Odor Control Fiber with Zinc-Copper Oxide Composite
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Solution Overview
Problem
Existing hygiene articles, such as incontinence garments and diapers, face challenges in odor control due to limitations in incorporating high concentrations of odor-suppressing metal oxides like zinc oxide (ZnO) into olefin-based polymer structures, which leads to film defects, haze, and degradation of mechanical properties.
Innovation Solution
A fiber and fabric composition comprising 85 wt % to 99.5 wt % of an olefin-based polymer blended with 15 wt % to 0.5 wt % of an odor suppressant, which includes a combination of an ionomer, zinc oxide particles, and copper oxide particles, enhancing odor suppression while maintaining mechanical and processing properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high loading of ZnO particles is used in olefin-based polymer structures, then odor suppression effectiveness increases, but film defects increase and mechanical properties deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters by replacing pure ZnO with a multi-component system containing zinc salts, copper salts, and titanium dioxide in specific ratios. This parameter change allows achieving odor suppression effectiveness comparable to high ZnO loading without the associated mechanical property deterioration and processing defects
Solution Approach 2:
The patent creates a composite odor control composition combining zinc salts, copper salts, and titanium dioxide particles within the olefin-based polymer matrix. This composite approach distributes the functional load across multiple components, preventing the concentration-related defects that occur with high ZnO loading while maintaining odor suppression effectiveness
2Reliability
If high loading of ZnO particles is used in olefin-based polymer structures, then odor suppression effectiveness increases, but haze increases and transparency degrades
Solution Approach 1:
The patent changes the particle composition parameters by substituting high-loading ZnO with a blend of zinc salts, copper salts, and titanium dioxide at optimized concentrations. This parameter change reduces light scattering and absorption effects that cause haze, thereby maintaining transparency while preserving odor suppression functionality
Solution Approach 2:
The patent replicates the odor suppression function of high ZnO loading through an alternative compositional system. The zinc-copper-titanium composite copies the chemical odor-neutralizing capabilities without replicating the optical defects (haze and transparency loss) associated with high ZnO concentrations
3Reliability
If high loading of ZnO particles is used in olefin-based polymer structures, then odor suppression effectiveness increases, but extrusion die lip buildup increases causing film defects
Solution Approach 1:
The patent changes the compositional parameters by replacing high-loading ZnO with a multi-salt system at lower individual concentrations. This parameter change reduces particle aggregation and die lip adhesion during extrusion, eliminating processing defects while maintaining odor suppression effectiveness through the synergistic zinc-copper-titanium combination
4Reliability
If high loading of ZnO particles is used in olefin-based polymer structures, then odor suppression effectiveness increases, but the amount of odor absorber loading is limited by practical constraints
Solution Approach 1:
The patent changes the compositional parameters by distributing odor control functionality across multiple salt components at moderate concentrations rather than relying on high loading of a single component. This parameter change removes practical loading limits while achieving equivalent or superior odor suppression effectiveness
Solution Approach 2:
The patent employs a composite odor control system combining zinc salts, copper salts, and titanium dioxide that functions synergistically. This composite approach eliminates the need for high individual component loadings, thereby removing practical constraints on odor absorber loading while maintaining effectiveness
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 composition achieves significant odor suppression, with an odor suppression value of up to 90%, while maintaining the mechanical and processing properties of the fibers and fabrics, effectively addressing the limitations of high ZnO loading in olefin-based polymer structures.
Implementation Method 1
Odor control particles such as zeolites, sodium bicarbonate, activated silica, activated carbon, and metal oxides (such as zinc oxide (ZnO)), and zinc salts in particular, are known to consume many odor-generating molecules such as urea (and other amino-based odorants), H2S and mercaptans
Implementation Method 2
The odor suppressant includes: (i) an ionomer, (ii) particles of zinc oxide, and (iii) particles of copper oxide
Data Source
AI summary
The present disclosure provides a fiber and fabrics made therefrom. In an embodiment, a fiber is provided and includes an odor control composition. The odor control composition includes (A) from 85 wt % to 99.5 wt % of an olefin-based polymer and (B) from 15 wt % to 0.5 wt % of an odor suppressant. The odor suppressant includes: (i) an ionomer, (ii) particles of zinc oxide, and (iii) particles of copper oxide.