Multi-Ply Fibrous Articles With Bonding for Flexibility and Dissolution
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Solution Overview
Problem
Current fibrous structures containing active agents struggle to achieve consumer-acceptable in-use properties such as structural integrity, flexibility, and dissolvability, particularly when comprising multiple plies, as they often prematurely fall apart during manufacturing, distribution, and use without maintaining adequate peel strength and flexibility.
Innovation Solution
The development of fibrous structures with fibrous elements that are mechanically or thermally bonded, or associated through moisture, to enhance inter-ply and intra-ply bond strength while maintaining flexibility and dissolvability, characterized by specific dimensions and peel forces, ensuring the structures remain intact during handling and use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fibrous structures are designed with multiple plies containing active agents, then the article provides sufficient functionality and active agent delivery, but the article exhibits insufficient structural integrity and prematurely falls apart during manufacturing, distribution, and use
Solution Approach 1:
The patent applies preliminary bonding actions during the manufacturing process to establish strong inter-ply connections before the article is put into service. The fibrous structures are bonded together under controlled conditions (temperature, pressure, moisture) to create permanent bonds that prevent premature separation during subsequent handling and use
Solution Approach 2:
The patent uses composite material structures combining multiple fibrous plies with different properties. Each ply can have tailored characteristics (hydrophilicity, strength, dissolution rate) while being bonded together to create a unified multi-functional article that maintains structural integrity throughout its lifecycle
2Strength
If bonding methods are strengthened to improve inter-ply and intra-ply bond strength, then the article maintains structural integrity, but the article loses flexibility and becomes too stiff for consumer use
Solution Approach 1:
The patent employs parameter changes in the bonding process by controlling temperature, pressure, and moisture levels to achieve optimal bond strength. By adjusting these parameters, the bonding method creates strong bonds that maintain structural integrity while preserving the natural flexibility of the fibrous materials
Solution Approach 2:
The patent uses moisture as an intermediary substance to facilitate bonding between plies. The moisture activates the bonding mechanism (such as hydrolysis of polyvinyl alcohol) to create strong bonds without requiring excessive heat or pressure that would compromise the flexibility of the fibrous structure
3Reliability
If the article is designed to maintain integrity during handling, then the article resists premature separation, but the article exhibits insufficient dissolution performance when needed for consumer use
Solution Approach 1:
The patent creates a dynamic bonding system where bonds are strong under dry conditions during manufacturing and handling, but become reversible or breakable when exposed to moisture during consumer use. This dynamic behavior allows the article to maintain integrity when needed and dissolve when required
Solution Approach 2:
The patent utilizes phase transitions of bonding materials (such as the gel-to-sol transition of polyvinyl alcohol) to achieve different states: a gel state that provides strong bonds during storage and handling, and a sol state that allows dissolution and separation during use. The bonding material transitions between these phases in response to environmental conditions
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 enhanced bonding and structural design of the fibrous structures achieve superior plybond, flexibility, and hand dissolution properties, preventing premature separation and ensuring effective performance during manufacturing, distribution, and consumer use.
Implementation Method 1
fibrous structures with fibrous elements that are mechanically or thermally bonded
Implementation Method 2
fibrous structures with fibrous elements that are mechanically or thermally bonded
Implementation Method 3
associated through moisture, to enhance inter-ply and intra-ply bond strength
Data Source
AI summary
Active agent-containing articles, for example fibrous structures, that exhibit consumer acceptable article in-use properties, such as article peel strength, flexibility, article dimensions, and/or dissolvability, and methods for making same are provided.