attachment, making it suitable for various applications including personal care and medical uses, while being cost-effective and easily manufactured.
Implementation Method 1
The superabsorbent polymer material substantially coats the absorbent particles and connects the absorbent particles into a porous absorbent network
Implementation Method 2
superabsorbent polymer material having a viscosity of less than about 10,000 cps
Implementation Method 3
The mixture is sprayed onto a form, and the mixture is dried to produce a porous absorbent structure substantially conforming to the shape of the form
Data Source
AI summary
A porous absorbent structure is disclosed which includes absorbent particles and a superabsorbent polymer material having less than about 1000 parts per million residual monoethylenically unsaturated monomer, the superabsorbent polymer material substantially coating the absorbent particles and connecting the particles into a porous network to form the porous absorbent structure.