Superabsorbent Polymer Sheet with Open Pore Channels
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Solution Overview
Problem
Current superabsorbent polymers in powder form are prone to scattering and leakage, and their use in hygiene products is limited by the need for fluff pulp, which is environmentally unfriendly and increases production costs, while existing fiber or non-woven forms do not adequately address absorption performance and flexibility.
Innovation Solution
A method for preparing a superabsorbent polymer sheet involving a monomer composition of acrylic acid-based monomers, poly(ethylene glycol) methyl ether (meth)acrylate, internal and inorganic foaming agents, and a polymerization initiator, which is then thermally or photopolymerized and dried to create a flexible sheet with an open pore channel structure for enhanced absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fluff pulp is used to fix superabsorbent polymer particles, then the shape of absorbent and hygiene products is maintained, but the products become thick and uncomfortable, and production costs increase
Solution Approach 1:
The invention extracts and removes the fluff pulp component from the absorbent structure, replacing it with a continuous superabsorbent polymer matrix that maintains shape without requiring additional bulk materials. This eliminates the need for fluff pulp while achieving the desired product thinness.
Solution Approach 2:
The invention creates a composite material system where superabsorbent polymer particles are embedded in a continuous matrix formed from the same polymer, replacing the traditional fluff pulp-superabsorbent polymer composite. This new composite structure provides both shape maintenance and thinness.
2Quantity of substance
If superabsorbent polymer is used in powder form, then absorption capacity is achieved, but the powder scatters and leaks during preparation and use
Solution Approach 1:
The invention merges the superabsorbent polymer particles with a continuous matrix material, creating an integrated sheet structure. This combination prevents the polymer particles from scattering and leaking while maintaining their absorption capacity, as they are bound within the continuous matrix.
Solution Approach 2:
The invention creates a flexible sheet structure where superabsorbent polymer particles are embedded in a continuous matrix film. This thin film structure prevents powder scattering and leakage while maintaining the absorption capacity of the embedded particles.
3Ease of operation
If fiber or non-woven form is used for superabsorbent polymer, then flexibility is improved, but absorption performance is reduced
Solution Approach 1:
The invention creates a composite material where superabsorbent polymer particles are dispersed in a continuous matrix of the same polymer. This composite structure provides both the flexibility of a film and the high absorption capacity of the superabsorbent polymer particles, resolving the trade-off between flexibility and absorption performance.
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 superabsorbent polymer sheet exhibits high absorption rates, flexibility, and improved permeability, functioning as a pulpless absorbent with connected pores for effective water absorption by capillary pressure, suitable for various applications.
Implementation Method 1
forming a water-containing gel polymer by performing thermal polymerization or photopolymerization of the monomer composition
Implementation Method 2
an encapsulated foaming agent, an inorganic foaming agent having an average particle size of 1 μm to 100 μm
Implementation Method 3
open pore channel structure in which pores are connected to each other, whereby water absorption by a capillary pressure may occur
Data Source
Figure 1
AI summary
A method of preparing a superabsorbent polymer sheet is provided. According to the method of preparing the superabsorbent polymer sheet of the present invention, a porous and flexible superabsorbent polymer sheet may be prepared.