3D Nonwoven Web Formation Using Cavities, Land Areas, and Fluid Pressure
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Solution Overview
Problem
Existing methods for manufacturing intricate and complex nonwoven webs are expensive and complex, failing to meet the demands of high-end consumers for more sophisticated three-dimensional features.
Innovation Solution
Utilizing a rotating collection surface with cavities and land areas to collect continuous filaments, applying fluid pressure to create regions with varying intensive properties, and bonding the intermediate web to form a final three-dimensional web.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional three-dimensional nonwoven making belts are used, then intricate and complex three-dimensional nonwoven webs can be produced, but the manufacturing process becomes expensive and complex
Solution Approach 1:
The patent employs a rotating collection surface that dynamically collects filaments and transfers them to a moving belt, creating three-dimensional structures through rotational motion rather than static complex machinery. The rotation speed and surface features (protrusions, recesses, or varied heights) dynamically shape the web structure during formation
Solution Approach 2:
The invention replaces complex mechanical three-dimensional making belts with a simpler rotating collection surface system. Instead of using mechanically complex belts with embedded three-dimensional features, the patent uses a rotating surface with varying heights or textures that imparts three-dimensionality through fluid dynamics and filament deposition patterns
2Manufacturing precision
If traditional three-dimensional nonwoven making belts are used, then intricate and complex three-dimensional nonwoven webs can be produced, but the manufacturing cost increases
Solution Approach 1:
The patent uses a rotating collection surface with simpler, more affordable materials compared to traditional three-dimensional making belts. The surface can be made from inexpensive materials with varying heights or textures, and the entire system is designed for cost-effective operation while producing high-quality three-dimensional webs
Solution Approach 2:
The invention changes the operational parameters by using a rotating surface at controlled speeds with varying filament deposition rates. By adjusting rotation speed, fluid pressure, and filament flow rates, the system achieves three-dimensional structures without requiring expensive specialized equipment, thereby reducing manufacturing costs
3Area of stationary object
If a rotating collection surface with cavities and land areas is used, then the footprint is reduced, but fluid pressure control becomes more challenging
Solution Approach 1:
The rotating collection surface is segmented into distinct cavities and land areas, allowing different regions to be optimized for specific functions. The cavities can be designed with specific depths and the land areas with specific heights, enabling localized control of filament deposition and fluid pressure without requiring a large overall footprint
Solution Approach 2:
The patent introduces a fluid pressure control system as an intermediary mechanism to manage the interaction between the rotating surface and filaments. By controlling fluid pressure differentials across the cavities and land areas, the system achieves precise control over filament deposition patterns without requiring complex mechanical adjustments
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
Produces high-quality, consumer-desirable three-dimensional nonwoven webs with varying properties in a cost-effective and simpler manner compared to traditional methods.
Implementation Method 1
applying a fluid pressure to the collection surface and collecting the filaments on the collection surface to create an intermediate three-dimensional web
Implementation Method 2
bonding the intermediate three-dimensional web using a bonding operation, such as air-through bonded, for example, to form a final three-dimensional web
Data Source
AI summary
A method of making a three-dimensional web is provided. The method comprises spinning continuous filaments from a spinneret, moving the spun continuous filaments along a travel path having an end, and rotating a collection surface at or proximate to the end of the travel path. The collection surface comprises cavities and land areas. The land areas are tangentially planar with an outer surface of the collection surface. The cavities are recessed with respect to the outer surface of the collection surface. The method comprises applying a fluid pressure to the collection surface and collecting the filaments on the collection surface to create an intermediate three-dimensional web having first regions formed in the cavities and second regions formed on the land areas. The first and second regions differ in at least one intensive property. The method comprises bonding the intermediate web using a bonding operation to form a final three-dimensional web.