Alginate Membrane Film Coating for Continuous Mass Production
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Solution Overview
Problem
Current methods for manufacturing alginate membranes are inefficient for mass production and do not effectively address the cost reduction and application versatility of alginate-based films, particularly in wound dressings and facial masks.
Innovation Solution
A film containing an alginate membrane is produced using a film carrier coated with separate layers of alginate solution and salt water solution containing divalent metal ions, where the coating processes involve soaking and spray-coating, allowing for continuous and quick mass production and control of membrane thickness through crosslinking reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional alginate membrane manufacturing methods are used, then membrane formation is achieved, but mass production efficiency is low and manufacturing cost is high
Solution Approach 1:
The patent implements continuous coating processes where alginate solution and salt water solution are applied continuously to the film carrier without interruption. This continuous action enables mass production of alginate membranes, significantly improving productivity while maintaining cost-effectiveness through optimized material usage and process efficiency.
2Ease of operation
If alginate membrane is formed on smooth film carrier surface, then membrane formation is achieved, but membrane separation from carrier is difficult
Solution Approach 1:
The patent applies different surface treatments to different regions or aspects of the film carrier. The surface properties are locally modified to control the interaction between the alginate membrane and carrier. This allows the membrane to form reliably on the carrier during production while enabling easy separation when needed, resolving the contradiction between connection reliability and separation ease.
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
This method enables the efficient and cost-effective mass production of alginate membranes with improved performance and application versatility, allowing for tight integration with film carriers and easy separation, depending on surface roughness, and allows for adjustable membrane thickness.
Implementation Method 1
The film carrier absorbs liquid
Implementation Method 2
crosslinking occurs between the two solutions on the surface of the film carrier to produce the film containing an alginate membrane
Data Source
Figure 1~2
Figure 3
AI summary
A film containing alginate membrane and a manufacturing method of the same are revealed. A film carrier is used to absorb liquid and is treated by two separate and continuous coating processes. At least one surface of the film carrier is coated with a layer of alginate solution containing a certain percent of sodium alginate or potassium alginate by weight and then is coated with a layer of salt water solution containing a certain percent of divalent metal ions. Then crosslinking occurs between the alginate in the alginate solution and the divalent metal ions in the salt solution on the surface of the film carrier or infiltrating into the film carrier so as to form a hydrogel complex membrane having a network structure. Thus the continuous and fast mass-production of the film is achieved.