Spunlace Nonwoven Absorbent Laminates for Liquid Distribution
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Solution Overview
Problem
Conventional absorbent cores with superabsorbent materials face challenges in liquid acquisition and distribution, leading to localized liquid transport and gel blocking, which can result in leakage.
Innovation Solution
A multi-layer absorbent laminate comprising a first and second laminate layer made of tissue or nonwoven, with an intermediate layer containing greater than 90% superabsorbent polymer, folded to form a longitudinally folded absorbent core with a central channel, enhancing liquid distribution and absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If superabsorbent materials are used in increasing amounts to thin out absorbent cores, then core thickness is reduced and fit to wearer is improved, but liquid acquisition and distribution capability deteriorates due to gel blocking
Solution Approach 1:
The absorbent core is divided into multiple functional layers: an acquisition layer with lower SAP content (0-60% by weight) for rapid liquid uptake and distribution, and a retention layer with higher SAP content (60-90% by weight) for liquid retention. This segmentation prevents gel blocking in the acquisition zone while maintaining thin overall profile.
Solution Approach 2:
Different regions of the absorbent core have different material compositions optimized for their specific functions. The acquisition layer uses a fibrous matrix with dispersed SAP particles to maintain porosity and enable rapid liquid transport, while the retention layer uses high SAP content for maximum absorption capacity. This local differentiation resolves the contradiction between thin profile and liquid distribution capability.
2Quantity of substance
If superabsorbent material is increased to improve liquid retention, then liquid retention capability is improved, but liquid transport is blocked due to gel formation
Solution Approach 1:
The core is segmented into acquisition and retention zones with different SAP concentrations. The acquisition layer maintains low SAP content (0-60%) to prevent gel blocking and enable rapid liquid transport, while the retention layer uses high SAP content (60-90%) for maximum liquid retention. This spatial segmentation allows both high retention and efficient transport without gel blocking interference.
Solution Approach 2:
The acquisition layer acts as an intermediary between the liquid insult and the retention layer. It rapidly acquires and distributes liquid through its fibrous matrix structure, preventing direct contact between large volumes of liquid and the high-SAP retention layer, thereby avoiding gel blocking while ensuring efficient liquid delivery to the retention zone.
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 improves liquid acquisition and distribution, reduces gel blocking, and provides a softer tactile feel while maintaining effective liquid retention, minimizing leakage.
Implementation Method 1
a spunlace nonwoven layer... enhancing liquid distribution and absorption
Implementation Method 2
an intermediate absorbent layer... comprising adhesive and greater than about 90 percent by weight super absorbent polymer
Implementation Method 3
superabsorbent materials... as it absorbs and retains liquid
Data Source
Figure 1A~1C
Figure 2~3
Figure 4~5B
AI summary
Absorbent laminates and folded multi-layer absorbent cores including one or more of the present absorbent laminates. The present absorbent laminates comprise an absorbent layer between two laminate layers, at least one of which absorbent laminates including a spunlace nonwoven. Some of the present multi-layer absorbent cores are folded to define a channel running longitudinally along the core to enhance liquid distribution and absorption.