Binder-Free Nonwoven Web via Hydroentanglement
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Solution Overview
Problem
There is a need for nonwoven web compositions that are economical, have good wet tensile strength, and are free from binders, adhesives, and thermal bonding fibers, with the option to be either dispersible or non-dispersible, suitable for a wide range of utilities while minimizing environmental impact.
Innovation Solution
A nonwoven web comprising a blend of defibrated or individualized natural plant-based fibers and staple fibers, produced through a continuous process involving dry laying and hydroentangling without the use of binders or thermal bonding fibers, allowing for customizable properties based on fiber composition and length, and a method to control dispersibility and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If binders, adhesives or thermal bonding fibers are used to improve wet tensile strength, then wet tensile strength is improved, but environmental impact increases and biodegradability decreases
Solution Approach 1:
The invention extracts and eliminates binders, adhesives, and thermal bonding fibers from the nonwoven web composition. The web is formed solely from a blend of cellulosic fibers and other fibers hydroentangled together, removing the harmful chemical components while maintaining structural integrity through physical entanglement of fibers.
Solution Approach 2:
The invention creates a disposable nonwoven web that is intentionally designed to be biodegradable and environmentally friendly. By using only natural or biodegradable fibers without synthetic binders, the web can be easily disposed of after use, aligning with the disposable nature of many nonwoven applications while minimizing environmental harm.
2Manufacturing precision
If a carrier web is used in airlace method to deposit and hydroentangle fibers, then fiber deposition and consolidation are improved, but device complexity and production cost increase
Solution Approach 1:
The invention extracts and eliminates the carrier web component from the airlace process. Instead of depositing fibers onto a carrier and then hydroentangling, the method directly hydroentangles the airlaid fiber blend without requiring a carrier web, simplifying the overall process and reducing equipment complexity.
Solution Approach 2:
The invention merges the fiber deposition and hydroentangling operations into a single integrated process. The airlaid fiber blend is directly subjected to hydroentangling treatment, combining what were previously separate steps (deposition on carrier + hydroentangling) into one continuous operation, thereby reducing process complexity.
3Strength
If hot air or spray adhesive is used to bond airlaid fibers in airlace method, then fiber bonding is improved, but use of harmful chemicals increases
Solution Approach 1:
The invention replaces thermal bonding (hot air) and chemical bonding (spray adhesive) with mechanical bonding through hydroentangling. High-pressure water jets mechanically entangle and bond the fibers together, eliminating the need for thermal energy and chemical adhesives while achieving sufficient fiber bonding strength.
Solution Approach 2:
The invention uses hydraulic energy in the form of high-pressure water jets to achieve fiber bonding. The water jets penetrate and entangle the fibers mechanically, providing bonding strength through hydraulic action rather than thermal or chemical means, thereby eliminating harmful chemical components.
4Strength
If binder fibers containing thermoplastic polymers are used to form fiber to fiber bonds, then wet tensile strength is improved, but biodegradability and environmental friendliness decrease
Solution Approach 1:
The invention extracts and eliminates binder fibers containing thermoplastic polymers from the nonwoven web. The web is constructed entirely from a fiber blend that is hydroentangled together, removing the need for synthetic binder fibers and thereby improving biodegradability and environmental friendliness while maintaining strength through physical entanglement.
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 provides nonwoven webs with controlled dispersibility and enhanced wet tensile strength, suitable for various applications, including disposable products and personal care items, while eliminating the use of harmful chemicals and reducing environmental impact.
Implementation Method 1
hydroentangling the dry laid web to consolidate the web on at least one side
Data Source
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AI summary
A nonwoven web, containing at least one first homogeneous layer consisting of a blend of at least one of defibrated natural plant based fibers, individualized natural plant based fibers and staple fibers is provided. The nonwoven web contains no binder, adhesive or thermal bonding fibers and a basis weight of the at least one homogeneous layer is from 20 g/m2 to 100 g/m2. When a weighted average fiber length of the at least one of defibrated natural plant based fibers, individualized natural plant based fibers and staple fibers is greater than about 4.0 mm, the nonwoven web is a non-dispersible product which does not meet the requirement for dispersibility in accordance with IND A/ED ANA GD4, and when a weighted average fiber length of the at least one of defibrated natural plant based fibers, individualized natural plant based fibers and staple fibers is less than about 4.0 mm, the nonwoven web is a dispersible product as defined in accordance with IND A/ED ANA GD4. Methods to prepare the nonwoven web are provided.