Thin Absorbent Core Structure With PET Yarn for Faster Liquid Flow
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Solution Overview
Problem
Conventional absorbent cores in disposable diapers rely on cellulose pulp, which is bulky and does not align with the trend towards super-thin diapers, lacking in liquid permeability and mobility.
Innovation Solution
A cross non-circular cross section yarn made from polyethylene terephthalate (PET) combined with particles having specific surface area and porosity, and a super absorbent polymer is used to create an absorbent core that enhances liquid permeability and hydrophobicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional cellulose pulp is used in absorbent core, then absorption capacity is maintained, but thickness and weight increase
Solution Approach 1:
The patent changes the physical and chemical parameters of the absorbent core by incorporating particles with specific surface area (50-500 m²/g) and using cross-noncircular cross-section yarns with controlled fineness (1-5 denier). These parameter changes enable reduced thickness while maintaining absorption capacity through enhanced surface area to volume ratio and improved liquid distribution
Solution Approach 2:
The patent creates a composite absorbent core structure combining cross-noncircular cross-section yarns made from polyethylene terephthalate with dispersed particles having high specific surface area. This composite approach allows the synergistic effect of the yarn structure and particle properties to achieve thin profile with adequate absorption performance
2Quantity of substance
If conventional cellulose pulp is used in absorbent core, then absorption function is provided, but liquid permeability and mobility are insufficient
Solution Approach 1:
The patent employs cross-noncircular cross-section yarns instead of conventional circular or random fiber structures. The asymmetric cross-sectional shape creates preferential liquid flow paths and improves liquid distribution across the absorbent core, thereby enhancing liquid permeability and mobility while maintaining absorption function
Solution Approach 2:
The patent utilizes particles with high specific surface area and controlled porosity characteristics. These porous particles create interconnected void spaces that facilitate rapid liquid penetration and mobility through the absorbent core while providing sufficient absorption capacity
3Speed
If particles with high specific surface area are introduced into PET yarn, then liquid permeability improves, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates particles with high specific surface area into the polyethylene terephthalate yarn during the yarn manufacturing process itself, rather than adding them later during absorbent core assembly. This preliminary action integrates the complex step into the existing yarn production line, minimizing additional manufacturing complexity while achieving improved liquid permeability
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 absorbent core achieves improved liquid permeability and mobility, enabling the production of a super-thin absorbent product with performance equivalent to or better than existing cellulose pulp, while reducing weight and thickness.
Implementation Method 1
a cross non-circular cross section yarn made from polyethylene terephthalate (PET) combined with particles having specific surface area and porosity
Implementation Method 2
the absorbent core is typically composed of a fluff pulp and a super absorbent polymer as a liquid absorbent material
Data Source
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AI summary
The present invention relates to an absorbent core of an absorbent product including a liquid-permeable top sheet, an absorbent dispersion layer disposed at a lower portion of the top sheet, an absorbent core disposed at a lower portion of the absorbent dispersion layer and absorbing and retaining liquids, and a liquid-impermeable back sheet disposed at a lower portion of the absorbent core, and the absorbent core has effects of having the convenience of storage and the activity when an absorbent product prepared therefrom is worn by a user and improving liquid permeability compared to an existing absorbent core.