Super Absorbent Polymer Non-Woven Fabric via Solution Blowing
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Solution Overview
Problem
Current super absorbent polymer technologies face limitations in productivity and permeability due to the inability to produce fibers with diameters greater than 10 μm, leading to restricted applications and potential skin issues from amine-based monomers, along with increased residual monomers from short polymerization times.
Innovation Solution
A super absorbent polymer non-woven fabric is developed using a solution blown process to create long fibers with diameters over 10 μm and a length of 0.1 m or more, incorporating a cross-linking agent with a glass transition temperature of 25°C or lower, and a polymerization initiator for enhanced flexibility and absorption rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If centrifugal spinning is used to manufacture super absorbent polymer fibers, then the fiber production process is simplified, but the fiber diameter is limited to 10 μm or less, reducing productivity and permeability
Solution Approach 1:
The patent changes the manufacturing parameters by switching from centrifugal spinning to solution blowing process, and adjusts the monomer composition ratios, polymerization conditions, and processing parameters to enable production of fibers with diameter greater than 10 μm while maintaining manufacturability
2Reliability
If amine-based monomers are used for amide cross-linking to enhance absorption, then absorption capacity is improved, but skin side effects and malodor problems occur
Solution Approach 1:
The patent converts the harmful amine-based monomers into beneficial alternatives by using carboxylic acid-based monomers that form amide cross-links through different mechanisms, achieving similar absorption capacity without the harmful skin side effects and malodor associated with amine-based monomers
Solution Approach 2:
The patent changes the chemical composition parameters by replacing amine-based monomers with carboxylic acid-based monomers, and adjusts the cross-linking mechanism and monomer ratios to maintain absorption performance while eliminating harmful effects
3Productivity
If ultraviolet irradiation is used for polymerization during monomer composition falling, then polymerization occurs, but the polymerization time is very short, increasing residual monomers and lowering permeability and absorption rate
Solution Approach 1:
The patent applies preliminary action by pre-dissolving monomers in appropriate solvents and pre-preparing polymerization systems with optimized initiators and conditions before the actual polymerization, enabling controlled and complete polymerization during the forming process without time constraints
Solution Approach 2:
The patent changes the polymerization parameters by adjusting initiator types and concentrations, monomer concentrations, temperature, and other conditions to achieve complete polymerization within the forming time, reducing residual monomers while maintaining productivity
4Ease of manufacture
If super absorbent polymer is manufactured as powder, then the material is easily produced, but it must be scattered or leaked during manufacturing and use, limiting its application range
Solution Approach 1:
The patent applies segmentation by transforming the bulk powder form into individual fibers through solution blowing process, creating a non-woven fabric structure that maintains ease of manufacture while enabling direct application without scattering or leakage, thus expanding application range
Solution Approach 2:
The patent changes the physical form parameter from powder to fiber, and adjusts the manufacturing process parameters to produce a non-woven fabric that combines manufacturing simplicity with enhanced adaptability and versatility in various applications
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 non-woven fabric exhibits high flexibility and fast absorption rates, suitable for various applications, including hygiene products and waterproofing, while maintaining high productivity and reducing residual monomers and skin issues.
Implementation Method 1
mixing the first aqueous polymer solution with a cross-linking agent having a glass transition temperature (Tg) of room temperature (25° C.) or lower to prepare a second aqueous polymer solution
Implementation Method 2
preparing a first aqueous polymer solution containing a hydrogel polymer by polymerizing an aqueous monomer solution containing an acrylic acid-based monomer having at least partially neutralized acidic groups, a comonomer having a glass transition temperature (Tg) of room temperature (25° C.) or lower, and a polymerization initiator
Implementation Method 3
spinning the second aqueous polymer solution by a solution blown process
Implementation Method 4
A super absorbent polymer (SAP) is a type of synthetic polymeric material capable of absorbing 500 to 1000 times its own weight of moisture
Data Source
AI summary
The present disclosure relates to a preparation method of a super absorbent polymer non-woven fabric and super absorbent polymer fibers prepared therefrom. According to the preparation method of the present disclosure, it is possible to provide super absorbent polymer fibers exhibiting high flexibility and fast absorption rate in the form of long fibers.