Water-Soluble Substrate Protrusions for Dissolution Resistance
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Solution Overview
Problem
Water-soluble substrates used in packaging materials, such as pouches, tend to leak or stick when exposed to small amounts of water or high humidity, and may fail to fully dissolve when intended, posing issues in storage and use.
Innovation Solution
A water-soluble substrate with water-insoluble particles partially embedded, forming protrusions on its surface, providing resistance to dissolution before immersion in water while ensuring rapid dissolution when submerged, and maintaining integrity during stretching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a water-soluble substrate is coated with a water-insoluble barrier coating to prevent premature dissolution, then resistance to dissolution is improved, but the coating may break during stretching causing the substrate to leak and stick
Solution Approach 1:
The patent applies a porous hydrophobic coating to the water-soluble substrate. The porous structure allows the coating to accommodate stretching deformation without breaking, while the hydrophobic nature maintains water resistance. The coating's porosity enables it to flex and stretch with the substrate while still providing effective barrier protection against water penetration during storage and handling.
2Speed
If a water-soluble substrate is made highly soluble to ensure rapid dissolution in water, then dissolution speed is improved, but the substrate becomes vulnerable to premature dissolution from small amounts of water or humidity
Solution Approach 1:
The patent creates a composite structure by combining a water-soluble substrate with a hydrophobic coating. The substrate provides rapid dissolution capability when intended (in large amounts of water), while the hydrophobic coating provides resistance to premature dissolution from small amounts of water or humidity. This composite approach allows both properties to coexist without compromising either function.
3Reliability
If a continuous barrier coating is applied to protect the water-soluble substrate, then dissolution resistance is improved, but the coating material usage increases and processing complexity increases
Solution Approach 1:
The porous structure of the hydrophobic coating provides effective water barrier protection with reduced material usage compared to a solid continuous coating. The porous architecture creates a tortuous path for water penetration, enhancing protection while using less coating material and simplifying the coating application process.
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 substrate exhibits improved resistance to accidental water exposure and maintains aesthetic transparency, with reduced coating material usage and enhanced durability during stretching, while ensuring rapid dissolution in water as intended.
Implementation Method 1
water-insoluble particles applied to at least one of said first and second surfaces, said water-insoluble particles being partially embedded in said water-soluble substrate and forming protruberances on said first or second surface
Data Source
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Figure 4
AI summary
A water-soluble substrate, and more particularly a water-soluble substrate that is resistant to dissolution, and methods of making the same are disclosed. The water-soluble substrate has a first and second surface. Water-insoluble particles are applied to and partially embedded in at least one of said first and second surfaces, thereby forming protruberances on said first and/or second surface. The protruberances have an average height of from 10 nanometer to 100 micrometer, and the average distance between adjacent peaks of said protruberances is from 10 nanometer to 200 micrometer. Articles, such as pouches, made from the water-soluble substrate, are also disclosed herein.