Modified Open-Cell Melamine Foam for Durable Grease Removal

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Solution Overview

Problem

Melamine-formaldehyde foams used for cleaning hard surfaces are effective but lack durability and efficiency in removing greasy soap scum and kitchen dirt, often crumbling when used with solvents.

Innovation Solution

Incorporating a linear polymer with a number average molecular weight between 500 to 10,000 g/mol into melamine-formaldehyde foams to create a cleaning implement with improved durability and soil removal capabilities, potentially in a multi-layered configuration with additional foam or materials for enhanced performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If melamine-formaldehyde foam is used to clean hard surfaces, then soil and stain removal performance is improved, but durability deteriorates as the foam crumbles when wetted

Engineering Contradiction:

ImprovedurabilityVSAvoidfoam crumbling

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent combines melamine-formaldehyde foam with a linear polymer (such as polyethylene glycol or polypropylene glycol) to create a composite cleaning implement. This composite structure integrates the soil-removal capabilities of melamine foam with the durability and binding properties of the linear polymer, preventing the foam from crumbling when wetted while maintaining effective cleaning performance on hard surfaces.

Inventive Principle:

Principle #40Composite materials

2Reliability

If substantial amounts of solvent are used to optimize soil removal, then cleaning effectiveness is improved, but loss of substance increases

Engineering Contradiction:

Improvecleaning effectivenessVSAvoidsolvent consumption

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent modifies the physical and chemical parameters of the cleaning implement by incorporating a linear polymer with specific molecular weight (500-10,000 g/mol) and concentration (0.1-5% by weight). This parameter change allows the foam to maintain structural integrity when wetted, enabling effective cleaning with reduced solvent consumption since the foam doesn't disintegrate and requires less water to function properly.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If melamine foam is used for cleaning, then soil removal performance is improved, but manufacturing complexity increases due to polymer incorporation

Engineering Contradiction:

Improvesoil removal performanceVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the melamine-formaldehyde foam synthesis process with the linear polymer incorporation in a single manufacturing step. The linear polymer is added to the foam formulation during production, combining two functional components into one integrated manufacturing process. This approach maintains improved soil removal performance while avoiding the need for separate polymer application steps, thereby limiting the increase in manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11877709B2Cleaning implement comprising a modified open-cell foam

Publication Date: 2024.01.23 PROCTER & GAMBLE CO

AI summary

The present invention relates to a cleaning implement that includes a melamine-formaldehyde foam. The melamine-formaldehyde foam includes from about 0.1 to about 5 weight % of at least one linear polymer with a number average molecular weight Mn in the range from 500 to 10,000 g/mol. Additionally the present invention encompasses processes for making and methods for cleaning hard surfaces with a cleaning implement according to the present invention.