Multi-Ply Cellulose Wet Wipe Design for High Absorbency and Low Cost
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Solution Overview
Problem
Conventional wet wipes made from synthetic fibers are costly and environmentally unsustainable, while cellulose-based wipes offer lower tensile strength and absorbent capacity, necessitating a cost-effective, high-absorbency cellulose-based wet wipe solution.
Innovation Solution
Development of multi-ply wet wipes composed entirely of papermaking fibers, free from synthetic fibers, with an absorbent capacity of at least 8 grams of wetting composition per gram of dry tissue, and a basis weight of 8 pounds per 3,000 square foot ream, enhancing absorbency and opacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional synthetic fiber nonwoven substrates are used, then high wet tensile strength and compatibility with wet wipe chemistry are achieved, but cost increases to $3,000 to $4,000 per ton and environmental sustainability deteriorates
Solution Approach 1:
The patent changes the material parameters by using 100% cellulose-based papermaking fibers instead of synthetic fibers, achieving cost reduction to around $800 per ton while maintaining acceptable strength through multi-ply construction with basis weights of at least 8 lb/rm per ply
Solution Approach 2:
The patent creates a composite structure by combining multiple plies of cellulose-based tissue with different orientations and properties, where the multi-ply construction compensates for the lower individual fiber strength to achieve adequate wet tensile strength for wet wipe applications
2Ease of manufacture
If cellulose-based papermaking fiber substrates are used, then cost reduces to around $800 per ton and environmental sustainability improves, but tensile strength and absorbent capacity deteriorate
Solution Approach 1:
The patent divides the wipe substrate into multiple plies of cellulose-based tissue, where each ply contributes to the overall strength and absorbency. The multi-ply construction allows the weak individual fibers to work together collectively, achieving adequate tensile strength while maintaining cost-effectiveness
Solution Approach 2:
The patent transitions from single-ply to multi-ply construction, adding the dimension of layering to compensate for the lower strength of individual cellulose fibers. This dimensional approach allows the wipe to achieve sufficient tensile strength through the combined effect of multiple layers
3Device complexity
If single-ply tissue is used, then simplicity is maintained, but absorbent capacity and liquid retention are insufficient
Solution Approach 1:
The patent segments the absorbent function across multiple plies, where each ply contributes to the total absorbent capacity. This segmentation allows the wipe to achieve high absorbency (at least 8 g/g) by combining the absorption capabilities of multiple layers rather than relying on a single thick ply
Solution Approach 2:
The patent merges multiple plies of tissue into a single multi-ply structure, combining their absorbent capacities to achieve the required 8 g/g absorption. This merging of multiple functional layers creates a unified wipe structure with enhanced liquid retention while maintaining operational simplicity
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 multi-ply cellulose-based wet wipes provide improved absorbent capacity, liquid retention, and opacity, addressing the limitations of single-ply tissues while maintaining a low cost and environmental sustainability.
Implementation Method 1
a multi-ply tissue impregnated with a wetting composition... has an absorbent capacity of at least about 8 grams of the wetting composition per gram of the dry multi-ply tissue
Implementation Method 2
The multi-ply tissue includes papermaking fibers... and has an absorbent capacity of at least about 8 g/g... providing improved absorbent capacity, liquid retention
Data Source
AI summary
The present invention is directed to wet wipes and methods of making thereof. In one aspect, a wet wipe includes a multi-ply tissue impregnated with a wetting composition. The multi-ply tissue includes papermaking fibers, is substantially free of synthetic fibers, and has an absorbent capacity of at least about 8 grams of the wetting composition per gram of the dry multi-ply tissue (g/g) as measured in accordance with American Society for Testing and Materials International (ASTM International) standard D4250. A single ply of the multi-ply tissue has a basis weight of at least 8 pounds per 3,000 square foot ream (lb/rm).