Stretchable Absorbent Composite with Porous Foam Matrix
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Solution Overview
Problem
Conventional absorbent composites are not stretchable, which hinders their ability to manage liquid effectively due to low liquid intake rates and poor liquid distribution, leading to issues with high-speed, high-pressure liquid insults pooling or running off before absorption can occur.
Innovation Solution
The development of absorbent composites with a combination of high stretchability and permeability, achieved by incorporating suitable superabsorbent materials, elastomeric materials, and pulp fibers in optimized ratios, allowing for improved liquid handling capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If elastomeric materials are added to absorbent composites to achieve stretchability, then the fit and containment are improved, but the liquid intake rate and permeability are reduced due to reduced inter-particle void volume
Solution Approach 1:
The patent utilizes a porous foam matrix as the base structure of the absorbent composite. This foam matrix provides inherent porosity and inter-particle void volume that maintains liquid permeability even when elastomeric materials are added for stretchability. The porous structure allows liquid to flow through while the elastomeric components provide the necessary elastic recovery and fit.
Solution Approach 2:
The patent creates a composite material system combining foam matrix, elastomeric materials, and superabsorbent particles. This composite approach allows each component to contribute its strengths: the foam provides structural porosity, the elastomeric materials provide stretchability and recovery, and the superabsorbent particles provide liquid absorption capacity. The synergistic combination resolves the contradiction between stretchability and liquid intake rate.
2Adaptability or versatility
If elastomeric materials are incorporated into absorbent composites, then the retraction force and fit are enhanced, but the wettability and liquid distribution are poor
Solution Approach 1:
The porous foam matrix serves as a hydrophilic network that facilitates liquid distribution throughout the composite. The interconnected pores of the foam structure guide liquid flow and ensure wetting of the superabsorbent particles, compensating for the poor wettability of the elastomeric materials. This allows the elastomeric components to provide retraction force without compromising liquid distribution.
Solution Approach 2:
The foam matrix acts as an intermediary between the liquid and the elastomeric materials. It provides a hydrophilic pathway for liquid to reach the superabsorbent particles, mediating the interaction between the liquid and the hydrophobic elastomeric components. This intermediary structure enables liquid distribution while allowing the elastomeric materials to maintain their retraction properties.
3Ease of manufacture
If conventional absorbent composites are used, then the manufacturing is simple, but the liquid handling ability is insufficient for high-speed, high-pressure liquid insults
Solution Approach 1:
The patent employs a composite material system combining foam matrix, elastomeric materials, and superabsorbent particles in specific ratios. This composite structure maintains manufacturing feasibility while significantly enhancing liquid handling ability. The foam matrix provides a pre-formed porous structure that facilitates liquid flow, the elastomeric materials provide stretchability for better fit, and the superabsorbent particles ensure rapid absorption of high-speed, high-pressure liquid insults.
Solution Approach 2:
The patent optimizes the ratios of foam matrix, elastomeric materials, and superabsorbent particles to achieve the desired balance between manufacturing simplicity and liquid handling ability. By controlling the composition parameters and processing conditions, the patent enables the production of composites with enhanced liquid intake rates and permeability while maintaining manufacturability through established foam and composite processing techniques.
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 absorbent composites demonstrate enhanced stretchability and permeability, enabling effective liquid management and improved fit and comfort in absorbent articles by maintaining liquid absorption efficiency even under pressure.
Implementation Method 1
the relatively large resistant force or retraction force of elastic matrices leads to low liquid intake rates/permeability due to significant reduction of inter-particle void volume
Implementation Method 2
suitable superabsorbent materials, elastomeric materials, and, optionally, pulp fibers are selected and combined in optimum ratios
Implementation Method 3
the relatively large resistant force or retraction force of elastic matrices leads to low liquid intake rates/permeability
Data Source
AI summary
A stretchable absorbent composite having a Composite Permeability of about 10 Darcy or more, or about 15 Darcy or more, and Composite Stretchability of about 30% or more, or about 50% or more, or about 100% or more, and a method of making such a stretchable absorbent composite. The stretchable absorbent composite includes a superabsorbent material, an elastomeric material, and, optionally, pulp fibers. More particularly, the stretchable absorbent composite may include between about 30% and about 85% by weight superabsorbent material, between about 5% and about 25% by weight elastomeric material, and between about 10% and about 70% by weight pulp fibers. The stretchability and liquid handling abilities of the stretchable absorbent composite renders the stretchable absorbent composite suitable for incorporation into a variety of absorbent articles, including personal care products, health/medical absorbent articles, and household/industrial absorbent articles, for example.