Filaments with High Active Agent Content for Rapid Release

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Solution Overview

Problem

Existing filaments and fibers typically have a higher content of filament-forming materials compared to active agents, limiting the delivery of active agents and requiring a higher cost and slower release rates, while also being unable to incorporate incompatible active agents effectively.

Innovation Solution

Developing filaments with a composition of less than 65% filament-forming materials and greater than 35% active agents by weight, allowing for the release of active agents when the filament's morphology changes, and using a spinning process with a filament-forming composition that includes polar solvents to produce nonwoven webs with enhanced active agent delivery.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If filaments contain higher content of filament-forming materials compared to active agents, then the filament structure is maintained, but the delivery efficiency of active agents is limited and release rate is slower

Engineering Contradiction:

Improvecontent of active agentsVSAvoiddelivery efficiency of active agents

Core Design Contradiction:

Quantity of substanceVSProductivity

Solution Approach 1:

The patent applies parameter changes by inverting the conventional composition ratio, formulating filaments with greater than 50% active agents by weight and less than 50% filament-forming materials. This radical parameter change enables the filament to maintain structural integrity while dramatically increasing active agent delivery efficiency and release rate, directly resolving the technical contradiction between quantity of active agents and delivery productivity

Inventive Principle:

Principle #35Parameter changes

2Quantity of substance

If filaments contain higher content of active agents, then the delivery of active agents is optimized, but the cost increases

Engineering Contradiction:

Improvecontent of active agentsVSAvoidmanufacturing cost

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The patent employs the principle of disposable materials by using water-soluble filament-forming materials that completely dissolve to release active agents. This approach eliminates the need for expensive recovery or recycling processes, making the high active agent content economically viable. The filament is designed to be consumed entirely during the delivery process, transforming the cost structure from long-term durable material to short-term sacrificial carrier

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Productivity

If filaments contain higher content of active agents, then the release rate increases, but the filament structure stability is compromised

Engineering Contradiction:

Improverelease rate of active agentsVSAvoidfilament structure stability

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The patent utilizes composite materials by combining water-soluble filament-forming materials with active agents in an inverted ratio. The water-soluble nature of the filament-forming material provides a controlled dissolution mechanism that maintains structural stability during handling and application, while enabling rapid release of active agents when water is present. This composite approach reconciles the contradiction between release rate and structural stability

Inventive Principle:

Principle #40Composite materials

4Adaptability or versatility

If conventional filaments are used, then the filament structure is maintained, but incompatible active agents cannot be incorporated effectively

Engineering Contradiction:

Improveincorporation of active agentsVSAvoidcompatibility of active agents

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The patent applies parameter changes by selecting water-soluble filament-forming materials as the continuous phase, creating a versatile matrix that can accommodate both hydrophilic and hydrophobic active agents through appropriate formulation. This parameter change in the base material composition enables effective incorporation of previously incompatible active agents while maintaining overall filament stability through the dominant continuous phase

Inventive Principle:

Principle #35Parameter changes

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

Enables the efficient and cost-effective delivery of active agents with faster release rates and the incorporation of previously incompatible agents, optimizing the use of active agents while maintaining the filament's structure and properties.

Implementation Method 1

a spinning process with a filament-forming composition that includes polar solvents to produce nonwoven webs

Methodology Applied

Scientific EffectPhase transition: Phase Change

Implementation Method 2

wherein the total level of the one or more filament-forming materials present in the filament is less than 65% by weight on a dry filament basis and the total level of the one or more active agents present in the filament is greater than 35% by weight on a dry filament basis

Methodology Applied

Scientific EffectDissolution:

Data Source

PatentUS11970789B2Filaments comprising an active agent nonwoven webs and methods for making same

Publication Date: 2024.04.30 PROCTER & GAMBLE CO

AI summary

Filaments that contain a filament-forming material and an additive, nonwoven webs, and methods for making such filaments are provided.