Hydrophilic Fibrous Elements Using Wetting Agent
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Solution Overview
Problem
Existing fibrous structures incorporating small diameter hydrophobic filaments face challenges in becoming less hydrophobic or hydrophilic due to ineffective wetting agents, leading to hydrophobic properties regardless of filament quantity.
Innovation Solution
A fibrous element comprising a polymer and a wetting agent, with the wetting agent present at 0-2% by weight, is spun to achieve a diameter of less than 2 μm and a contact angle of less than 80°, enabling the formation of fibrous structures that can be made hydrophilic by activating the wetting agent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional wetting agents are used on hydrophobic fibrous elements, then the surface tension of absorbed fluids is reduced, but the ability of the fibrous structure to hold onto the fluid deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the wetting agent concentration within 0.01-5% by weight of the polymer and maintaining filament diameters between 0.5-2.0 μm. These specific parameter ranges optimize the balance between reducing surface tension and maintaining fluid holding capacity, resolving the contradiction between making the structure less hydrophobic and preserving its ability to hold fluid.
Solution Approach 2:
The patent employs dynamic control of wetting agent activation, where the wetting agent can be activated at different stages (during spinning or post-processing). This dynamic approach allows the system to transition from a hydrophobic state during manufacturing to a hydrophilic state when fluid absorption is needed, thereby resolving the contradiction between surface tension reduction and fluid holding ability.
2Area of stationary object
If the diameter of fibrous elements is reduced to less than 2 μm, then the surface area increases, but the effectiveness of wetting agents deteriorates
Solution Approach 1:
The patent resolves this contradiction by establishing specific parameter ranges: filament diameters of 0.5-2.0 μm combined with wetting agent concentrations of 0.01-5% by weight of the polymer. This precise parameter control ensures that the increased surface area from small diameter filaments is effectively utilized by the wetting agent, overcoming the reduced effectiveness typically observed at such small scales.
Solution Approach 2:
The patent creates a composite fibrous structure where ultra-fine filaments (0.5-2.0 μm) are combined with specifically formulated wetting agents. This composite approach allows the small diameter filaments to provide high surface area while the wetting agent compensates for the reduced effectiveness at small scales, achieving both increased surface area and effective wetting.
3Object-affected harmful factors
If wetting agent concentration is increased to make fibrous structures hydrophilic, then the contact angle decreases, but the manufacturing complexity increases
Solution Approach 1:
The patent simplifies manufacturing by establishing an optimal wetting agent concentration range of 0.01-5% by weight of the polymer. This parameter range is sufficient to achieve the desired contact angle reduction (making the structure hydrophilic) without requiring excessive amounts of wetting agent or complex multi-step processing, thereby reducing manufacturing complexity while achieving the hydrophilic effect.
Solution Approach 2:
The patent applies preliminary action by incorporating the wetting agent into the polymer matrix before spinning the filaments. This pre-mixing approach ensures uniform distribution of the wetting agent throughout the fibrous structure, eliminating the need for post-processing treatments or complex application equipment, thus reducing manufacturing complexity while achieving effective contact angle reduction.
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 approach successfully creates fibrous elements and structures that can be effectively hydrophilized, overcoming the limitations of prior wetting agents and enhancing the absorbent capacity of fibrous structures.
Implementation Method 1
Wetting agents have been used both as surface treating agents on hydrophobic fibrous elements, such as polypropylene filaments and/or polyester fibers, and as melt treating agents within polymer melt compositions that are spun into filaments
Data Source
AI summary
Fibrous elements, such as filaments, and more particularly to fibrous elements employing a polymer and a wetting agent, methods for making such fibrous elements, fibrous structures employing such fibrous elements, methods for making such fibrous structures and packages containing such fibrous structures are provided.