Low-Density Cleaning Substrate for Controlled Fluid Release
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Solution Overview
Problem
Existing cleaning substrates, such as wipes, often have high basis weights to maximize absorption but appear flimsy due to low density, and lack the ability to controllably release pre-loaded cleaning compositions effectively.
Innovation Solution
A low-density substrate with an optimized pore volume distribution, allowing for controlled release of cleaning compositions, achieved by expanding the substrate in the z-direction and using a combination of fibers like meltblown, spunbond, and bicomponent fibers, with a basis weight of 15 to 80 gsm, enabling effective cleaning of both hard and soft surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If higher basis weight substrates are used to maximize absorption capacity, then absorption capacity is improved, but the substrate appears flimsy and thin to consumers
Solution Approach 1:
The patent applies dimensionality change by expanding the substrate in the z-direction (thickness direction) through controlled pore volume distribution and fiber arrangement. This creates a low-density substrate with enhanced bulk appearance while maintaining low basis weight (15-80 gsm), resolving the contradiction between absorption capacity and perceived thickness.
2Quantity of substance
If higher basis weight substrates are used to maximize absorption capacity, then absorption capacity is improved, but the cost of the substrate increases
Solution Approach 1:
The patent utilizes porous materials with optimized pore volume distribution to achieve high absorption capacity at low basis weight (15-80 gsm). The controlled pore structure allows efficient fluid uptake and retention without requiring excessive material quantity, thereby reducing cost while maintaining performance.
3Quantity of substance
If traditional non-woven materials are used with high absorption capacity, then absorption is improved, but the ability to controllably release cleaning composition is reduced
Solution Approach 1:
The patent applies local quality by creating different pore size distributions within the substrate structure. Specific pore sizes are optimized for absorption while other pore structures facilitate controlled release. This localized differentiation of pore characteristics enables both high absorption capacity and controllable release of cleaning compositions.
4Weight of moving object
If low-density substrate is used to reduce material quantity, then cost is reduced, but strength and structural integrity may be compromised
Solution Approach 1:
The patent employs composite materials with optimized fiber compositions and pore structure configurations. The combination of different fiber types and the controlled pore volume distribution create a low-density substrate (15-80 gsm) that maintains sufficient structural integrity and strength for cleaning applications while minimizing material quantity.
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 substrate provides enhanced bulk appearance and effective cleaning performance while maintaining a low cost and sufficient strength, allowing for efficient release of cleaning agents, reducing the need for excessive fluid application and extending cleaning power.
Implementation Method 1
the substrate contains an optimized pore volume distribution that enables it to absorb and hold cleaning compositions
Implementation Method 2
The pore volume distribution of the substrate enables it to release the cleaning compositions in a controlled manner
Data Source
AI summary
The present invention is directed to a low-density substrate, which has an optimized pore volume distribution. The optimized pore volume distribution allows the substrate to hold at least 50 percent of its cumulative volume within pores with a radius size of about 110 to 250 microns. The optimized pore volume distribution can also be characterized by having a dry fibrous web that absorbs less than 20 percent of the cumulative volume of the fibrous web at a pore radius of 75 microns. The optimized pore volume distribution of the substrate enables it to controllably release a fluid composition effectively onto a surface. The basis weight of the substrate is about 80 to 20 gsm and the density of the substrate is below 0.1 g/cc. The substrate may be a pre-loaded wipe, which is either moistened by a consumer prior to use or moistened prior to packaging. The composition loaded onto the substrate may contain dry and/or liquid compositions preferably for cleaning hard or soft surfaces.