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FORMATS FOR APPLICATION OF SUPERABSORBENT POLYMERS
The predominant formats for superabsorbent polymer applications typically fall into one of three categories. These include the use of the polymer in its raw powder form, or the utilization of superabsorbent granules combined with fibers and bonded within cellulose or non-woven laminates, as well as in airlaid structures.
The superabsorbent polymer in powder format is generally used for absorbing biological fluids and industrial aqueous fluids, such as spills in medical or commercial facilities, and for specialized usages in funeral homes etc.
Cellulose or polyester-based non-woven laminates containing superabsorbent polymer are produced via a relatively simple high pressure laminating process.
The carrier substrate, be it tissue, airlaid or polyester-type non-woven, moves beneath a dispenser that releases superabsorbent polymers, offering flexibility in polymer weights applied to the carrier. Subsequently, the carrier with superabsorbent polymers pass through a fine water spray to initiate bonding via partial water absorption. The upper substrate is then layered onto the moist superabsorbent polymers and promptly undergoes high-temperature, high-pressure lamination, arresting the absorption process and creating hydrogen bonds. Alternatively, bonding mechanisms like hot melt adhesive or particulate adhesive blended with the superabsorbent polymer, can be employed. These substances melt and disperse throughout the laminate structure during passage through the heated compression zone. Following lamination, the rolls of laminate are securely encased in polyethylene bags due to their hygroscopic nature. Once sealed they can be shipped to the final article manufacturer for further processing.
The third and most often used format for superabsorbent polymers is within an airlaid structure.
Airlaid cores are available in several formats, including latex bonded, hydrogen bonded, thermal bonded, or multi-bonded. The fundamental process shares similarities with lamination, but airlaid structures involve the deposition of cellulose fibers onto the carrier, along with the incorporation of additives like bicomponent fibers, liquid or particulate adhesives, and alternative substrates. Various airlaid processes may employ multiple formers to deposit distinct layers of fluff and superabsorbent polymers, each with different weights per layer. In comparison to simple tissue-SAP-tissue laminates, airlaid processes and additive options offer a broad range of improved performance and aesthetic or tactile characteristics, such as excellent wicking, stronger bonds, softness, and conformability. This versatility makes them suitable for a diverse array of applications.
The Power of Absorption: How Superabsorbent Polymers are Changing the World
Here are a few additional applications showing how Superabsorbent Polymers are changing the world.
Meat and fruit pads
Many meat packages in supermarkets now feature absorbent pads at the bottom of a tray to capture escaping juices from the meat. This serves two primary purposes. Firstly, it prevents the leakage of juices onto customers and the supermarket fridge/floor, enhancing cleanliness. Secondly, by effectively absorbing the liquid, these pads help inhibit the proliferation of microbes that could otherwise spoil the meat, contributing to the overall freshness and quality of the product.
Wound dressings
For chronic or acute wounds, such as arterial or venous ulcers, characterized by substantial exudate or blood discharge over an extended duration, specialized dressings incorporating superabsorbent polymers are employed. These dressings possess the ability to absorb and contain the exudate effectively. Due to their high capacity, they can remain in place for extended periods, minimizing the need for frequent dressing changes. This not only enhances patient comfort but also reduces the overall trauma associated with multiple dressing changes.
Medical/surgical pads
Medical pads containing superabsorbent material serve a diverse range of specialized applications within hospitals, laboratories, and other medical facilities. These applications span from pads on operating tables designed to absorb liquids released during surgery to spill pads utilized for mopping up various fluids released by patients on equipment or floors. Additionally, laboratories use pads to contain fluids associated with the testing of biological samples. The versatility of medical pads makes them crucial in maintaining cleanliness, managing fluids, and ensuring a hygienic environment across various healthcare settings.
Fuel and Oil Filtration / Separation (Dewatering)
Superabsorbent polymers exhibit a strong affinity for aqueous liquids but remain inert when it comes to oil-based liquids. This characteristic makes them highly effective in water absorption from various sources, including aviation fuel, gasoline, and diesel, when integrated into fuel filters. The selective absorption properties of superabsorbent polymers contribute to their usefulness in managing and separating contaminating liquids in fuel filtration applications.
Biohazard Absorption and Protection
Superabsorbent polymers, owing to their exceptional absorbency capacity, offer ideal packaging solutions for substances categorized as Category A infectious and Category B/UN3373 biological substances, complying with regulations set by USDOT and IATA ISSG. These regulations establish specific requirements for the type and structure of packaging used for transporting these substances. A crucial element in this packaging is the inclusion of sufficient absorbent products to effectively capture all biological liquids, including urine, blood, fecal matter, and similar fluids. This ensures compliance with regulations while also contributing to the safe and secure transportation of hazardous biological materials.
Environmental Protection
Superabsorbent polymers and media play a crucial role in environmental protection, showcasing their utility beyond personal care and industrial applications. The high absorbency capacity of superabsorbent materials makes them valuable components in environmental solutions.
One notable application is the incorporation of superabsorbent materials into “absorbent socks” and hazmat spill kits. These are employed to contain aqueous chemical leaks, preventing the spread of contaminants into the surrounding environment. Additionally, a relatively new application involves using superabsorbent materials in “sand-less, sandbags” available in many DIY retail outlets. These permeable sacks contain superabsorbent materials that rapidly expand upon contact with water. This expansion due to the high water absorption capacity allows them to form a physical barrier, helping to limit potential flood damage from river or sea water. This demonstrates the versatility of superabsorbent polymers in addressing environmental challenges and enhancing protective measures.
Agricultural Applications
Agriculture and horticulture use superabsorbent polymer granules to control soil moisture e.g. seed coating, water conservation or enhancement of soil physical properties to increase water retention properties. The agricultural application is particularly important in sandy soil and typically uses potassium polyacrylate based super absorbent polymer which is not harmful to plants and seeds.
Other applications
Artificial snow for movies and theatrical effects is a particularly unique, but very effective application for superabsorbent polymer. By changing the cross linking agent for the polymer the gel polymerization process takes on a distinct behavior. The attached link provides a fun demonstration of how ‘artificial snow’ is produced using dried superabsorbent granules.
Instead of forming one solid mass the individual dried superabsorbent granules absorbed water without bonding to adjacent hydrated granules, creating the appearance of individual fluffy snow flakes. The hydrated structure of the ‘snow flakes’ gives them a moist feel however, they cannot combine to create ‘snow balls’! Over time, the water absorption is reversed through evaporation, causing the granules to revert back to their dried format. This recyclable nature allows them to be reused as needed.
Cement modifiers for civil engineering projects
Underground wire and cable water blocking.
Gelok’s Quality and Versatility in Superabsorbent Polymer Applications
Gelok extends its capabilities to produce specialized laminates tailored for water retention by utilizing various grades of tissue, polyester or airlaid substrates. These laminates incorporate a blend of superabsorbent materials and adhesive to optimize water absorption and retention properties.
All Gelok laminates and airlaid-style cores are manufactured in the form of bulk rolls, providing the flexibility to be slit into customer-specified widths or sheeted according to specific requirements. This adaptability ensures that Gelok products can be seamlessly integrated into diverse applications.
It’s worth noting that Gelok maintains high-quality standards in its manufacturing processes. The plant operates under a certified Quality Management System, as attested by Intertek, demonstrating conformity with ISO 9001:2015. This certification underscores Gelok’s commitment to delivering products that meet rigorous quality standards.
Contact us to learn more about Gelok’s superabsorbent polymers.