Porous Absorbent Structure With SAP-Coated Particle Network
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Solution Overview
Problem
There is a need for absorbent articles that are both effective and easily manufacturable in all regions, with sufficient absorbency and integrity to meet global hygiene needs, while traditional methods are complex and costly, and existing alternatives lack sufficient absorbency.
Innovation Solution
A method of forming a porous absorbent structure by mixing an aqueous superabsorbent polymer material with absorbent particles at specific ratios, spraying the mixture onto a form, and drying to induce cross-linking, using sodium polyacrylate as the superabsorbent polymer and various absorbent particles like cellulose and flours, to create a network that enhances absorbency and integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional disposable absorbent articles are manufactured using complex multi-layer structures (topsheet, backsheet, absorbent core), then absorbency and functionality are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The invention combines superabsorbent polymer particles with natural fiber materials (cotton, cellulose, wood pulp) to create a composite absorbent structure. This composite approach achieves high absorbency through the superabsorbent polymer while the natural fibers provide structural integrity and fluid distribution, eliminating the need for complex multi-layer synthetic structures.
Solution Approach 2:
The invention changes the physical and chemical parameters of the absorbent material by using superabsorbent polymers with specific grafting ratios (5-50% by weight) and crosslinking densities. These parameter optimizations enable high absorbency with simpler structures, as the superabsorbent polymer particles can absorb hundreds of times their weight in fluid while maintaining structural stability.
2Reliability
If absorbent articles are manufactured using traditional methods, then product integrity and absorbent capacity are improved, but ease of manufacture and global accessibility worsen
Solution Approach 1:
The invention segments the absorbent article into distinct functional components: superabsorbent polymer particles for fluid absorption, natural fiber matrix for structural support, and optional elastic components for fit. This segmentation allows each component to be optimized independently and manufactured using simpler, more accessible processes in various global locations.
Solution Approach 2:
The invention embraces the disposable nature of absorbent articles by using cost-effective natural fibers and superabsorbent polymers that can be manufactured locally. The design prioritizes ease of manufacture and local material availability over durability, allowing simple production processes that can be implemented in diverse global manufacturing environments.
3Reliability
If superabsorbent polymer material is used to enhance absorbency, then absorbency is improved, but viscosity increases making spraying difficult
Solution Approach 1:
The invention carefully controls the viscosity parameters of the superabsorbent polymer slurry by adjusting polymer concentration, particle size distribution, and slurry composition. By maintaining viscosity within the range of 50-500 Pa·s, the formulation achieves optimal balance between absorbency (requiring high polymer content) and sprayability (requiring lower viscosity).
Solution Approach 2:
The invention applies different quality characteristics to different aspects of the superabsorbent polymer material: high polymer concentration and crosslinking density for absorbency in the dried applied layer, but controlled particle size and slurry composition for low viscosity and good sprayability during application. This local quality differentiation resolves the contradiction between absorbency and ease of manufacture.
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 high absorbency, integrity, and flexibility, with a Peak Stretch of at least 10% and Peak Energy of at least 150 g/cm, suitable for use in various absorbent products, including personal care and medical applications.
Implementation Method 1
porous absorbent structure conforming to the shape of the form
Implementation Method 2
superabsorbent polymer material
Implementation Method 3
drying the mixture to induce cross-linking in the superabsorbent polymer material
Implementation Method 4
spraying the mixture of superabsorbent polymer material and absorbent particles onto a form
Data Source
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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.