Chlorine Dioxide Composite Matrix for Low-Temperature Extrusion
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Solution Overview
Problem
Existing chlorine dioxide-releasing materials face challenges in cost-effective packaging due to the bulkiness and high fabrication costs of sachets, and limitations in polymer matrices for extruded sheets caused by the low decomposition temperature of chlorite anions, leading to reduced ClO2 yield and undesirable matrix materials with low water vapor permeability.
Innovation Solution
A composite article integrating a ClO2-producing material into an organic matrix that is formable below 150°C, allowing contact with activating stimuli and permeable to ClO2, using low melting molecular solids or thermoformable polymers like polyethylene glycol wax and EVA, which facilitates ClO2 generation and release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If polyethylene matrix is used for extruded ClO2-releasing sheet, then extrusion temperature can be kept low (about 150°C), but water vapor permeability is low and chlorite decomposition can occur
Solution Approach 1:
The patent uses a composite matrix system combining polyethylene with porogenic agents (such as starch, cellulose, or synthetic polymers) that create porous structures. This composite approach allows the polyethylene to provide low extrusion temperature while the porogenic agents create water vapor permeable pathways and prevent chlorite decomposition through the formed pore structure.
Solution Approach 2:
The patent incorporates porogenic agents that decompose during or after extrusion to create porous structures in the matrix. These pores enable water vapor penetration to activate ClO2 release while maintaining the low extrusion temperature benefit of polyethylene. The porous structure also prevents chlorite decomposition by providing escape pathways for gases.
2Object-affected harmful factors
If sachets are used to package ClO2-producing powder, then user protection and powder containment are improved, but packaging cost and bulkiness increase
Solution Approach 1:
The patent extracts the ClO2-producing powder from traditional sachet packaging and integrates it directly into an extruded polymer matrix. This eliminates the need for separate sachet fabrication, reducing packaging costs and bulkiness while maintaining safety through the matrix encapsulation that prevents direct powder contact.
Solution Approach 2:
The patent merges the packaging function and the ClO2-release function into a single integrated extruded matrix product. The polymer matrix serves both as the structural container (replacing the sachet) and as the medium that holds and releases the ClO2-producing materials, eliminating the need for separate packaging components.
3Productivity
If chlorite anion concentration is increased in extruded sheet, then maximum ClO2 yield is improved, but risk of explosive oxidation of polyethylene increases
Solution Approach 1:
The patent uses porogenic agents to create porous structures that provide escape pathways for oxygen and other gases generated during ClO2 production. This porous structure prevents pressure buildup that could lead to explosive oxidation, allowing higher chlorite concentrations to be used safely to achieve maximum ClO2 yield.
Solution Approach 2:
The patent introduces porogenic agents as intermediary materials that mediate between the chlorite anion and the polyethylene matrix. These agents decompose to create pores that facilitate safe gas release, enabling higher chlorite concentrations without increasing the explosive oxidation risk to unacceptable levels.
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 solution enables stable storage and efficient ClO2 production with higher yields, reducing packaging costs and improving handling, while maintaining safety and effectiveness in releasing ClO2 upon exposure to stimuli.
Implementation Method 1
a material capable of producing ClO2 upon exposure to an activating stimulus... When the composite article is exposed to an activating stimulus, such as water or light, the organic matrix permits at least some contact between the ClO2-producing material and the activating stimulus, which in turn causes the material to generate ClO2
Implementation Method 2
The organic matrix is also permeable to ClO2 so as to allow at least a portion of ClO2 generated by the ClO2-producing material to escape the composite article
Data Source
AI summary
A composite article that includes a ClO2-producing material integrated into an organic matrix and methods of using the same are described. The organic matrix of the composite article is formable at a temperature under about 150° C., permits contact between an activating stimulus (e.g., water vapor and/or electromagnetic energy) and the ClO2-producing material when the composite article is exposed to the activating stimulus, and is permeable to ClO2.