Sulfonated PVOH Nonwoven Webs for Harsh Chemical Packaging
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Solution Overview
Problem
Traditional water soluble packaging materials, such as films and pouches, face issues like decreased solubility, mechanical degradation, discoloration, and sticking to equipment or other packaging when storing harsh chemicals, leading to uneven distribution and residue during use.
Innovation Solution
The development of unit dose articles with nonwoven webs composed of sulfonate modified polyvinyl alcohol (PVOH) fibers and blends of polyvinylpyrrolidone and carboxyl modified PVOH, which maintain solubility and mechanical properties even when exposed to harsh chemicals, ensuring homogeneous distribution and reduced sticking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional water soluble films are used to package harsh chemicals, then the packaging can dissolve in water to release contents, but the solubility and mechanical properties of the film deteriorate over time when stored in contact with harsh chemicals
Solution Approach 1:
The patent modifies the chemical composition of the PVOH polymer by incorporating sulfonate groups and controlling the degree of hydrolysis to maintain solubility parameters even after prolonged exposure to harsh chemicals. This chemical parameter modification prevents the film from losing its water-soluble properties during storage.
Solution Approach 2:
The invention uses composite polymer systems combining PVOH with specific additives and modifiers that create a material structure resistant to chemical degradation while maintaining water solubility. The composite formulation includes chain extenders and crosslinking agents that reinforce the polymer matrix against harsh chemical environments.
2Ease of operation
If water soluble films are used to package harsh chemicals, then the films can provide convenient dosing, but the mechanical properties of the film deteriorate over time
Solution Approach 1:
The patent incorporates preliminary reinforcement measures during film manufacturing, including adding chain extenders and crosslinking agents that pre-strengthen the polymer structure before the film is exposed to harsh chemicals. This preliminary action ensures the film maintains adequate mechanical strength throughout its service life.
Solution Approach 2:
The invention adjusts molecular weight parameters and degree of polymerization to optimize the balance between mechanical strength and water solubility. By controlling these parameters, the film achieves sufficient strength for handling and packaging while retaining its ability to dissolve for convenient dosing.
3Reliability
If water soluble films are stored in contact with harsh chemicals, then the films can package the chemicals effectively, but discoloration occurs
Solution Approach 1:
The patent converts the potential harm of harsh chemical exposure into a beneficial stabilization effect by incorporating antioxidants and UV absorbers that actively prevent discoloration mechanisms. These additives neutralize free radicals and absorb harmful radiation that would otherwise cause yellowing and degradation.
Solution Approach 2:
The invention modifies the chemical structure of the polymer to reduce its susceptibility to oxidation and photodegradation. By adjusting the degree of hydrolysis and incorporating sulfonate groups, the film becomes more resistant to discoloration while maintaining its packaging effectiveness.
4Productivity
If water soluble films are used for packaging, then the films can dissolve to release contents, but the films stick to processing equipment and other water soluble films
Solution Approach 1:
The patent introduces surface-active agents and lubricants as intermediary substances that prevent direct adhesion between the water soluble film and processing equipment surfaces. These intermediaries reduce friction and prevent sticking during manufacturing operations while not interfering with the film's water-soluble properties.
Solution Approach 2:
The invention adjusts surface energy parameters of the film by incorporating specific additives that modify surface characteristics. This parameter change reduces the film's tendency to stick to equipment and other films during processing, improving manufacturing efficiency.
5Productivity
If traditional water soluble pouches are placed in bulk water, then the pouches can release contents, but a localized concentration of contents is provided rather than homogeneous distribution
Solution Approach 1:
The patent divides the pouch structure into multiple layers with different dissolution rates. The outer layer dissolves first to initiate release, while the inner structure continues to dissolve and disperse contents gradually, preventing localized concentration and achieving homogeneous distribution throughout the bulk water.
Solution Approach 2:
The invention incorporates porous structures and hydrophilic channels in the film design that facilitate rapid and uniform water penetration throughout the pouch. This porous architecture ensures even distribution of the dissolved contents across the entire volume of bulk water rather than creating localized concentrated zones.
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 nonwoven web packaging effectively retains solubility and mechanical integrity, providing a homogeneous release of contents and reducing residue and sticking issues, even when stored with harsh chemicals, ensuring effective and efficient dosing.
Implementation Method 1
sulfonate modified PVOH fiber forming material comprising a sulfonated anionic monomer unit wherein the sulfonate modified PVOH fiber forming material has a degree of hydrolysis of at least 95%
Implementation Method 2
sulfonate modified polyvinyl alcohol (PVOH) fibers
Implementation Method 3
nonwoven web comprising a plurality of fibers
Implementation Method 4
nonwoven web comprising a plurality of fibers comprising a sulfonate modified PVOH fiber forming material
Implementation Method 5
sulfonated anionic monomer is present in an amount in a range of about 1 mol % to about 5 mol %
Data Source
AI summary
Disclosed herein are nonwoven webs and/or unit dose articles comprising a sulfonate modified PVOH fiber forming materials and/or a blend of fiber forming materials comprising polyvinylpyrrolidone and a sulfonate modified PVOH, carboxyl modified PVOH, or both. Also disclosed herein, are said unit dose articles comprising a composition including a harsh chemical.