Reinforced Sponge Cloth Composition for Dry-State Bend Stability
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Solution Overview
Problem
Dry sponge cloths with net reinforcement are brittle and break easily under mechanical loading, while pre-moistened versions lack bending stability and have limited abrasion resistance.
Innovation Solution
Incorporating short fibers and hydrophilic, permanently softening polymers into the cellulose-based sponge cloth to enhance mechanical stability and abrasion resistance, with the net providing reinforcement and the polymers reducing crystallization tendencies of cellulose.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a net reinforcement is used in sponge cloth, then production is simplified and manufacturing cost is reduced, but the sponge cloth becomes brittle and breaks easily under mechanical loading in dry state
Solution Approach 1:
The patent combines net reinforcement with short fiber reinforcement to create a composite structure. The net provides the primary reinforcement framework while the short fibers fill the spaces between net intersections, creating a more distributed and effective reinforcement system that prevents brittleness while maintaining manufacturing efficiency.
Solution Approach 2:
The short fibers are distributed throughout the sponge cloth matrix, providing localized reinforcement at points where stress concentrates between net intersections. This local quality enhancement addresses the brittleness issue without requiring a complete redesign of the manufacturing process.
2Ease of operation
If the sponge cloth is kept moist by impregnation with aqueous solution, then flexibility and hand are improved, but bending stability is lost and abrasion resistance is limited
Solution Approach 1:
The dual reinforcement system of net and short fibers creates a composite structure that maintains structural integrity even when moist. The short fibers distribute stresses more evenly throughout the material, preventing the loss of bending stability that normally occurs when the cloth is kept moist for flexibility.
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 sponge cloth becomes bending stable in the dry state and exhibits improved abrasion resistance, maintaining integrity and flexibility, as demonstrated by increased folding cycles and Veslic test results.
Implementation Method 1
hydrophilic, permanently softening polymers... reducing crystallization tendencies of cellulose
Implementation Method 2
sponge cloth material... porous structure
Implementation Method 3
impregnated with an aqueous solution of a hygroscopic salt
Data Source
AI summary
A cellulose sponge cloth containing a net or grid as internal reinforcement is provided, with the sponge cloth further including a uniform distribution of fibers and/or durably softening polymers that are not water-leachable. The sponge cloth is produced by the viscose process by mixing with the fibers and/or the softening polymers and the pore former with cellulose xanthate and forming the resulting sponge cloth raw material into a thin layer. The grid or net is placed onto this layer, followed by a further layer of the sponge cloth raw material. Coagulation and regeneration baths and optional wash baths are used to dissolve the pore former out of the sponge cloth and regenerate the cellulose. The sponge cloth is bend-resistant, it does not break in the dry state. The sponge cloth is envisioned for cleaning and decontamination.