Residual Sanitization Coating Particle Size Control

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Solution Overview

Problem

Existing dispensing systems for residual surface sanitization or disinfection formulations struggle to achieve uniform coverage and durability on surfaces, particularly when using hands-free, non-pressurized sprayer devices, leading to inconsistent sanitization or disinfection.

Innovation Solution

A system comprising a sanitization or disinfection formulation and a device with a sprayer configured to deliver a coating with a Dv50 particle size distribution of less than 150 μm, achieving a residual coating coverage efficiency of at least 30 cm2/mm2, which covers a majority of the surface and provides durable residual sanitization or disinfection for a specified time period.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a thicker coating is applied to ensure sufficient coverage and durability, then the sanitization or disinfection effectiveness is improved, but the coating becomes tacky and leaves visible residue

Engineering Contradiction:

Improvesanitization effectivenessVSAvoidtacky residue

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the physical parameters of the spray system, specifically controlling particle size distribution (Dv50 < 150 μm) and spray pressure, to achieve optimal coating thickness that provides sanitization effectiveness without excessive buildup that causes tackiness and visible residue

Inventive Principle:

Principle #35Parameter changes

2Object-generated harmful factors

If a thinner coating is applied to avoid tackiness and visible residue, then the surface appearance is improved, but the coverage becomes insufficient and sanitization effectiveness is reduced

Engineering Contradiction:

Improvevisible residueVSAvoidsanitization coverage

Core Design Contradiction:

Object-generated harmful factorsVSReliability

Solution Approach 1:

The patent optimizes spray parameters including particle size distribution (Dv50 < 150 μm, Dv90 < 500 μm, Dv10 < 80 μm) and spray pressure to achieve a thin but uniform coating that covers the surface adequately without becoming tacky or leaving visible residue

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The coating is applied as numerous fine particles rather than large droplets, creating a uniform distributed layer that provides sufficient coverage at low thickness, preventing both inadequate sanitization and excessive residue

Inventive Principle:

Principle #1Segmentation

3Reliability

If the coating is applied to cover the entire surface uniformly, then the sanitization coverage is improved, but the application complexity increases requiring wiping or spreading

Engineering Contradiction:

Improveuniform coverageVSAvoidapplication simplicity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The spray system is designed to self-regulate and automatically achieve uniform coverage across the surface without requiring manual intervention for wiping or spreading, with the formulation and spray parameters optimized to distribute evenly on application

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent optimizes spray parameters (particle size, pressure, flow rate) and formulation properties to enable the coating to spread and level automatically upon application, achieving uniform coverage without requiring additional manual steps

Inventive Principle:

Principle #35Parameter changes

4Duration of action of stationary object

If the coating must be durable enough to withstand rubbing and abrasion, then the duration of protection is improved, but the coating becomes less compliant with surface disturbances

Engineering Contradiction:

Improvecoating durabilityVSAvoidcoating compliance

Core Design Contradiction:

Duration of action of stationary objectVSStability of the object's composition

Solution Approach 1:

The patent optimizes the coating formulation and application parameters to achieve a coating thickness and composition that balances durability against abrasion with compliance to surface disturbances, preventing both premature wear and excessive stiffness

Inventive Principle:

Principle #35Parameter changes

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 system effectively achieves uniform and durable residual surface sanitization or disinfection, ensuring consistent protection against microbes for a period of 12 hours to 1 month, without leaving a tacky or visible residue.

Implementation Method 1

a sprayer configured to spray the formulation onto a surface as a coating

Methodology Applied

Scientific EffectSpray: Fluid Spray

Implementation Method 2

coatings that are applied onto a hard surface and allowed to dry

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS20250114493A1Hard surface residual sanitization or disinfection coating and methods for doing the same

Publication Date: 2025.04.10 THE CLOROX CO

AI summary

System and methods for dispensing a residual surface sanitization or disinfection formulation on a surface. The system may include a formulation and a device. The device includes a sprayer configured to spray the formulation onto a surface as a coating. The spray has a Dv50 particle size distribution of less than about 150 μm and the coating has a residual coating coverage efficiency of at least 30 cm2/mm2. Additionally, the coating covers a majority of the surface and provides a durable coating on the surface for a time period therefore providing residual sanitization or disinfection to the surface over the time period.