Dispersible Moist Wipe Fiber Composition for Strength and Flushability
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Solution Overview
Problem
Flushable moist wipes take too long to break down in sanitation systems, risking blockages and requiring additional structural elements that compromise dispersibility or increase costs.
Innovation Solution
A method involving a nonwoven tissue web made from 70-90% natural fibers and 10-30% regenerated fibers, formed using a specific jetting process to create a dispersible sheet with sufficient in-use strength and rapid dispersibility, avoiding costly binders and synthetic fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If known flushable moist wipes use thermoplastically bonded bi-component fibers to increase in-use strength, then in-use strength is improved, but dispersibility deteriorates
Solution Approach 1:
The patent replaces thermoplastic bonding (thermal/chemical system) with hydroentanglement (mechanical system). High-pressure water jets mechanically entangle cellulose fibers to provide in-use strength without compromising dispersibility, as the mechanical entanglement dissolves in water unlike thermoplastic bonds
Solution Approach 2:
The patent changes the bonding mechanism parameter from thermoplastic fusion to hydroentangled mechanical interlocking. This parameter change allows the wipe to maintain strength through physical entanglement that naturally dissolves in water, resolving the contradiction between strength and dispersibility
2Strength
If known flushable moist wipes add triggerable salt-sensitive binder to increase in-use strength, then in-use strength is improved, but cost increases
Solution Approach 1:
The patent uses pure cellulose fibers that self-bond through hydroentanglement without requiring external binders. The cellulose fibers provide inherent bonding capability through mechanical entanglement, eliminating the need for costly salt-sensitive binders while maintaining in-use strength
Solution Approach 2:
The patent employs inexpensive cellulose fibers as the primary material that can be mechanically entangled to provide temporary strength during use, then naturally disperses after use. This replaces expensive chemical binders with a cost-effective fiber-based solution
3Strength
If known flushable moist wipes incorporate high quantity of synthetic fibers to increase in-use strength, then in-use strength is improved, but dispersibility deteriorates and cost increases
Solution Approach 1:
The patent changes the fiber composition parameter from synthetic fibers to 100% cellulose fibers. This material parameter change enables both adequate in-use strength through hydroentanglement and complete dispersibility in water, eliminating the problems associated with synthetic fiber content
4Object-generated harmful factors
If known flushable moist wipes use entangled fibers without additional structure, then dispersibility is improved, but in-use strength deteriorates
Solution Approach 1:
The patent uses high-pressure water jets (hydraulic system) to entangle cellulose fibers during manufacturing. The hydraulic entanglement process creates sufficient in-use strength through mechanical interlocking while maintaining the inherent dispersibility of cellulose fibers, eliminating the need for additional non-dispersing structural elements
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 produces wipes with adequate in-use strength that disperse quickly, preventing sanitation system blockages while being cost-effective, using a combination of natural and regenerated fibers and a unique jetting process to enhance hydroentanglement and dispersibility.
Implementation Method 1
The nonwoven tissue web is sprayed with a first plurality of jets... The nonwoven tissue web also is sprayed with a second plurality of jets...
Data Source
AI summary
A method for making a dispersible nonwoven sheet generally comprises dispersing natural fibers and regenerated fibers in a ratio of about 70 to about 90 percent by weight natural fibers and about 10 to about 30 percent by weight regenerated fibers in a liquid medium to form a liquid suspension. The liquid suspension is deposited over a foraminous forming wire to form a nonwoven tissue web. The nonwoven tissue web is sprayed with a first plurality of jets. Each jet of the first plurality of jets is spaced from an adjacent one of the first plurality of jets by a first distance. The nonwoven tissue web also is sprayed with a second plurality of jets. Each jet of the second plurality of jets is spaced from an adjacent one of the second plurality of jets by a second distance, and the second distance is less than the first distance. The nonwoven tissue web is dried to form the dispersible nonwoven sheet.