Thin Fluid Absorbent Core With Optimized Superabsorbent Polymer
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Solution Overview
Problem
Existing fluid-absorbent products, such as disposable diapers, face challenges with gel blocking, reduced fiber content leading to deformation, and inadequate fluid acquisition and rewet performance, especially when trying to maintain thin profiles.
Innovation Solution
A fluid-absorbent core comprising at least one absorption layer with 80% by weight of water-absorbent polymer particles, 0-10% by weight of adhesive, and 0-10% by weight of fibrous material, where the water-absorbent polymer particles have a vortex of 40 s or less, roundness of 0.79 to 0.85, and a CRC of 38 g/g to 85 g/g, and are surface post-crosslinked.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the proportion of cellulose fibers in the water-absorbing storage layer is lowered to produce thin disposable diapers, then the thickness is reduced, but the shape retaining ability and structural integrity deteriorate
Solution Approach 1:
The patent changes the physical and chemical parameters of the superabsorbent polymer particles, specifically controlling their size distribution (D10, D50, D90 values), roundness (0.70-0.85), and surface properties through surface post-crosslinking. These parameter changes enable the particles to maintain structural integrity and shape retention in thin profiles without relying on high fiber content.
2Length of stationary object
If the proportion of cellulose fibers is reduced or eliminated, then the thickness is reduced, but gel blocking occurs and fluid permeation is blocked
Solution Approach 1:
The patent modifies the gel structure by controlling the swelling properties of superabsorbent polymer particles through surface post-crosslinking and optimizing particle size distribution. This creates a controlled gel structure that allows fluid permeation while maintaining high absorption capacity, preventing gel blocking in thin profiles.
Solution Approach 2:
The patent creates a composite structure combining superabsorbent polymer particles with minimal fibrous material (0-10% cellulose fibers or other fibers) and adhesive binders. This composite approach enables thin profile construction while maintaining structural integrity and preventing gel blocking through the synergistic combination of materials.
3Length of stationary object
If the proportion of cellulose fibers is reduced, then the thickness is reduced, but the ability to fix water-absorbent polymer particles deteriorates
Solution Approach 1:
The patent optimizes the particle size parameters (D10, D50, D90) and roundness of superabsorbent polymer particles to enhance their interlocking and fixation properties. The controlled size distribution and spherical shape improve particle packing and mechanical interlocking, enabling effective fixation with minimal fibrous material.
Solution Approach 2:
The patent employs adhesive binders in combination with minimal fibrous material to create a composite matrix that effectively fixes superabsorbent polymer particles. This composite approach provides sufficient structural support and particle fixation in thin profiles without requiring high fiber content.
4Reliability
If thicker acquisition-distribution layers are used to prevent leakage, then fluid acquisition and rewet performance improve, but the thickness increases
Solution Approach 1:
The patent enhances the performance of individual superabsorbent polymer particles through surface post-crosslinking and optimized size distribution, enabling each particle to contribute more effectively to fluid acquisition and leakage prevention. This high particle efficiency allows thin profile construction while maintaining reliable leakage protection.
Solution Approach 2:
The patent creates an optimized composite structure with superabsorbent polymer particles, minimal fibrous material, and adhesive binders that work synergistically to provide effective fluid acquisition and leakage prevention in a thin configuration, eliminating the need for thick acquisition-distribution layers.
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 prevents gel blocking, enhances fluid storage capacity to prevent leakage, improves rewet performance, and maintains fast surface dryness and long-time dryness, even with minimal fibrous material.
Implementation Method 1
a flexible, vapor permeable and fluid-absorbent core, showing fast absorption rates and being able to retain quantities of body fluids
Implementation Method 2
water-absorbent polymer particles H having a vortex of 40 s or less and having a roundness of 0.79 to 0.85 and/or a CRC of 38 g/g to 85 g/g
Implementation Method 3
vapor permeability without wetting through for the lower liquid-impervious layer
Implementation Method 4
the layer comprising at least 80% by weight of water-absorbent polymer particles, 0 to 10% by weight of an adhesive and from 0 to 10% by weight of fibrous material
Data Source
AI summary
The present disclosure relates to fluid absorbent cores including at least one absorption layer, the layer including at least 80% by weight of water-absorbent polymer particles, 0 to 10% by weight of an adhesive and from 0 to 10% by weight of fibrous material, wherein the water-absorbent polymer particles within the absorption layer are water-absorbent polymer particles having a vortex of 40 s or less and having a roundness of 0.79 to 0.85 and/or a CRC of 38 g/g to 85 g/g.