Thin Super Absorbent Polymer Film Without Fluff Pulp
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Solution Overview
Problem
Existing super absorbent polymers require auxiliary substances like fluff pulp for shape retention, leading to thickness limitations, wearability issues, and variable absorption performance, and the powder form is prone to scattering and leakage.
Innovation Solution
A method to produce a film-type super absorbent polymer by mixing an acrylic acid-based monomer with a cellulose-based thickener, moisturizing agent, and polymerization initiator, forming a hydrogel polymer film through heat and/or light irradiation, and drying to create a flexible, thin film without auxiliary substances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If fluff pulp is used as an auxiliary substance to fasten super absorbent polymer particles and maintain shape, then the absorber can maintain its shape and structure, but the thickness of the absorber and hygiene products increases and wearability deteriorates
Solution Approach 1:
The patent merges the super absorbent polymer particles with a film-forming composition to create an integrated absorber structure. The SAP particles are embedded in a continuous film matrix formed from the composition containing polymerizable monomers, eliminating the need for separate fluff pulp binding material while maintaining shape retention.
Solution Approach 2:
The invention creates a composite material system where super absorbent polymer particles are combined with a film-forming composition that contains polymerizable monomers, crosslinking agents, and other components. This composite structure provides both shape retention and thin profile without requiring traditional fluff pulp.
2Stability of the object's composition
If fluff pulp is used to maintain absorber shape, then structural integrity is improved, but manufacturing cost increases due to additional material and processing
Solution Approach 1:
The patent combines multiple functions into a single film-forming composition that simultaneously provides binding, shape retention, and absorption capabilities. This eliminates the need for separate fluff pulp material and reduces manufacturing steps, thereby lowering production costs while maintaining structural integrity.
Solution Approach 2:
The film-forming composition serves multiple functions: it acts as a binding agent to hold SAP particles, provides structural integrity and shape retention, and contributes to the overall absorption performance. This multi-functionality eliminates the need for dedicated fluff pulp and reduces material costs.
3Quantity of substance
If powder-type super absorbent polymer is used, then absorption capacity is achieved, but the powder scatters or leaks during manufacturing and use
Solution Approach 1:
The patent encapsulates super absorbent polymer particles within a continuous film structure formed from the film-forming composition. This film matrix prevents the SAP particles from scattering or leaking during handling and use, while the particles retain their full absorption capacity within the confined film structure.
Solution Approach 2:
The invention creates a composite where powder SAP particles are embedded in a continuous film matrix. This composite structure eliminates the harmful scattering and leakage properties of loose powder while preserving the high absorption capacity of the SAP particles.
4Quantity of substance
If powder-type super absorbent polymer is used, then absorption function is provided, but uniform control of absorption characteristics is difficult due to varying content distribution
Solution Approach 1:
The patent creates a homogeneous distribution of super absorbent polymer particles within the continuous film matrix. The film-forming composition ensures uniform dispersion and consistent content distribution throughout the absorber structure, enabling precise control of absorption characteristics across the entire product.
Solution Approach 2:
The composite structure of embedded SAP particles in a continuous film matrix provides uniform spatial distribution and consistent absorption performance. This eliminates the variability associated with powder-type SAP and enables precise manufacturing control.
5Quantity of substance
If sheet-type super absorbent polymer with particle diameter of 0.2 to 2.0 mm is used, then absorption performance is improved, but the sheet thickness cannot be reduced to 0.5 mm or less
Solution Approach 1:
The patent uses a film-forming composition that creates a continuous thin film matrix embedding SAP particles. This film structure enables the absorber to achieve ultra-thin dimensions of 0.5 mm or less while maintaining adequate absorption performance through the distributed SAP particles within the film.
Solution Approach 2:
The invention changes the structural parameters by transitioning from discrete particles requiring fluff pulp to an integrated film matrix with embedded particles. This parameter change enables ultra-thin thickness while preserving absorption function through optimized particle distribution within the film.
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 film exhibits excellent absorption performance, flexibility, and prevents scattering or leaking, allowing for thinner products with uniform absorption characteristics.
Implementation Method 1
forming a hydrogel polymer film by irradiating heat and/or light while drawing the monomer composition film
Implementation Method 2
A super absorbent polymer (SAP) is a type of synthetic polymeric material capable of absorbing 500 to 1000 times its own weight of moisture
Implementation Method 3
drying the hydrogel polymer film
Data Source
AI summary
The present disclosure relates to a preparation method for a super absorbent polymer film. Specifically, it relates to a preparation method for a new type of super absorbent polymer film, which is thin and exhibits excellent absorption performance. In addition, the super absorbent polymer film of the present disclosure has excellent flexibility and excellent mechanical properties, is free from scattering or leaking, and does not require an auxiliary substance such as pulp, so that products can be made thinner and the manufacturing process and costs may be reduced.