Water-absorbent core production system with alternating layer connectivity
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Solution Overview
Problem
Current production methods for water-absorbent cores in sanitary articles face challenges such as stratification after water absorption, poor multi-point water absorption performance, and low production efficiency, leading to comfort and usage issues.
Innovation Solution
A production system that includes a manufacturing mechanism with a transmission component, vacuum adsorption device, and hot air penetration device to laminate fluff pulp, hot-melt fibers, and super absorbent polymer, followed by ultrasonic cutting to fuse hot-melt fibers, enhancing connectivity and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fluff pulp and polymer absorbent resin are mixed on-line to reduce cost, then production cost is reduced, but the polymer layer becomes stratified after water swelling and connectivity is insufficient
Solution Approach 1:
The absorbent core is divided into multiple alternating layers of fluff pulp and polymer absorbent resin, with each layer serving distinct functions. This segmentation prevents stratification by distributing polymer layers throughout the structure rather than concentrating them in one location, maintaining connectivity and structural integrity during water swelling.
Solution Approach 2:
The invention creates a composite structure combining fluff pulp and polymer absorbent resin in alternating layers. This composite material approach leverages the complementary properties of both materials - fluff pulp provides structural framework and capillary action, while polymer layers provide absorption capacity, achieving both cost-effectiveness and structural stability.
2Stability of the object's composition
If multiple molding and lamination processes are used to create multi-layer structure, then layer connectivity is improved, but production efficiency decreases and labor consumption increases
Solution Approach 1:
Multiple layers of fluff pulp and polymer absorbent resin are combined in a single continuous forming process rather than through multiple separate molding and lamination steps. This merging of operations maintains layer connectivity through alternating layer formation while dramatically improving production efficiency and reducing labor requirements.
Solution Approach 2:
The forming process operates continuously to create alternating layers of fluff pulp and polymer absorbent resin in a single pass. This continuous action eliminates the interruptions and additional processing steps associated with multiple molding and lamination operations, maintaining connectivity while enhancing productivity.
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 system improves layer connectivity, reduces stratification, and increases production efficiency while maintaining effective water absorption, thereby enhancing the performance and usability of water-absorbent cores.
Implementation Method 1
the vacuum adsorption device is disposed adjacent to the transmission component, and a position of the vacuum adsorption device corresponds to a position of the plurality of outlets, such that the mixture of fluff pulp and hot-melt fibers can be absorbed on the transmission component
Implementation Method 2
the hot air penetration device is configured to perform a hot air penetration treatment to the laminate
Implementation Method 3
the slitting mechanism includes an ultrasonic cutting device configured to ultrasonically cut the laminate after the hot air penetration treatment and fuse hot-melt fibers at a cut portion of the laminate
Data Source
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AI summary
A production system of a water-absorbent core. The supplying component thereof is configured to convey the fluffy cotton to the starting end of the transmission component, and the plurality of outlets of the supplying component for conveying the mixture of the fluff pulp and the hot-melt fibers to the transmission component are all located in the middle portion of the transmission component, the feeding port for conveying the super absorbent polymer to the transmission component and the outlets are arranged alternately along the transmitting direction of the transmission component, and each feeding port is located between the two outlets; the vacuum adsorption device can cause the mixture to be absorbed on the transmission component; the hot air penetration device performs hot air penetration treatment on the laminate; and the ultrasonic cutting device of the slitting mechanism is configured to ultrasonically cut the laminate after the hot air penetration treatment.