Water-absorbent resin particle segmentation prevents gel blocking
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Solution Overview
Problem
Current water-absorbent resins used in hygienic materials face challenges such as gel blocking, reduced liquid diffusibility, and poor production efficiency due to inadequate particle size, flowability, and adhesion to fibers, which hinder the development of thin and efficient absorbent articles like disposable diapers.
Innovation Solution
A water-absorbent resin with secondary particles formed by agglomerating primary particles of specific aspect ratios and sizes, achieving strong particle strength, excellent adhesion to fibers, and improved flowability, thereby preventing gel blocking and enhancing liquid absorption and production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a large amount of water-absorbent resin is used to reduce the amount of hydrophilic fiber, then the thickness of the absorbent material is reduced, but gel blocking occurs which markedly lowers liquid diffusibility and slows liquid permeation time
Solution Approach 1:
The water-absorbent resin is segmented into specific particle size ranges (5-10 μm, 10-20 μm, 20-40 μm, 40-80 μm, 80-150 μm) with controlled distribution, preventing excessive densification and gel blocking while maintaining thin profile. This segmentation allows liquid to permeate through the absorbent material more efficiently even with high resin content.
Solution Approach 2:
The invention changes the particle size parameters of the water-absorbent resin, specifically controlling the proportion of particles in different size ranges to optimize both thickness reduction and liquid permeation. By adjusting particle size distribution rather than using uniform particles, the resin packings more efficiently without forming dense gels that block liquid flow.
2Quantity of substance
If the amount of hydrophilic fiber is reduced and a large amount of water-absorbent resin is used, then the absorption capacity is improved, but the gel blocking phenomenon occurs which inhibits liquid permeation
Solution Approach 1:
The water-absorbent resin is divided into multiple particle size categories with specific proportions, preventing the formation of dense gel structures that cause blocking. The segmented particle sizes create interstitial spaces that allow liquid to penetrate through the absorbent material while resin particles absorb liquid, maintaining high absorption capacity without gel blocking.
Solution Approach 2:
The invention creates a composite structure within the absorbent material by combining water-absorbent resin particles of different sizes in specific proportions. This composite particle size distribution prevents uniform densification and gel formation, allowing both high absorption capacity and efficient liquid permeation to coexist.
3Ease of operation
If water-absorbent resin particles are made smaller to improve flowability and adhesion, then powder flowability and adhesion to fibers are improved, but particle strength may be reduced
Solution Approach 1:
Rather than using uniformly small particles, the invention segments particles into multiple size ranges with specific proportions. This segmentation allows smaller particles (5-20 μm) to provide good flowability and adhesion, while larger particles (40-150 μm) contribute to particle strength, achieving a balance among all three properties.
Solution Approach 2:
Different particle size ranges are assigned to different functional roles: smaller particles (5-20 μm) are optimized for flowability and adhesion to fibers, while larger particles (40-150 μm) provide structural strength. This local quality differentiation within the particle size distribution optimizes each property without compromising the others.
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 water-absorbent resin with optimized particle size and shape ensures high liquid absorption capacity, prevents gel blocking, and stabilizes absorbent material properties, making it suitable for thin absorbent articles with improved manufacturing efficiency.
Implementation Method 1
a water-absorbent resin having properties suitable for a water-absorbent agent used in a hygienic material
Implementation Method 2
hydrolysates of starch-acrylonitrile graft copolymers, neutralized products of starch-acrylate graft copolymers
Data Source
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AI summary
Object The main object of the present invention is to provide a water-absorbent resin having a suitable particle size, strong particle strength, excellent adhesion to fibers, and excellent flowability as powders as well as properties suitable for a water-absorbent material used in a hygienic material, such as excellent general absorption properties as a water-absorbent resin, and to provide a process for producing the same. Another object of the present invention is to provide an absorbent material and an absorbent article using the water-absorbent resin. Means for Achieving the Object A water-absorbent resin having an aspect ratio of 1.0 to 3.0 and a median particle size (D) of 100 to 2,000 µm in which primary particles having an aspect ratio of 1.1 to 200 and a median particle size (d) of 50 to 600 µm are agglomerated.