Fibrous Wipe Composition for Low-Basis-Weight Opacity and Strength
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Solution Overview
Problem
Manufacturing disposable wipes that balance strength, flexibility, thickness, opacity, and cost-effectiveness is challenging, as reducing basis weight to lower costs often compromises cleaning efficiency and consumer acceptance.
Innovation Solution
A fibrous material comprising 20-90% low denier thermoplastic fibers, 10-80% high denier thermoplastic fibers, and 0.2-4% opacifying agent, which maintains higher strength, thickness, and opacity at lower basis weights, enhancing consumer confidence and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the amount of fibers is reduced to lower basis weight and manufacturing cost, then manufacturing cost is reduced, but strength, thickness, opacity, and coverage are adversely affected
Solution Approach 1:
The patent applies composite materials by combining three distinct fiber types (high denier thermoplastic, low denier thermoplastic, and biodegradable fibers) in specific weight percentages to create a nonwoven substrate that achieves both cost reduction and maintained strength. The composite structure allows each fiber type to contribute its unique properties, with the total fiber content reduced while maintaining structural integrity through optimized composition.
Solution Approach 2:
The patent employs parameter changes by specifying precise denier ranges for different fiber types (high denier: 2.0-10.0, low denier: 0.5-2.0) and their weight percentages in the composite. This controlled variation in fiber parameters enables optimization of the substrate's physical properties while reducing overall basis weight and manufacturing cost.
2Ease of manufacture
If the amount of fibers is reduced to lower basis weight, then manufacturing cost is reduced, but thickness and coverage are adversely affected
Solution Approach 1:
The composite material structure utilizes the volumetric properties of low denier fibers (which have higher volume-to-weight ratio) to maintain substrate thickness despite reduced overall fiber content. The combination of high denier structural fibers with low denier volumetric fibers creates a cost-effective substrate with preserved thickness characteristics.
3Ease of manufacture
If the amount of fibers is reduced to lower basis weight, then manufacturing cost is reduced, but opacity is adversely affected
Solution Approach 1:
The composite material composition strategically incorporates biodegradable fibers (30-70% by weight) that provide inherent opacity, along with specific ratios of high and low denier thermoplastic fibers. This multi-component composite achieves the desired opacity at reduced basis weight by leveraging the optical properties of different fiber types rather than relying solely on increased fiber quantity.
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 combination of low and high denier thermoplastic fibers with an opacifying agent in the fibrous material achieves improved physical properties, such as higher strength and opacity, while reducing manufacturing costs, thus delivering high-quality wipes at lower basis weights.
Implementation Method 1
an opacifying agent... to increase its opacity
Implementation Method 2
an opacifying agent... to increase its opacity
Data Source
AI summary
A fibrous material suitable for making wipes is provided. The fibrous material comprises a mixture of high denier thermoplastic fibers, low denier thermoplastic fibers and an opacifying agent.