Super Absorbent Polymer with Encapsulated Foaming Agent
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Solution Overview
Problem
Current super absorbent polymers face challenges in achieving excellent initial absorption capacity, particularly in sanitary materials like diapers and sanitary napkins, due to limitations in surface area and production methods such as suspension polymerization's use of organic solvents and solution polymerization's production of amorphous particles with small surface areas.
Innovation Solution
A super absorbent polymer is developed with a cross-linked polymer powder and a surface cross-linked layer, using an encapsulated foaming agent with a core-shell structure to create polymer particles with large pores, enhancing the surface area and initial absorption capacity, achieved through crosslinking polymerization, drying, pulverizing, and classifying the hydrogel polymer, followed by surface cross-linking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If suspension polymerization is used to produce super absorbent polymer with large surface area, then initial absorption capacity is improved, but production cost increases due to organic solvent recycling
Solution Approach 1:
The patent extracts and removes the organic solvent from the polymerization system by using water as the continuous phase and encapsulated foaming agents instead of traditional organic solvent-based suspension polymerization, thereby eliminating recycling costs while maintaining particle morphology
Solution Approach 2:
The patent incorporates encapsulated foaming agents that create porous structures within the polymer particles during polymerization, resulting in high surface area particles with improved initial absorption capacity without requiring organic solvents
2Ease of manufacture
If solution polymerization is used to produce super absorbent polymer economically, then production cost is reduced, but surface area decreases due to amorphous particle formation
Solution Approach 1:
The patent uses encapsulated foaming agents during solution polymerization to create porous structures within the polymer particles, transforming the normally amorphous dense particles into porous particles with high surface area, thus resolving the contradiction between economic production and surface area
Solution Approach 2:
The patent changes the physical state and structure of the polymer particles by controlling the polymerization conditions and using foaming agents, transforming the particle morphology from amorphous dense structure to porous structure with enhanced surface area
3Manufacturing precision
If conventional foaming agents are used in solution polymerization, then surface area is increased, but initial absorption capacity remains insufficient
Solution Approach 1:
The patent uses encapsulated foaming agents as intermediaries that provide controlled foam generation during polymerization, creating optimal pore structures that enhance both surface area and initial absorption capacity, unlike conventional foaming agents that fail to provide sufficient absorption performance
Solution Approach 2:
The patent creates a composite structure by encapsulating foaming agents within the polymer matrix, forming a composite material with optimized pore distribution and structure that simultaneously achieves high surface area and excellent initial absorption capacity
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 super absorbent polymer exhibits a large specific surface area and excellent initial absorption capacity, enabling quick absorption of body fluids and a dry, soft touch feeling in sanitary materials, while also addressing production cost and efficiency issues.
Implementation Method 1
using an encapsulated foaming agent with a core-shell structure to create polymer particles with large pores
Implementation Method 2
a distilled water absorption capacity is at least 150 g/g
Data Source
AI summary
The present invention relates to a super absorbent polymer. The super absorbent polymer contains polymer particles formed of large pores in a certain amount or more, and thus can exhibit large surface area and excellent initial absorption capacity. Therefore, when the super absorbent polymer is used, it can provide a sanitary material such as a diaper or a sanitary napkin which can quickly absorb body fluids and impart a dry and soft touch feeling.