Algae-derived flexible foam, and a method of manufacturing the same
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Solution Overview
Problem
The textile industry faces challenges in achieving uniform dispersion and concentration of metallic antimicrobial agents, leading to issues like clumping, high material costs, oxidation, and environmental concerns, while seeking sustainable and renewable alternatives for antimicrobial, antifungal, and antiviral properties.
Innovation Solution
Development of algae-derived sulfated polysaccharides and foams, which are used to create antimicrobial, antifungal, and antiviral properties in textiles and foams, derived from algae biomass, offering environmental benefits and no need for pesticides, with applications in various products like footwear, furniture, and medical devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallic particles are used as antimicrobial agents, then antimicrobial and antifungal properties are achieved, but uniform dispersion and concentration are difficult to obtain due to clumping
Solution Approach 1:
The patent uses metallic soaps (soaps of active metals like zinc, aluminum, or calcium with fatty acids having 12-22 carbon atoms) as intermediary compounds. These metallic soaps serve as mediators that provide antimicrobial activity while maintaining uniform dispersion in the polymer matrix, eliminating the clumping problem associated with metallic particles. The metallic soap molecules distribute evenly throughout the polymer, ensuring consistent antimicrobial protection without aggregation.
Solution Approach 2:
The patent changes the physical and chemical parameters of the antimicrobial agent by converting metallic particles into metallic soaps. This transformation alters the solubility, molecular structure, and distribution characteristics of the active metal compounds. The metallic soaps have appropriate melting points and compatibility with polymers, enabling uniform mixing and dispersion at concentrations of 0.1-10% by weight without the aggregation issues of metallic particles.
2Reliability
If metallic particles are used as antimicrobial agents, then antimicrobial activity is achieved, but material cost increases
Solution Approach 1:
The patent employs metallic soaps as cost-effective alternatives to expensive metallic particles. The metallic soaps can be produced more economically through straightforward chemical reactions between metallic oxides or hydroxides and fatty acids. These compounds provide sufficient antimicrobial activity at lower costs and can be easily incorporated into polymer products during standard manufacturing processes, reducing overall material costs while maintaining effective antimicrobial protection.
3Reliability
If metallic particles are used as antimicrobial agents, then antimicrobial properties are achieved, but oxidation occurs during use
Solution Approach 1:
The patent uses metallic soaps with stable chemical compositions that resist oxidation during product use. The fatty acid chains in metallic soaps provide steric protection and chemical stability, preventing oxidation of the active metal centers. This ensures long-term stability of the antimicrobial properties without the oxidation degradation problems associated with metallic particles, maintaining effective protection throughout the product lifecycle.
4Reliability
If metallic particles are used in textiles, then antimicrobial properties are achieved, but negative health and environmental consequences occur
Solution Approach 1:
The patent employs metallic soaps as safer alternatives to metallic particles in textile applications. The metallic soap molecules are less likely to cause adverse health effects due to their molecular structure and lower bioavailability compared to metallic particles. They also exhibit reduced environmental toxicity while maintaining effective antimicrobial activity against bacteria, fungi, and viruses in textile products, addressing both health and environmental concerns.
5Productivity
If conventional foamable materials are used, then foam production is achieved, but environmental friendliness and sustainability are compromised
Solution Approach 1:
The patent modifies the chemical composition parameters of foamable materials by incorporating metallic soaps and utilizing alternative blowing agents. This enables sustainable foam production with reduced environmental impact while maintaining productive foam generation capabilities. The formulation changes allow for eco-friendly foam manufacturing processes that produce effective antimicrobial foam products.
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 algae-derived foams and fibers provide effective antimicrobial, antifungal, and antiviral properties, reducing material costs and environmental impact while maintaining performance, making them suitable for diverse applications.
Implementation Method 1
sulfated polysaccharides derived from renewable non-terrestrial plants exhibiting exceptional antimicrobial, antifungal, antibacterial, antiviral, and/or antiinflammatory properties and characteristics
Implementation Method 2
exhibiting exceptional antimicrobial, antifungal, antibacterial, antiviral, and/or antiinflammatory properties and characteristics
Implementation Method 3
a process for producing a foamed material so as to produce various flexible and/or rigid foamable compositions from one or more of an algae biomass, copolymer carrier resins, and/or other foaming ingredients
Data Source
AI summary
This document presents algae-derived antimicrobial fiber substrates, and a method of making the same. The fiber may be a synthetic fiber, but can also be formed as a cellulosic (e.g., cotton). In various implementations, an algae-derived antimicrobial fiber substrate can be made to have identical properties and characteristics of nylon-6 of nylon 6-6 polymer or the like, and yet contain antimicrobial, anti-viral, and/or flame retardant algal derived substances. Any of various species of red algae, brown algae, blue-green algae, and brown seaweed (marine microalgae and/or macroalgae) are known to contain a high level of sulfated polysaccharides with inherent antimicrobial, antiviral, and flame-retardant properties, and can be used as described herein. Additionally disclosed are algae-derived flexible foams, whether open-cell or closed-cell, with inherent antimicrobial, antiviral, and flame resistant properties. Further, a process of manufacturing is presented wherein the process may include one or more of the steps of: harvesting algae-biomass; sufficiently drying the algae biomass; blending the dried algae biomass with a carrier resin and various foaming ingredients; adding an algal-derived antimicrobial compound selected from various natural sulfated polysaccharides present in brown algae, red algae, and/or certain seaweeds (marine microalgae); and adding a sufficient quantity of dried algae biomass to the formulation to adequately create a fire resistant flexible foam material.