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Super absorbent polymers (SAPs) and super absorbent fibers (SAFs) have the ability to absorb and store large amounts of liquid. They are used widely in disposable hygiene products like diapers and feminine products. SAFs were developed in the early 1990s as an alternative to granular SAPs and offer advantages in applications like cable wrapping, medical devices, and food packaging. SAFs can be manufactured into a variety of fabrics and products for uses in agriculture, apparel, hygiene, and other industries.
Super absorbent polymers (SAPs) and super absorbent fibers (SAFs) have the ability to absorb and store large amounts of liquid. They are used widely in disposable hygiene products like diapers and feminine products. SAFs were developed in the early 1990s as an alternative to granular SAPs and offer advantages in applications like cable wrapping, medical devices, and food packaging. SAFs can be manufactured into a variety of fabrics and products for uses in agriculture, apparel, hygiene, and other industries.
Super absorbent polymers (SAPs) and super absorbent fibers (SAFs) have the ability to absorb and store large amounts of liquid. They are used widely in disposable hygiene products like diapers and feminine products. SAFs were developed in the early 1990s as an alternative to granular SAPs and offer advantages in applications like cable wrapping, medical devices, and food packaging. SAFs can be manufactured into a variety of fabrics and products for uses in agriculture, apparel, hygiene, and other industries.
Superabsorbent polymers, generally referred to as SAPs, have the ability to absorb and store many times their own weight of aqueous liquids. For this reason, they have been widely employed in the disposable hygiene sectorin diapers, feminine care items and adult incontinence products. SAPs are barely 25 years old. They were first introduced commercially into the hygiene market by Japans Unicharm in 1982 and were adopted in the mid-1980s by the brands of major Western consumer product companies such as Procter & Gamble and Kimberly Clark. Today, the bulk of global SAP production, by far, is being swallowed up by the nonwoven disposable hygiene products industry. But small quantities of SAPs are also being used in other fieldsespecially in advancing the growth of crops, where there is vast potential for future growth. SAPs are also being employed in other applicationsincluding food packaging, the protection of cables from water damage, and firefighting aids. Besides granular super absorbent polymers, super absorbent fiber (SAFs) technology was developed in early 1990s. While significantly more expensive than the granular polymers, the super absorbent fibers offer technical advantages in certain niche markets including cable wrap, medical devices and food packaging. Super Absorbent Fibres Super-absorbent fiber has the property of absorbing moisture up to several thousand times its original weight, undergoing significant expansion, and eventually becoming a gel. It is white, odourless and has the appearance and handling characteristics of a textile fiber. As such, it can be used to produce a wide range of non- woven, woven fabrics, yarns and tapes for a wide range of applications. As a fibrous super absorbent, SAF allows for ease of handling and gives rise to exceptionally substantive and even distribution profiles within final fabric construction, excellent retention and low shedding. It can be produced in a range of absorbency Page Number 2 of 9
grades, staple length and dtex, to suit different requirements. Characteristic SAF is available in a wide range of highly absorbent grades SAF is a non-irritant SAF can be used in applications demanding robust toxicological profiling SAF is FDA approved SAF does not melt. It begins to decompose extremely slowly at temperatures >200C SAFs fibre density is approximately 1.4g/ml Chemistry Super Absorbent Fibres(SAF) is a cross-linked terpolymer of acrylic acid (AA), methylacrylate (MA) and a small quantity of a special Acrylate/methacrylate monomer (SAMM) in which the acrylic acid is partially neutralized to the sodium salt. The cross- links between the polymer chains are formed as ester groups by reaction between the acid groups in acrylic acid and the hydroxyl groups in hydroxypropylmethacrylate.
Where: AA = { -CH2CH(COOH) } from acrylic acid AANa = { -CH2CH(COONa) } from acrylic acid and NaOH MA = { -CH2CH(COOCH3) } from methylacrylate R = - COOCH2CH(CH3) The values of W, X, Y & Z depend on the quantities of monomer raw materials used. The values of U and V depend on the amount of heat treatment applied.
Manufacturing The raw materials of Super Absorbent Fibres(SAF) are mixed together with water and reacted using a polymerization initiator. The very high conversion of monomer raw materials to polymer is achieved. Page Number 3 of 9
The aqueous polymer solution is then extruded into a hot air stream and dried. The filaments are then heated to dry and cure the polymer, producing filaments of Super Absorbent Fibres(SAF) which are insoluble in water. Moisture may be added to the fibres to aid processing.
Acrylic Acid Methyl Acrylate NaOH Polymerization in water Polymer Extrusion: Evaporation of water produces cylindrical fibres of precise diameter & length Thermal & conditioning treatments. Product Packaging. Physical Properties SAF does not melt. It begins to decompose very slowly at temperatures above 200 C. Fibre density is approximately 1.4 g/ml.
Yarn manufacture SAF can be processed by all well-known staple fibre spinning systems. Typically, SAF is blended with other synthetic fibres such as polyester, nylon, cellulosics and aramids. These fibre blends are normally processed using the cotton and semi-worsted systems. A wide range of spun yarns can be produced using common spinning technologies. The discontinuous fibres are coated with a binder material and with the binder material adhering the fibres to super absorbent particles, fibres in the product are substantially unbounded except to the super absorbent particles. The binder may be present at an amount which is sufficient to substantially and continuously coat the fibres. Plural coatings of various binder materials may be used. The binder material may be heat fusible or heat curable and the treated fibres mixed with other fibres for use in producing a wide variety of products . Page Number 4 of 9
Application of Super Absorbent Fibers Apparels SAF can be converted into a wide range of disposable and durable fabrics for use within performance apparel. Being fibre-based, it can be precisely tailored into a diverse range of coolant fabric formats that offer the potential for enhanced design and performance. Such fabrics create the optimum conditions to significantly reduce heat stress and fatigue, increase wearer comfort and maximise physical performance even in the most extreme environments. Solutions that can be worn both next to skin and over outer clothing are available and are based on cooling through evaporation of absorbed water, or cooling through absorption of body perspiration.
Cooling through absorption of body perspiration This technology provides effective results when wearers are working in challenging environments or wearing heavy outer clothing. It can be converted into a wide range of washable garments which are worn next to the skin under heavy clothing. The fabric stimulates the dissipation of heat and moisture through the rapid absorption and containment of body sweat. The material in touch with the skin remains relatively dry and conducts heat away from the hot areas of the body. Systems based on this core fabric are the perfect solution for the armed forces, fire fighters,police force and for workers undertaking heavy physical work, and can also be employed in sports and other general apparel items. Page Number 5 of 9
Cooling through evaporation This functionality can be achieved by incorporating a SAF containing absorbent nonwoven within two outer fabrics, thus creating a three-layer absorption cooling fabric. This can then be tailored as required into a final garment which should be worn over outer clothing. In order to activate, the wearer simply pre-soaks the garment with water and wears as normal. As a result of evaporation, the cooling effect occurs. Items made using this technology can be reused through multiple wetting and drying cycles.
Agriculture SAFs ability to absorb up to 200 times its own weight in water, and 60 times its own weight in saline, at an extremely fast absorption rate. This key property offers an ideal way of ensuring optimum water conditions while effectively reducing overall water usage through reduction in evaporative loss and water seepage Such fabrics are designed for the controlled delivery of water and nutrients to different root systems as and when required, whilst significantly reducing evaporative loss and water seepage. It can be used as both temporary and long-term solutions, from hanging basket liners to commercial scale projects, even in areas of low water availability.
Liner fabrics These are tailored fabrics which can be cut to shape and used to line the base of potted plants and hanging baskets. They work by Page Number 6 of 9
absorbing the necessary quantity of water and, in turn, provide a continuous and optimum moisture environment to whichever plant is being grown. Liner fabrics can also be used in vertical gardens, where they offer the ability to hold water in the vertical position while resisting seepage. Surface fabrics These fabrics can be positioned around the base of the potted plant (on top of the soil) and offer additional benefits in reducing weed growth and improving the overall thermal regulation of the soil environment. As with liner fabrics, significant reduction in evaporative loss is also achieved. Ground fabrics These are long-term durable fabrics developed to be buried below ground level, providing water management in both commercial and domestic situations.This is particularly advantageous in areas of low rainfall and/or limited availability of irrigation water.
Hygiene SAF is the key component in disposable hygiene market. It is used for wide range of soft, discreet and comfortable nonwoven fabric cores that provide superior fluid absorption, and low re-wet performance, in ultra-thin femme-hygiene, diaper and incontinence products. Feminine-hygiene The super absorbent technology is choice for feminine hygiene products. The fact that it can be used for the production of extremely discreet end products makes it ideal for use in the fabric cores of ultra- thin product lines. This, coupled with lower-wet performance, provides improved user comfort levels, which is a significant purchase consideration in this sector. Page Number 7 of 9
Diapers SAF offers the potential for enhanced and innovative new diaper design, removing the need for complex absorbent containment systems. SAF-integrated nonwoven fabric cores have been designed to provide overall reductions in raw material usage, thus resulting in less environmental impact when disposed. They also provide improved levels of softness and comfort. Adult Incontinence Disposable incontinence products designed using a SAF- based nonwoven core are very discreet, yet still provide excellent absorption performance. Development projects are also being undertaken to establish a washable material for use in this sector.
Medical SAF technology has been extensively developed for use in advanced moist wound care dressings. Once converted, the resulting versatile, consistently high performing fabrics provide a therapeutic effect and aid healing, especially when used in the treatment of chronic burns and wounds with high exudates. Rapid uptake and retention of exudates from an infected area facilitates the perfect environment for effective management and swift healing, by controlling moisture levels around the wound whilst preventing excess wetting. This is essential in creating an optimum environment to aid the healing process and prevent further bacterial growth.
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Packaging SAF is the key component in a wide range of food contact exudates management fabrics, that effectively lock away loose liquids within their core. Such fabrics have substantive and even super absorbent distribution profiles, offering truly unparalleled levels of consistent absorption and retention performance. They are highly efficient for keeping meat, fish, poultry - and a whole range of other perishable foodstuffs - packaged in optimised conditions whilst both on and off the shelf.
Filters A significant reason for the majority of oil and fuel system failures is the presence of high water levels, in dispersed and free water form. SAF allows to achieve optimum levels of water and particulate removal in aviation and automotive fuels and a wide range of oils. SAF is the key component for a wide range of unique, enhanced nonwoven filter media fabrics. Such fabrics help eradicate the effects of water contamination in critical performance situations. Their versatility enables real cost savings over Page Number 9 of 9
traditional cellulosic-based absorption media and offers full compliance potential to stringent international filtration standards particularly in the aviation fuel and hydraulic oil markets. Cables SAF can be converted into spun yarns and nonwoven tapes that provide optimum protection for internal and external cable applications. This dry active system prevents water passage along the cable from a joint or point of sheath damage. The highly effective protection is achieved by a SAF- containing water-swellable yarn or tape being incorporated into the cable during manufacture.
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