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Introduction of Super Absorbent Polymer

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
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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.
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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
.
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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.
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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
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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.
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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
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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.