Antimicrobial hydrophilic polyurethane foam sponges
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Solution Overview
Problem
Hydrophilic polyurethane sponges face issues with antimicrobial treatments, as those used on cellulosic sponges are ineffective, leading to bacterial, fungal, and mold growth due to their moist environment, which affects consumer preference and safety.
Innovation Solution
Incorporating an antimicrobial composition with an acetate salt solution humectant or a non-halogen humectant salt solution having a pH between 3 and 10 and water activity less than 0.9 into hydrophilic polyurethane foam sponges to partially or completely kill microorganisms such as bacteria, fungi, and viruses, while maintaining moisture and preventing mold growth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If hydrophilic polyurethane sponges are kept in a moist condition to maintain loft and softness, then consumer preference is satisfied, but microbial growth (bacteria, fungus, mold) is promoted
Solution Approach 1:
The patent converts the harmful effect of moisture (which promotes microbial growth) into a beneficial state by using it as a vehicle to deliver antimicrobial agents. The moisture that would otherwise cause problems is instead used to dissolve and distribute water-soluble antimicrobial compounds throughout the sponge matrix, transforming the harmful moist environment into a controlled delivery system for protection.
Solution Approach 2:
The patent introduces water-soluble antimicrobial agents as intermediaries between the moist sponge environment and the microorganisms. These agents act as mediators that specifically target and eliminate microbes without interfering with the sponge's moisture retention or its loft and softness properties, allowing the sponge to maintain its desirable physical state while being protected from microbial contamination.
2Reliability
If conventional antimicrobial treatments are applied to hydrophilic polyurethane sponges, then microbial protection is achieved, but the treatments are ineffective due to material incompatibility
Solution Approach 1:
The patent changes the chemical parameters of the antimicrobial treatment by selecting water-soluble compounds specifically suited for hydrophilic polyurethane sponges. This involves changing from conventional oil-based or non-polar antimicrobial agents to water-based, polar compounds that are compatible with the hydrophilic nature of the sponge material, ensuring effective penetration and sustained release within the polyurethane matrix.
Solution Approach 2:
The patent creates a composite system combining hydrophilic polyurethane sponge material with water-soluble antimicrobial agents. This composite approach ensures compatibility between the sponge matrix and the antimicrobial treatment, allowing the antimicrobial compounds to be effectively incorporated, distributed, and released from the sponge structure without compromising either the sponge's physical properties or the antimicrobial efficacy.
3Stability of the object's composition
If sponges are packaged in a moist condition to prevent shrinkage and stiffness, then product quality is maintained, but package stability is compromised due to microbial contamination
Solution Approach 1:
The patent applies preliminary action by incorporating antimicrobial protection into the sponge before packaging. The water-soluble antimicrobial agents are pre-loaded into the sponge matrix, creating a protective barrier that activates upon packaging. This preliminary treatment ensures that when the sponge is packaged in its moist, quality-maintaining state, the antimicrobial agents are already in place to prevent microbial growth, thereby maintaining both product quality and package stability simultaneously.
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 antimicrobial composition effectively kills microorganisms within the sponges, maintaining their loft and softness while preventing bacterial and fungal growth, ensuring consumer safety and product stability.
Implementation Method 1
incorporating an antimicrobial composition including an acetate salt solution humectant within the hydrophilic polyurethane foam sponges
Implementation Method 2
a non-halogen humectant comprising a salt solution having a pH between about 3 and 10 and a water activity of less than 0.9 at 25° C
Implementation Method 3
hydrophilic polyurethane foam sponge having a wet wipe water holding capacity of between about 0.2 g/g foam and about 10 g/g foam
Data Source
AI summary
The inventors of the present disclosure recognized that, surprisingly, the antimicrobial treatments used on cellulosic sponges do not work in hydrophilic polyurethane sponges. As such, the inventors of the present disclosure discovered a need for an antimicrobial treatment for use on hydrophilic polyurethane foam sponges. The present inventors invented one antimicrobial composition for use on hydrophilic polyurethane foam sponges including an acetate salt solution humectant. The present inventors invented another antimicrobial composition for use on hydrophilic polyurethane foam sponges including a non-halogen humectant comprising a salt solution having a pH between about 3 and 10 and a water activity of less than 0.9 at 25° C.