Multi-Ply Flushable Wipe Fiber Composition for Dispersion and Strength
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Solution Overview
Problem
Current flushable wipe products are not truly flushable as they do not disperse well in household toilet/septic systems, often clogging sewage systems, and contain significant synthetic fibers, failing to meet eco-friendly and biodegradable standards.
Innovation Solution
A three-layer wipe design with external layers composed of 50-100% natural fibers and a core layer of foam-formed fiber blends, including long synthetic fibers, along with water-soluble binders that disintegrate upon dilution, ensuring the wipe disintegrates during flushing and maintains strength for pre-moistening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If size-based flushable wipes are used to pass through plumbing systems, then the wipes can be flushed immediately, but they do not break down into smaller pieces or fiber clusters and often plug up sewage systems
Solution Approach 1:
The wipe is constructed with a multi-ply structure where outer plies contain short synthetic fibers (3-19 mm) that segment and disperse rapidly in water, while inner plies contain longer synthetic fibers (20-50 mm) that maintain structural integrity during flushing. This segmentation allows the wipe to break down into smaller fiber clusters that can pass through sewage systems without clogging
Solution Approach 2:
The patent applies different fiber length parameters across different plies of the wipe. Outer plies use short fibers (3-19 mm) for rapid dispersion, while inner plies use longer fibers (20-50 mm) for strength. This parameter variation enables the wipe to transition from an intact structure during flushing to dispersed fibers in sewage systems
2Strength
If synthetic fibers are used in flushable wipes to maintain strength, then the wipes can be handled and pre-moistened, but they fail to disperse adequately and are not truly flushable
Solution Approach 1:
Different regions of the wipe have different fiber compositions optimized for their specific functions. Outer plies contain short synthetic fibers (3-19 mm) that disperse rapidly to reduce clogging, while inner plies contain longer synthetic fibers (20-50 mm) that maintain structural strength. This local quality differentiation allows the wipe to simultaneously achieve strength and dispersibility
Solution Approach 2:
The wipe uses composite fiber materials combining natural fibers and synthetic fibers in specific ratios across different plies. Outer plies have higher synthetic fiber content (10-40%) for dispersion, while inner plies have lower synthetic fiber content (5-20%) for strength. This composite structure resolves the contradiction between strength and dispersibility
3Object-generated harmful factors
If natural fibers are used to create biodegradable and eco-friendly wipes, then the wipes meet environmental standards, but they lack the strength properties needed for pre-moistening and handling
Solution Approach 1:
The wipe structure assigns different fiber types to different regions based on functional requirements. Outer plies use predominantly natural fibers (60-90%) for biodegradability and eco-friendliness, while inner plies use a blend of natural and synthetic fibers (80-95% natural, 5-20% synthetic) for structural strength. This local quality differentiation allows the wipe to simultaneously achieve environmental friendliness and functional strength
Solution Approach 2:
The patent creates composite fiber structures combining natural fibers for biodegradability with synthetic fibers for strength. The composite composition varies by ply: outer plies are 60-90% natural fibers for environmental friendliness, while inner plies are 80-95% natural fibers with 5-20% synthetic fibers for maintaining structural integrity during handling and pre-moistening
4Strength
If binders are used to hold wipe plies together to maintain strength, then the wipes can be pre-moistened without losing strength, but the binders may prevent proper disintegration during flushing
Solution Approach 1:
The binder composition and concentration are carefully controlled to achieve optimal performance. Binders are applied at specific concentrations (0.5-5% of dry fiber weight) and use water-soluble formulations that maintain strength during pre-moistening but dissolve during flushing. This parameter control allows the binder to provide temporary strength that disappears when needed for disintegration
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 solution provides a truly flushable, biodegradable wipe that prevents sewage system clogging and meets eco-friendly criteria by using natural fibers and controlled binder solubility, ensuring effective dispersion and reduced environmental impact.
Implementation Method 1
water-soluble binders that disintegrate upon dilution, ensuring the wipe disintegrates during flushing
Data Source
AI summary
A multi-ply flushable wipe includes a ply having first and second exterior layers and a middle layer disposed therebetween. Each of the exterior layers includes at least 50% by weight natural fibers. When foam-formed, the middle layer includes at least 25% by weight natural fibers. In embodiments, the middle layer may include at least 75% by weight natural fibers. The middle layer also includes synthetic fibers that have a length within the range of 1 mm and 20 mm. The wipe may have a length weight weighted average fiber length of less than 4 mm and a wet CD strength of greater than 20 N/m. Each ply of the wipe may be formed by wetlaying the first and second exterior layers and a foam formed middle layer to form a web, imprinting the web with a structured fabric, and drying the web. The plies are then attached using a binder.