3D Nonwoven Substrate with Apertured Zones for Compressed Packaging
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Solution Overview
Problem
There is a need for improved nonwoven fabrics with three-dimensional surface features that maintain physical integrity and softness, while also providing enhanced fluid acquisition and breathability, and can be packaged in a compressed form without losing their aesthetic and functional properties.
Innovation Solution
The development of a three-dimensional nonwoven substrate with visually discernible zones, including apertured zones, that have varying intensive properties such as basis weight and thickness, and are formed using a specific process involving a forming belt with discrete belt patterns, allowing for the retention of three-dimensional features during packaging and use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If nonwoven fabrics are compressed for packaging, then distribution cost and handling convenience are improved, but three-dimensional surface features and aesthetic properties are lost
Solution Approach 1:
The nonwoven fabric is divided into multiple layers with different functions: a first nonwoven layer providing structural support and a second nonwoven layer providing the three-dimensional surface features. This segmentation allows the first layer to maintain shape during compression while the second layer provides the desired aesthetic properties when uncompressed.
Solution Approach 2:
The invention uses a composite structure combining two different nonwoven materials with complementary properties. The first nonwoven layer is selected for compression resistance and structural integrity, while the second layer is selected for softness and three-dimensional surface features, creating a composite material that exhibits both sets of properties.
2Productivity
If apertures are formed in nonwoven fabrics, then fluid acquisition and breathability are improved, but material strength and physical integrity are reduced
Solution Approach 1:
Apertures are formed only in the first nonwoven layer where they provide fluid acquisition benefits, while the second nonwoven layer remains substantially intact to provide the necessary tensile strength and tear resistance. This local application of apertures allows the fabric to have both high fluid permeability and high structural strength.
3Shape
If variable basis weight nonwovens are used, then aesthetic properties and visual impression are improved, but aperture formation becomes difficult due to tearing concerns
Solution Approach 1:
The variable basis weight nonwoven fabric is segmented into two layers: a first layer with higher basis weight providing structural support suitable for aperture formation, and a second layer with lower basis weight providing aesthetic properties. This segmentation allows apertures to be formed in the first layer without risking tears in the overall fabric structure.
4Volume of moving object
If three-dimensional features are retained after compression, then in-bag stack height is reduced, but compression resistance must be increased
Solution Approach 1:
The composite structure of two nonwoven layers is designed so that the first layer has high compression resistance to maintain three-dimensional features during packaging, while the overall composite structure achieves reduced in-bag stack height through the combined properties of both layers, balancing compression resistance with space efficiency.
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 solution enables nonwoven fabrics that retain their softness, absorbency, and aesthetic benefits even after compression packaging, reducing in-bag stack height and maintaining performance, making them convenient for handling and distribution while maintaining their as-made characteristics.
Implementation Method 1
The apertures can be uniformly sized and shaped circular or ovate apertures throughout their area, and such circular or ovate apertures may be uniformly spaced in the cross-machine direction and/or the machine direction with respect to each other. The aperture patterns can allow for fluid penetration and/or absorbency throughout their area.
Data Source
AI summary
A three-dimensional substrate has a central longitudinal axis extending perpendicular to a central lateral axis. A line taken in a direction parallel to or perpendicular to the central lateral axis of the three-dimensional substrate has a non-apertured, first visually discernible zone in the substrate and a second visually discernible zone in the substrate. The first visually discernable zone has a pattern of three-dimensional features on a first surface or a second surface. At least some of the three-dimensional features define a microzone having a first region and a second region. The first region and the second region have a difference in value for an intensive property. The second visually discernable zone defines apertures. The apertures have an Effective Aperture Area in a range of about 0.3 mm2 to about 15 mm2.