Fibrous Substrate with In Situ Solid Hypochlorite Precipitate
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hypohalite-based disinfectant substrates face stability issues due to decomposition during storage and packaging, leading to reduced efficacy over time, especially in pre-wetted wipes and dry substrates with uneven distribution and slow release rates of hypochlorite, which are exacerbated by the use of binders and large particle sizes.
Innovation Solution
A process forming a solid hypochlorite precipitate on a fibrous substrate by exposing it to an aqueous alkaline earth salt solution and treating it with a hypohalite solution, allowing the precipitate to form around the fibers, resulting in a substrate that is substantially free of binders and adhesives, with the hypochlorite evenly distributed throughout, enabling rapid release upon moisture exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hypohalite solution is loaded onto an absorbent substrate to create pre-wetted wipes, then the substrate can provide disinfection capability, but the substrate lacks stability and decomposes during storage leading to reduced efficacy
Solution Approach 1:
The patent changes the physical state of the hypohalite from liquid (in solution) to solid (precipitate), which fundamentally alters the stability characteristics. The solid precipitate form remains stable during storage while still providing disinfection efficacy when activated by moisture during use.
Solution Approach 2:
The patent utilizes phase transition of the hypohalite from liquid phase (in solution) to solid phase (precipitate). This phase change enables the substrate to maintain stability during storage while retaining the ability to release active hypohalite when exposed to moisture during use.
2Reliability
If solid hypohalite particles are adhered to the substrate surface, then the substrate can provide disinfection capability, but the particles are unevenly distributed and release slowly
Solution Approach 1:
The patent merges the hypohalite precipitate with the substrate structure itself, forming an integrated composite where the precipitate is distributed throughout the substrate matrix rather than merely adhered to the surface. This integration ensures uniform distribution and rapid, consistent release.
Solution Approach 2:
The patent utilizes the porous structure of the fibrous substrate to distribute and hold the solid hypohalite precipitate uniformly throughout the material. The porous network allows for even dispersion of particles and rapid capillary wicking of moisture to the active sites, enabling fast release.
3Strength
If binders or adhesives are used to attach hypohalite particles to the substrate, then the particles can be retained on the substrate, but the binders interfere with the quick release of hypochlorite
Solution Approach 1:
The patent removes and eliminates the binder or adhesive component from the system entirely. Instead of using binders to attach hypohalite particles, the invention uses the fibrous substrate structure itself and the formation of solid precipitate to retain and release the active material without any interfering binder substances.
4Ease of operation
If large particle sizes are used for solid hypochlorite, then the particles can be easily handled and applied, but the release rate becomes too slow
Solution Approach 1:
The patent changes the particle size parameter to an optimal range that balances handling ease with rapid release. The solid hypochlorite precipitate is formed as fine particles that can be easily incorporated into the substrate while maintaining sufficient surface area for rapid dissolution and release when activated by moisture.
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 resulting hypohalite-releasing substrate maintains effective disinfection capabilities for an extended period, ensuring rapid and uniform hypochlorite release without the need for sealable containers or binders, enhancing stability and performance compared to prior art.
Implementation Method 1
allowing the alkaline earth salt solution to react with the hypohalite solution to form solid hypochlorite precipitate around the fibers in the fibrous material
Implementation Method 2
capable of rapid release of hypochlorite upon exposure to moisture or liquid
Data Source
AI summary
A cleaning substrate which comprises at least one layer of a solid hypohalite precipitate, wherein the hypohalite precipitate is formed in situ on the layer of substrate material. A process for making a fibrous cleaning substrate comprising the steps of: a) providing at least one layer of fibrous material; b) exposing the fibrous layer to an aqueous alkaline earth salt solution; c) treating the fibrous layer with a hypochlorite solution; d) allowing the aqueous alkaline earth salt solution combine with the hypochlorite solution to form a solid hypochlorite precipitate around the fibers in the fibrous material and a liquid phase, and e) removing at least 65% of the liquid phase from the fibrous substrate.