Soft Absorbent Sandwich Web with High SAM Concentration
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Solution Overview
Problem
Current absorbent structures with high concentrations of superabsorbent materials (SAM) face challenges in achieving both high absorbency and good tactile properties, while also requiring complex manufacturing processes and limited liquid distribution capabilities.
Innovation Solution
A liquid absorbent sandwich web composition featuring 70-90% SAM, 5-25% interspersed cellulosic fibers, and 1-5% self-crosslinking latex binder, with a manufacturing process involving compaction and thermal treatment to form a particle matrix and induce crosslinking, enhancing absorbency and mechanical strength while maintaining softness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If high concentrations of superabsorbent material (SAM) are used to increase absorbency, then the absorbency is improved, but the tactile properties and softness deteriorate
Solution Approach 1:
The patent uses a composite structure combining cellulosic fibers (5-25%) with superabsorbent material (70-90%) to create a material that maintains softness while achieving high absorbency. The cellulosic fibers act as a soft matrix that distributes the SAM particles, preventing the harsh tactile sensation associated with high SAM concentrations alone.
Solution Approach 2:
The patent applies binder material selectively at specific locations and concentrations to immobilize SAM particles only where necessary, rather than uniformly throughout the entire structure. This localized binding approach maintains softness in non-critical areas while providing particle stability where needed.
2Quantity of substance
If high concentrations of superabsorbent material (SAM) are used to increase absorbency, then the absorbency is improved, but the liquid distribution capability deteriorates
Solution Approach 1:
The patent creates regions with different SAM concentrations and fiber distributions to optimize both absorption and distribution. The cellulosic fibers provide channels for liquid distribution while the SAM particles provide absorption capacity, with each component performing its optimal function in specific local zones.
Solution Approach 2:
The patent divides the absorbent structure into functional zones where SAM particles are distributed among cellulosic fibers, creating a segmented architecture that facilitates liquid distribution pathways while maintaining high absorption capacity in specific regions.
3Quantity of substance
If high concentrations of superabsorbent material (SAM) are used to increase absorbency, then the absorbency is improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent employs a self-crosslinking binder that automatically forms crosslinks under processing conditions without requiring additional chemical treatments or complex manufacturing steps. The binder material self-assembles and crosslinks during the normal web formation and drying process, eliminating the need for separate bonding operations.
Solution Approach 2:
The patent utilizes changes in processing parameters (temperature, moisture content) to trigger crosslinking of the binder material, allowing the manufacturing process to proceed using standard equipment and conditions. The crosslinking occurs automatically as the web passes through the dryer section, converting the binder from a liquid state to a crosslinked gel state without additional processing steps.
4Quantity of substance
If high concentrations of superabsorbent material (SAM) are used to increase absorbency, then the absorbency is improved, but the mechanical strength deteriorates
Solution Approach 1:
The patent creates a composite structure where cellulosic fibers form a mechanical framework that provides tensile strength and structural integrity, while SAM particles are distributed within this framework to provide absorbency. The composite architecture allows each component to contribute its primary function without compromising the other.
Solution Approach 2:
The binder material acts as an intermediary that bonds SAM particles to the cellulosic fiber matrix, creating a unified structure where the fibers provide mechanical strength and the binder ensures particle immobilization. This intermediary bonding mechanism allows high SAM concentrations to be incorporated while maintaining mechanical integrity through the fiber-binder-particle network.
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 solution achieves high absorbency with improved liquid handling and mechanical strength, maintaining softness and immobilizing SAM particles effectively in both dry and wet states, suitable for high SAM concentrations beyond 70%.
Implementation Method 1
a self-crosslinking latex binder
Implementation Method 2
The binder material comprises a self-crosslinking latex binder
Implementation Method 3
self-crosslinking latex binder
Implementation Method 4
thermal treatment to form a particle matrix and induce crosslinking
Implementation Method 5
compaction and thermal treatment to form a particle matrix
Implementation Method 6
70-90% SAM, 5-25% interspersed cellulosic fibers
Data Source
Figure 1
AI summary
The present invention is a liquid absorbent sandwich web as can be used in absorbent products such as in disposable absorbent articles such as diapers, feminine hygiene articles or incontinence devices, and to the manufacturing of such webs. The liquid absorbent sandwich web provides high absorbent capacity without compromising softness.