Profiled Aliphatic Polyurethane Foam for Absorbency and Air Flow
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Solution Overview
Problem
Existing absorbent articles face challenges in achieving a balance between absorbency and comfort, with traditional foam pads causing pressure points and inadequate air circulation, and the manufacturing process is inefficient and costly.
Innovation Solution
The development of profiled absorbent aliphatic polyurethane foam products with indented and raised portions, allowing for enhanced fluid distribution and air flow, produced through an in-line profiling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional foam pads are used for absorbency, then fluid absorption is achieved, but pressure points form and air circulation is blocked
Solution Approach 1:
The foam product incorporates regions of varying density within the same structure - high density regions for fluid absorption and low density regions for air circulation and comfort. This local variation in material properties resolves the contradiction by allowing different areas to perform different functions simultaneously.
Solution Approach 2:
The foam is divided into distinct high density and low density regions, creating a segmented structure where each segment serves a specific function. The high density segments provide absorbency while the low density segments maintain air flow and reduce pressure points.
2Shape
If foam is contoured, shaped or embossed after production line release, then profiled surfaces are achieved, but production time and cost increase
Solution Approach 1:
The foam product is shaped and contoured during the foaming process itself, before the foam fully cures and solidifies. This preliminary shaping action eliminates the need for subsequent contouring operations, reducing production time and cost while achieving the desired profiled surface.
Solution Approach 2:
The shaping and foaming operations are merged into a single integrated process. The profiled surface is created as part of the foam formation process rather than as a separate post-processing step, combining multiple functions into one operation.
3Quantity of substance
If high density foam is used throughout, then fluid absorption capacity increases, but air circulation and comfort decrease
Solution Approach 1:
Different regions of the foam have different density characteristics - high density regions for absorption and low density regions for air circulation. This local differentiation allows the foam to simultaneously provide both fluid absorption capacity and breathability for wearer comfort.
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 profiled foam provides improved comfort by distributing fluid evenly and enhancing air flow, while being produced efficiently and cost-effectively.
Implementation Method 1
the present inventors have found that profiled absorbent foams and foam products, in particular aliphatic foams and foam products, exhibit an advantageous capillary motor effect during the absorption of fluid
Data Source
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AI summary
The present invention relates to foam. In particular, the present invention relates to profiled foams and processes for profiling absorbent foam products. More particularly, the present invention relates to processes for producing a profiled absorbent polyurethane foam product, comprising the steps of foaming, curing, profiling and drying, wherein profiling occurs before drying; and absorbent aliphatic polyurethane foam products having at least one profiled surface.