High-Active Agent Filaments for Nonwoven Webs
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Solution Overview
Problem
Existing filament technologies have limitations in incorporating active agents at levels greater than filament-forming materials, with a need for filaments that can release active agents when exposed to conditions of intended use, while maintaining a high active agent content and minimizing costs.
Innovation Solution
Development of nonwoven webs comprising filaments with a high percentage of active agents and low percentage of filament-forming materials, where the active agents are integrated within the filament structure rather than as coatings, allowing for efficient delivery and release under specific conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the total level of active agents in filaments is increased to exceed the total level of filament-forming materials, then the delivery efficiency and performance of active agents is improved, but the filament structure stability and manufacturability deteriorate
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition parameters of the filament-forming materials to enable stable filament structures with high active agent content. Specifically, it uses water-soluble polymers (polyvinyl alcohol, starch, cellulose derivatives) as filament-forming materials that can maintain structural integrity while containing greater than 50 wt% active agents. The polymer selection and molecular weight parameters are optimized to balance structure stability with active agent release capability.
Solution Approach 2:
The patent employs composite materials by combining water-soluble polymers with high concentrations of active agents (surfactants, enzymes, bleaching agents, etc.) to create a composite filament structure. The polymer matrix provides structural stability while the embedded active agents deliver functional performance. This composite approach allows the filament to simultaneously maintain structural integrity and achieve superior active agent delivery efficiency.
2Ease of manufacture
If the total level of active agents in filaments is increased to exceed the total level of filament-forming materials, then the cost effectiveness is improved, but the manufacturing complexity and process control difficulty increase
Solution Approach 1:
The patent applies segmentation by dividing the filament formulation into distinct functional components: water-soluble polymer matrix (10-60 wt%) and active agent mixture (40-90 wt%). This segmentation allows for independent optimization of each component and simplifies the manufacturing process. The polymer provides structural function while the active agent mixture provides functional performance, enabling cost-effective production with reduced process complexity.
Solution Approach 2:
The patent uses parameter changes by establishing specific concentration ranges for filament-forming materials (10-60 wt%) and active agents (40-90 wt%) that optimize both manufacturing ease and cost effectiveness. Within these parameter ranges, the formulation achieves stable filament formation while maximizing active agent content, thereby reducing material costs and simplifying manufacturing processes.
3Device complexity
If dissolvable fibers are coated with active agents rather than having active agents integrated within the fibers, then the filament structure simplicity is maintained, but the active agent delivery efficiency and release control deteriorate
Solution Approach 1:
The patent applies the nested doll principle by embedding active agents within the filament structure during fiber formation, creating a core-shell type configuration where active agents are nested within the polymer matrix. This integrated structure ensures uniform distribution and controlled release of active agents, achieving superior delivery efficiency while maintaining filament structural simplicity. The active agents are incorporated into the filament cross-section rather than applied as surface coatings.
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
This approach enables optimal delivery of active agents with a higher concentration than filament-forming materials, enhancing performance and reducing costs, while allowing for the incorporation of otherwise incompatible agents in a nonwoven web.
Implementation Method 1
a nonwoven web comprising filaments formed from a filament-forming composition... the one or more extrusion heads comprises a plurality of spinnerets
Data Source
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AI summary
Filaments that contain a filament - forming material and an additive, nonwoven webs, and methods for making such filaments are provided. The level of one or more additives in the filament is 35% or more weight on a dry filament basis