Composite Sheet Abrasiveness Control via Meltblown Biodegradable Layers

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Solution Overview

Problem

Current composite wipes are either weak, uniformly thin, and non-compostable, lacking tailored abrasive properties for various consumer and industrial applications.

Innovation Solution

A method of producing composite sheets with controlled abrasiveness by meltblowing biodegradable polymers onto a base layer, creating layers with specific fiber diameters and compositions, allowing for customizable abrasive properties and compostability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If composite wipes are made with uniform thin structure using conventional processes, then manufacturing simplicity is maintained, but abrasive properties cannot be tailored and strength is reduced

Engineering Contradiction:

Improveabrasive propertiesVSAvoidcomposite structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The composite sheet is divided into distinct functional layers: a base layer providing structural support and an abrasive layer with controlled fiber diameters (0.3-20 μm) providing tailored abrasive properties. This segmentation allows each layer to be optimized independently for its specific function while maintaining overall product performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the composite sheet have different properties - the base layer has one set of characteristics while the abrasive layer has different characteristics including specific fiber diameter ranges and material composition. This local quality variation enables the sheet to provide both structural integrity and customized abrasive performance in different locations.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If conventional thermoplastic fibers are used in composite wipes, then abrasive properties can be achieved, but compostability is lost

Engineering Contradiction:

ImprovecompostabilityVSAvoidprocessing requirements

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent changes the material parameter from conventional thermoplastics to biodegradable polymers including polylactic acid (PLA), polyhydroxyalkanoates (PHA), and other bio-based polymers. This parameter change enables compostability while maintaining the ability to undergo meltblowing processing, thus preserving ease of manufacture through existing industrial processes.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The use of biodegradable polymers aligns with the disposable nature of wipes, allowing the product to fulfill its short service life function and then decompose environmentally. This principle supports the transition to compostable materials that match the temporary use pattern of wipe products.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Adaptability or versatility

If fiber diameter is reduced to increase abrasiveness, then abrasive properties improve, but fiber strength decreases

Engineering Contradiction:

ImproveabrasivenessVSAvoidfiber strength

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The abrasive layer contains fibers with diameters in the range of 0.3-20 μm, with smaller diameter fibers concentrated in regions where high abrasiveness is needed. The base layer contains larger diameter fibers providing structural strength. This local quality distribution optimizes both abrasiveness and overall sheet strength.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The composite structure combines fibers of different diameters and materials - fine diameter biodegradable fibers in the abrasive layer for abrasiveness, and larger diameter fibers in the base layer for strength. This composite approach allows simultaneous achievement of contradictory properties through material combination.

Inventive Principle:

Principle #40Composite materials

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 method enables the creation of composite sheets with tailored abrasive properties and biodegradability, suitable for diverse applications, including wipes, while ensuring environmental sustainability.

Implementation Method 1

meltblowing a second polymer onto a first surface of the base layer to form a first abrasive layer comprising meltblown fibers of the second polymer

Methodology Applied

Scientific EffectMeltblowing: Melting

Data Source

PatentUS11787152B2Method of preparing a composite sheet

Publication Date: 2023.10.17 NORTH CAROLINA STATE UNIV

AI summary

A composite sheet comprising two or more layers is described where the degree of abrasiveness of can be controlled. The sheet can comprise partially or wholly biodegradable or compostable materials or blends thereof. Methods of preparing the composite sheets are also described.