Mesh-Reinforced Cellulose Sponge Cloth That Resists Dry Brittleness
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Solution Overview
Problem
Existing sponge cloths with mesh reinforcement are brittle and prone to breaking under mechanical stress when dry, lacking the kink resistance and abrasion resistance of fiber-reinforced cloths.
Innovation Solution
Incorporating short fibers and permanently softening hydrophilic polymers into the cellulose sponge cloth produced by the viscose process, with a network or grid for internal reinforcement, ensuring even distribution and mechanical stability without affecting biodegradability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a net or grid is used for reinforcement in sponge cloth, then production is simpler and easier, but the cloth becomes brittle and breaks easily under mechanical stress when dry
Solution Approach 1:
The patent combines two different reinforcement approaches: a net or grid structure for simplified production and short fibers for mechanical strength. The short fibers (10-40% by weight) are distributed throughout the cellulose matrix to provide kink resistance and prevent breaking, while the net or grid provides the basic structural framework, achieving both ease of manufacture and mechanical stability.
Solution Approach 2:
The sponge cloth uses a composite structure combining cellulose base material, short fibers for reinforcement, and a net or grid for structural support. This multi-component composite approach allows the material to benefit from the advantages of each component: the simplicity of net reinforcement and the mechanical strength of fiber reinforcement, while mitigating their individual disadvantages.
2Strength
If short fibers are added to improve mechanical stability, then the cloth becomes more resistant to breaking, but the production process becomes more complex
Solution Approach 1:
The patent specifies precise parameters for the short fibers to optimize both performance and manufacturability: fiber length of 0.1 to 0.6 cm and content of 10 to 40% by weight. These parameter ranges ensure adequate mechanical reinforcement while maintaining reasonable production complexity. The fibers are distributed throughout the cellulose matrix during the viscose process, integrating reinforcement into the existing manufacturing flow.
3Ease of operation
If the sponge cloth is kept moist to improve flexibility, then the cloth becomes more flexible and has better grip, but additional impregnation and packaging steps are required
Solution Approach 1:
The patent modifies the chemical composition by adding permanently softening hydrophilic polymers (2 to 50% by weight) that retain moisture within the cellulose matrix. This compositional change allows the sponge cloth to maintain flexibility and softness in its natural state without requiring external impregnation with hygroscopic salt solutions, thereby improving ease of operation while avoiding additional processing steps.
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 sponge cloth is stable in bending even when dry, with enhanced mechanical stability and abrasion resistance, extending its lifespan and usability.
Implementation Method 1
The cellulose is regenerated in a heated, alkaline coagulation bath
Implementation Method 2
The cellulose is regenerated from the cellulose xanthate in coagulation and regeneration baths
Implementation Method 3
The Glauber's salt has a very low melting point (around 32 to 33 °C). It is therefore melted and dissolved in the coagulation bath
Implementation Method 4
The Glauber's salt has a very low melting point (around 32 to 33 °C). It is therefore melted and dissolved in the coagulation bath
Implementation Method 5
the sponge cloth strips are impregnated with an aqueous solution of a hygroscopic salt, in particular magnesium chloride
Implementation Method 6
permanently softening polymers that cannot be washed out with water are also distributed evenly and three-dimensionally in the sponge cloth
Data Source
AI summary
A sponge cloth based on cellulose is disclosed, featuring internal reinforcement in the form of a mesh or grid that also incorporates evenly distributed fibers and/or permanently water-resistant, softening polymers. The sponge cloth is manufactured using the viscose process, in which cellulose xanthate is mixed with the fibers and/or the softening polymers and the pore-forming agent, and the resulting sponge cloth raw material is formed into a thin layer. The grid or mesh is then applied to this layer, followed by another layer of the sponge cloth raw material. In alkaline or acidic coagulation and regeneration baths, as well as in washing baths, the pore-forming agent is dissolved and the cellulose is regenerated from the cellulose xanthate. The sponge cloth does not break even when dry; that is, it is crease-resistant. The sponge cloth is primarily intended for cleaning and cleaning purposes in households and industry.