Multilayer Dryer Sheet Interior Softener Penetration

Solution Overview

Problem

Existing dryer sheets struggle to provide sufficient fabric softening benefits for large loads of laundry without causing staining and with an acceptable feel for users.

Innovation Solution

A multilayer dryer sheet comprising a nonwoven fibrous first layer and a second layer, with a fabric softener composition applied to the interior surfaces of both layers, allowing part of the composition to penetrate into the layers while keeping the exterior surfaces largely free from the composition, thus optimizing the distribution and release of the fabric softener.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If greater quantities of fabric softening actives are provided on dryer sheets, then fabric softening benefit is improved, but staining of garments occurs and consumer contact with actives increases

Engineering Contradiction:

Improvequantity of fabric softening activeVSAvoidstaining of garments

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The dryer sheet is divided into multiple layers (first layer and second layer) with different functions. The first layer contains the fabric softening composition and is designed to be consumed, while the second layer is a durable nonwoven fabric that provides structural support and prevents direct contact between actives and consumer skin. This segmentation allows high quantity of actives to be carried without causing staining or excessive consumer contact.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second layer acts as an intermediary between the fabric softening composition and the external environment. It allows the actives to be transferred to garments during the drying process while preventing direct contact between the actives and consumer skin, thus reducing staining and contact-related issues.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Quantity of substance

If greater quantities of fabric softening actives are provided on dryer sheets, then fabric softening benefit is improved, but consumer contact with actives increases leading to unacceptable feel

Engineering Contradiction:

Improvequantity of fabric softening activeVSAvoidconsumer contact with actives

Core Design Contradiction:

Quantity of substanceVSEase of operation

Solution Approach 1:

The dryer sheet is divided into multiple layers (first layer and second layer) with different functions. The first layer contains the fabric softening composition and is designed to be consumed, while the second layer is a durable nonwoven fabric that provides structural support and prevents direct contact between actives and consumer skin. This segmentation allows high quantity of actives to be carried without causing staining or excessive consumer contact.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second layer acts as an intermediary between the fabric softening composition and the external environment. It allows the actives to be transferred to garments during the drying process while preventing direct contact between the actives and consumer skin, thus reducing staining and contact-related issues.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Quantity of substance

If traditional sized dryer sheets are used with greater quantities of actives, then fabric softening benefit is improved, but actives coat the surface creating poor feel

Engineering Contradiction:

Improvequantity of fabric softening activeVSAvoidsurface coating of actives

Core Design Contradiction:

Quantity of substanceVSShape

Solution Approach 1:

The dryer sheet is divided into multiple layers (first layer and second layer) with different functions. The first layer contains the fabric softening composition and is designed to be consumed, while the second layer is a durable nonwoven fabric that provides structural support and prevents direct contact between actives and consumer skin. This segmentation allows high quantity of actives to be carried without causing staining or excessive consumer contact.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first layer is designed with specific local properties to hold and release the fabric softening composition. It has a structure that allows the actives to be distributed throughout the layer rather than coating the surface, providing uniform distribution and preventing surface coating issues while maintaining high active quantity.

Inventive Principle:

Principle #3Local quality

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 multilayer dryer sheet effectively delivers a sufficient quantity of fabric softening benefits to large loads of laundry, minimizing the risk of staining and ensuring an acceptable feel for users by controlled release and distribution of the fabric softener composition.

Implementation Method 1

part of the fabric softener composition is on the first layer interior surface and partially penetrating into the first layer

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Data Source

PatentUS12241044B2Multi-layer dryer sheet folded such that indented embossments face towards one another

Publication Date: 2025.03.04 PROCTER & GAMBLE CO

AI summary

A dryer sheet including: a nonwoven fibrous first layer and a nonwoven fibrous second layer joined to the first layer. The first layer has a first layer interior surface. The first layer has a first layer exterior surface area. The second layer has a second layer exterior surface area. The dryer sheet includes a fabric softener composition. Part of the fabric softener composition is on said first layer interior surface and partially penetrating into said first layer. The first layer exterior surface is free from said fabric softening composition over more than about 60% of said first layer exterior surface. The second layer exterior surface is free from said fabric softening active over more than about 60% of said second layer exterior surface.