Process for manufacturing scrubby substrates and substrates made therefrom
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing scrubby substrates for household cleaning lack sufficient abrasivity and durability, often requiring binders for attachment and having uneven scrubbing performance due to the formation of fibers or filaments during manufacturing processes.
Innovation Solution
An in-line process that extrudes molten polymer resin through heated nozzles into a stream of hot inert gas to form discontinuous globules or continuous fibers with irregular cross-sections, which are deposited onto a base substrate layer without binders, creating a multi-layer scrubby substrate with enhanced abrasivity and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional meltblown processes are used to create scrubby substrates, then the substrates can be manufactured, but they lack sufficient abrasivity and durability
Solution Approach 1:
The patent changes the physical parameters of the extrusion process, specifically controlling the distance between the nozzle and collector to less than 15 cm and adjusting polymer resin parameters, to transform the output from uniform fibers to irregular globules that provide superior abrasivity while maintaining durability
Solution Approach 2:
The patent creates local quality variations by producing globules with irregular cross-sections and thicknesses rather than uniform fibers, concentrating abrasive properties in specific regions where the globules make contact with surfaces during scrubbing
2Strength
If binders are used to attach the scrubby layer to the base substrate, then adhesion is achieved, but the complexity of the manufacturing process increases
Solution Approach 1:
The patent extracts and eliminates the binder component from the manufacturing process entirely. The molten polymer resin is applied directly to the base substrate without any additional adhesive layers, simplifying the process while maintaining strong adhesion through the inherent stickiness of the molten polymer
Solution Approach 2:
The molten polymer resin serves its own adhesion function without requiring a separate binder. The polymer's natural properties provide the bonding mechanism, making the system self-sufficient and eliminating the need for additional materials
3Productivity
If uniform fibers are produced during extrusion, then the manufacturing process is stable, but the scrubbing performance becomes uneven
Solution Approach 1:
The patent intentionally introduces asymmetry and irregularity into the fiber structure by controlling extrusion parameters to produce globules with varying shapes, sizes, and cross-sections. This asymmetry is what creates the superior and more consistent scrubbing performance across different areas of the substrate
4Strength
If additional heat treatments are applied after scrubby layer formation, then bonding is enhanced, but the production time and energy consumption increase
Solution Approach 1:
The patent performs the bonding action preliminarily during the extrusion process itself. The molten polymer resin bonds to the base substrate as it is being deposited, eliminating the need for subsequent heat treatment steps to enhance bonding
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 process results in scrubby substrates with improved abrasivity and durability, providing a better scrubbing performance compared to traditional meltblown products, with enhanced adhesion that resists flaking off during use, and can be integrated into existing production lines without additional heat treatments.
Implementation Method 1
melting a polymer resin material, and extruding the molten polymer resin through one or more orifices of a heated nozzle into a stream of hot inert gas
Implementation Method 2
hot inert gas which attenuates the molten resin into globules
Implementation Method 3
The globules are collected onto at least a portion of the surface of the base substrate layer, and upon cooling and solidification of the molten polymer resin, they are abrasive, providing a rough, scrubby texture
Data Source
Figure 1~2
Figure 3A
Figure 3B~3C
AI summary
In-line processes for producing scrubby substrates, and related scrubby substrate cleaning articles. The process may include melting a polymer resin material, and extruding or otherwise dispensing the molten polymer resin material through one or more orifices of a heated nozzle, into a stream of hot inert gas, which attenuates the molten resin, so that the resin forms into elongated globules (rather than fibers or filaments). Such globules may have irregular cross-section and/or irregular thickness along a length of the globules. Alternatively, the molten resin may be formed into substantially continuous or discontinuous string or chain pattern of abrasive fibers, exhibiting a high frequency, low amplitude substantially linear pattern on the base substrate. In either case the globules or abrasive fibers are collected onto at least a portion of a base substrate layer to form a scrubby substrate that is more abrasive than typical meltblown materials.