Continuous Dissolvable Foam Manufacturing Process
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Solution Overview
Problem
Existing processes for manufacturing dissolvable porous solid personal care products face challenges with cost efficiency, manufacturing rate, and product variability, particularly in achieving uniform consistency and faster drying times.
Innovation Solution
A continuous process involving the preparation of a pre-mixture with specific surfactant, polymer, and plasticizer ratios, followed by heating and aeration to create uniform bubble sizes, which are then extruded and dried to form a flexible, open-celled foam structure with consistent density and faster dissolution properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If batch processing is used to manufacture dissolvable porous solid structures, then product variability is reduced, but manufacturing rate and productivity are lowered
Solution Approach 1:
The patent applies preliminary action by pre-mixing the polymer and surfactant components before aeration. This pre-mixing step ensures uniform distribution of ingredients, which maintains product consistency while enabling continuous high-speed manufacturing. The pre-formed mixture is then rapidly aerated and extruded, achieving both quality and productivity goals.
Solution Approach 2:
The patent implements continuity of useful action through a continuous extrusion process where the pre-mixed composition is continuously aerated, extruded through a die, and formed into dissolvable structures. This continuous operation eliminates batch-to-batch variations while maintaining high manufacturing throughput, resolving the contradiction between consistency and productivity.
2Use of energy by stationary object
If traditional drying processes are used, then energy consumption is high, but drying time is extended
Solution Approach 1:
The patent utilizes the porous structure inherent in the dissolvable solid structures to enable rapid drying. The open-celled foam architecture created during extrusion provides extensive surface area and air permeability, allowing moisture to escape quickly. This natural porosity reduces both drying time and energy consumption compared to traditional dense material drying processes.
Solution Approach 2:
The patent applies parameter changes by controlling the aeration and extrusion parameters to create an optimal porous structure that facilitates rapid moisture evaporation. By adjusting air incorporation, extrusion pressure, and die geometry, the process creates a structure with optimized pore size and distribution that accelerates drying while minimizing energy input.
3Manufacturing precision
If aeration is applied to create uniform bubble sizes, then foam consistency is improved, but process complexity increases
Solution Approach 1:
The patent uses an intermediary approach by incorporating air through a straightforward aeration step in the extrusion process. Rather than complex multi-stage aeration systems, the process uses a single aeration zone where air is introduced into the pre-mixed composition under controlled pressure and flow conditions. This simple intermediary step achieves uniform bubble sizes without requiring elaborate equipment.
Solution Approach 2:
The patent achieves uniform foam structure through parameter changes in the aeration process, specifically controlling air flow rate, pressure, and mixing intensity. By optimizing these parameters, the process creates consistent bubble sizes and distribution without requiring complex mechanical aeration devices, maintaining process simplicity while achieving high foam uniformity.
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 continuous process results in a more uniform and consistent open-celled foam structure, enabling faster manufacturing, drying, and dissolution, while reducing energy requirements and product variability.
Implementation Method 1
aeration to create uniform bubble sizes
Implementation Method 2
dried to form a flexible, open-celled foam structure
Data Source
Figure 1
Figure 2~4
AI summary
A continuous process for making a flexible porous dissolvable solid structure with open celled foam. The continuous process has the steps of preparing a pre-mixture comprising surfactant, polymer, water, and optionally plasticizer; aerating the pre-mixture to form a wet aerated pre-mixture; extruding the wet aerated pre-mixture to form one or more sheets on a belt; and drying the sheets to form an Article having an open celled foam.