Extruded Dryer Bars With Controlled Void Volume for Crack Resistance
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Solution Overview
Problem
Existing methods for manufacturing dryer bars often result in products that are brittle, prone to cracking, and exhibit yellowing due to oxidation, making them unsuitable for competitive pricing in the consumer market.
Innovation Solution
A single screw extrusion process is used to create dryer bars with a fabric softening composition that includes a quaternary ammonium compound, achieving a void volume percentage of 3% to 10%, which enhances durability and reduces brittleness, while maintaining effective fabric softening performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional melting and pouring methods are used to manufacture dryer bars, then the manufacturing process is simple, but the resulting bars exhibit brittleness and are prone to cracking
Solution Approach 1:
The patent applies parameter changes by modifying the manufacturing process parameters - using extrusion technology with controlled temperature, pressure, and screw rotation speed to achieve optimal material density and structural integrity, thereby resolving the contradiction between manufacturing simplicity and bar strength
Solution Approach 2:
The patent replaces the traditional melting and pouring mechanical system with an extrusion system that uses a single screw to convey and compress the composition through a die, creating a more structurally sound bar that resists cracking while maintaining ease of manufacture
2Ease of manufacture
If traditional manufacturing methods are used, then production cost is low, but the bars undergo yellowing due to oxidation
Solution Approach 1:
The patent implements an inert atmosphere by purging the extruder and die with nitrogen gas during the extrusion process, preventing oxidation of the fabric softener composition and eliminating yellowing while maintaining cost-effective production through a relatively simple modified extrusion system
3Strength
If void volume is increased to reduce brittleness, then bar durability improves, but manufacturing precision becomes more difficult to control
Solution Approach 1:
The patent employs feedback control by monitoring and adjusting extrusion parameters (temperature, pressure, screw speed) during manufacturing to achieve consistent void volume within the optimal 3-10% range, ensuring both durability and manufacturing precision
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 produces dryer bars that are more durable, less prone to cracking, and maintain effective fabric softening performance, addressing the issues of brittleness and yellowing, thus enabling competitive pricing in the market.
Implementation Method 1
A first aspect of the invention provides for a dryer bar comprising a fabric softening composition, wherein the fabric softening composition comprises a void volume percentage from about 0.33% to about 20% with respect to the total volume of the composition
Implementation Method 2
The single screw is capable of conveying the composition through the channel of the feed region, cooling region, and heating/static region
Implementation Method 3
heating/static mixing region downstream from the cooling region, wherein the single screw is capable of conveying the composition through the channel of the feed region, cooling region, and heating/static region
Data Source
AI summary
Dryer bars having certain defined void volumes.