Multi-Ply Dispersible Wipe Crimping Process

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Solution Overview

Problem

Existing flushable wet wipes often require significant agitation to break apart after flushing and may not achieve the right balance of in-use strength and post-flush dispersibility, posing challenges for compatibility with sewer and septic systems.

Innovation Solution

A process involving the creation of a multi-ply dispersible wipe by superposing two cellulose fiber webs, applying an aqueous solution, crimping to create a composite web with a crimp pattern, and dividing it into discrete wipes, which allows for enhanced in-use strength and easy dispersibility after flushing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hydroentangling technology is used to make flushable wet wipes, then the wipes can be made with cellulose fibers, but the wipes require substantial agitation to break apart and do not lose significant strength in static environments

Engineering Contradiction:

Improvein-use strengthVSAvoiddispersibility after flushing

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The wipe is constructed as a multi-ply structure with distinct layers (first web, second web, third web) that can separate from each other during flushing. The crimp pattern creates localized bonding zones rather than uniform bonding across the entire wipe, enabling segmental disintegration into smaller pieces that can pass through sewer systems more easily.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The crimp pattern applies bonding only in specific localized areas rather than uniformly across the entire wipe surface. This creates regions of varying bond strength - the crimped areas provide structural integrity during use, while the non-crimped areas remain weaker and facilitate easier separation during flushing.

Inventive Principle:

Principle #3Local quality

2Strength

If a binder on a cellulose substrate is used to achieve in-use strength, then the binder bonds fibers together in a network, but the binder is expensive and it is challenging to achieve the right balance of in-use strength and post-flush dispersibility

Engineering Contradiction:

Improvein-use strengthVSAvoidbalance of strength and dispersibility

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent removes the expensive chemical binder entirely from the system. Instead, mechanical bonding through crimping and hydroentangling of cellulose fibers is used to provide the necessary in-use strength. This extraction of the binder component eliminates the cost issue and simplifies the dispersibility mechanism to purely physical rather than chemical bonds.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the chemical bonding mechanism (binder) with a mechanical bonding mechanism (crimping and hydroentangling). The mechanical interlocking of fibers through crimp patterns and hydroentangling provides sufficient strength during use while allowing for easier dispersibility through mechanical separation rather than chemical bond breaking.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If multi-ply construction is used to increase thickness and strength, then the wipe has sufficient in-use strength, but the wipe may not break apart easily after flushing

Engineering Contradiction:

Improvein-use strengthVSAvoiddispersibility after flushing

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The multi-ply construction is segmented into distinct webs with varying degrees of bonding. The crimp pattern creates localized bonding zones between plies, while leaving other areas with weaker or no bonding. This segmentation allows the multi-ply structure to provide strength where needed while facilitating separation into individual plies or smaller pieces during flushing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the multi-ply wipe have different bonding characteristics. The crimped areas provide strong inter-plies bonding for structural integrity, while the non-crimped areas have weaker bonding that allows for easier separation during flushing. This local variation in bond quality resolves the contradiction between overall strength and dispersibility.

Inventive Principle:

Principle #3Local quality

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 process results in wipes that maintain strength during use while efficiently breaking down post-flush, ensuring compatibility with sewer and septic systems and improving the balance of in-use strength and dispersibility.

Implementation Method 1

applying an aqueous solution to the first web

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Implementation Method 2

crimping the second web to the first web to create a composite web

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS11542664B2Process for making a multi-ply dispersible wipe

Publication Date: 2023.01.03 KIMBERLY CLARK WORLDWIDE INC

AI summary

A process for making a multi-ply dispersible wipe includes providing a first web and a second web, each web comprising cellulose fibers; superposing the first web over the second web; applying an aqueous solution to at least the first web; after the aqueous solution is applied to the first web, crimping the second web to the first web to create a composite web; cutting or perforating the composite web to define a plurality of multi-ply wet wipes; and packaging the composite web/wet wipes into a package.