Multi-Component Bonded Fiber Structures for Anisotropic Fluid Control

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Solution Overview

Problem

Existing bonded polymeric fiber structures often result in isotropic properties, limiting their ability to tailor specific fluid manipulation and structural characteristics, particularly in multi-component applications where distinct components with different properties are needed.

Innovation Solution

The development of multi-component structures comprising a three-dimensional bonded fiber component and non-fibrous components, where each component can have unique characteristics such as porosity, surface energy, and material properties, allowing for tailored fluid flow and structural support, achieved through specific manufacturing processes that enable fiber intermingling and interface bonding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If bonded polymeric fiber structures are used, then fluid storage and manipulation capabilities are improved, but the structures exhibit isotropic properties that limit tailoring of specific fluid manipulation characteristics

Engineering Contradiction:

Improvefluid manipulation characteristicsVSAvoidisotropic properties

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The invention divides the bonded fiber structure into multiple distinct components, each with different fiber types, porosity levels, and material properties. This segmentation allows each component to perform specific fluid manipulation functions while collectively providing anisotropic behavior at the composite level, resolving the contradiction between versatility and compositional uniformity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the bonded fiber structure are assigned different fiber types and porosity characteristics to create localized functional zones. For example, hydrophilic fibers are placed in regions requiring fluid absorption while hydrophobic fibers are positioned in regions requiring fluid repulsion, enabling tailored fluid manipulation without requiring the entire structure to be isotropic.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If multiple fiber types are combined in polymeric fiber components, then specific combinations of characteristics are achieved, but manufacturing complexity increases

Engineering Contradiction:

Improvecombination of characteristicsVSAvoidmanufacturing process

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Multiple fiber types and non-fibrous components are merged into a single integrated bonded fiber structure through co-forming processes. This combining approach allows diverse characteristics to be achieved in one manufacturing step rather than requiring separate assembly operations, reducing manufacturing complexity while maintaining versatility.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention uses composite materials comprising different fiber types (e.g., hydrophilic and hydrophobic fibers) and non-fibrous components bonded together to create a multi-functional structure. This composite approach enables the achievement of specific characteristic combinations through material selection rather than complex manufacturing processes.

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If non-fibrous components are included in multi-component structures, then additional structural and functional properties are provided, but the interface bonding between components becomes more challenging

Engineering Contradiction:

Improvestructural and functional propertiesVSAvoidinterface bonding

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The bonding process parameters are adjusted to accommodate different component types. For example, bonding temperature, pressure, and time are optimized to ensure reliable bonding between fibrous and non-fibrous components with different thermal and mechanical properties, thereby maintaining interface reliability while providing diverse structural and functional characteristics.

Inventive Principle:

Principle #35Parameter changes

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 approach enables the creation of anisotropic structures with tailored fluid flow and structural properties, enhancing applications such as ink cartridges, air fresheners, and filtration systems by accommodating different fluid flow characteristics and evaporation rates, while providing mechanical support and aesthetic considerations.

Implementation Method 1

transport a bodily fluid by capillary action to a test site or diagnostic device

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

bonded fiber structures have been shown to take up ink of various formulations and controllably release it

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Data Source

PatentUS7888275B2Porous composite materials comprising a plurality of bonded fiber component structures

Publication Date: 2011.02.15 POREX TECHNOLOGIES CORP

AI summary

An integrally formed multi-component structure is disclosed, the multi-component structure comprising a plurality of components, at least one of which is a three-dimensional bonded fiber fluid transmissive component comprised of a plurality of polymeric fibers bonded to each other at spaced apart contact points, the fibers collectively defining tortuous fluid flow paths, and wherein each component has an interface with at least one other component.