Laminated Nonwoven Fabric With 3D Embossing for Lower Weight
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Solution Overview
Problem
Conventional nonwoven fabrics used in disposable products face issues such as electrostatic charge leading to chemical absorption, requiring thicker materials for strength and absorption, and contributing to waste due to high material usage.
Innovation Solution
A laminated nonwoven fabric with a spunbond inner layer and meltblown outer layers, incorporating a three-dimensional embossed pattern, which enhances tensile strength, absorption, and particle pick-up while reducing material weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional nonwoven fabrics use thicker and heavier materials to meet tensile strength and elongation requirements, then mechanical strength is improved, but material weight and waste increase
Solution Approach 1:
The patent applies composite materials by combining multiple nonwoven fabric layers with different properties (spunbond, meltblown, and bonded fleece layers) to achieve the required tensile strength and mechanical properties. This allows the use of lighter individual materials that collectively provide the necessary strength without requiring a single heavy material, thus resolving the contradiction between strength and weight.
Solution Approach 2:
The patent implements local quality by creating regions of different fabric weights and densities within the same nonwoven fabric structure. Specific areas have higher material concentration for strength requirements, while other areas use lighter materials, allowing the overall fabric weight to be reduced while maintaining necessary tensile strength in critical regions.
2Quantity of substance
If polyester or cotton-based cleaning towels are used, then absorption capability is improved, but electrostatic charge causes chemical absorption from disinfecting solution
Solution Approach 1:
The patent uses composite materials by combining different fiber types (polypropylene, polyester, cotton) in specific layers and ratios. The meltblown layer provides absorption capability while the spunbond and bonded fleece layers provide structural support and reduced electrostatic charge, allowing the fabric to absorb liquids without excessively attracting chemicals from disinfecting solutions.
Solution Approach 2:
The patent applies parameter changes by modifying the electrostatic properties of the fabric through material selection and layer configuration. By using polypropylene in the meltblown layer and controlling the blend ratios, the fabric's electrostatic charge is reduced, preventing excessive chemical absorption from disinfecting solutions while maintaining liquid absorption capability.
3Reliability
If heavier nonwoven fabrics are used to meet mechanical requirements, then durability is improved, but waste generation increases
Solution Approach 1:
The patent applies composite materials by creating a multi-layer structure where each layer contributes specific durability properties. The spunbond layer provides tensile strength, the meltblown layer provides flexibility and absorption, and the bonded fleece layer provides surface durability. This composite approach achieves required durability with less total material weight, reducing waste generation compared to using a single heavy material.
Solution Approach 2:
The patent implements segmentation by dividing the nonwoven fabric into functional layers, each optimized for specific mechanical requirements. This allows precise placement of material where needed for durability, rather than uniformly thick fabric throughout, reducing overall material usage and waste while maintaining necessary durability for the application.
Data Source
AI summary
Laminated, nonwoven fabrics and food service wipes formed from the nonwoven fabrics are disclosed. The laminated, nonwoven fabrics forming the food service wipes include an inner layer formed from a spunbond material, and a first outer layer disposed over the inner layer. The first outer layer is formed from a meltblown material. Additionally, the laminated, nonwoven fabrics forming the food service wipes include a second outer layer disposed over the inner layer, opposite the first outer layer. Moreover, the laminated, nonwoven fabrics include a three-dimensional (3D) embossed pattern.