Cellulose Application Assembly for Viscose Composite Nonwoven Webs

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing composite nonwoven webs for hygiene wipes, primarily made of polyester/polypropylene and viscose fibers, are not biodegradable, leading to increased production costs when replacing viscose with more expensive natural fibers like cellulose, and existing machinery is not suitable for producing viscose-with-cellulose composite nonwoven webs.

Innovation Solution

Replace the second carding unit in the production line with a device for applying natural short fibers, particularly cellulose, using a circulating conveyor belt and a headbox for precise application, and incorporate water jet consolidation to bond the layers, allowing the production of a viscose-with-cellulose composite nonwoven web.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If polyester/polypropylene and viscose fibers are used to produce composite nonwoven webs, then good performance characteristics such as absorbency and tear resistance are achieved, but the wipes are not biodegradable

Engineering Contradiction:

Improveperformance characteristicsVSAvoidbiodegradability

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention changes the material composition parameters by replacing synthetic polyester/polypropylene fibers with natural cellulose fibers while maintaining the composite nonwoven web structure. This substitution transforms the product from non-biodegradable to biodegradable while preserving the required performance characteristics through careful selection of fiber properties and web architecture.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If viscose fibers are replaced with natural short fibers such as cellulose, then production costs are reduced and biodegradability is improved, but existing carding machines are not suitable for processing natural short fibers

Engineering Contradiction:

Improveproduction costVSAvoidmachine suitability

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The invention replaces the mechanical carding system with a water jet consolidation system. Instead of using carding teeth to process and align fibers, the patent employs high-velocity water jets to entangle and bond the natural short cellulose fibers with the viscose layer, creating a composite nonwoven web without requiring traditional carding machinery.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention utilizes hydraulic principles by employing water jet consolidation technology. High-pressure water jets are directed at the fiber web to entangle and bond the cellulose and viscose fibers together, replacing mechanical carding actions with hydraulic forces to achieve fiber consolidation and web formation.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Device complexity

If a single carding unit is used to process natural short fibers, then machine complexity is reduced, but the quality and integrity of the composite nonwoven web deteriorates

Engineering Contradiction:

Improvenumber of carding unitsVSAvoidweb quality

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enables the production of biodegradable hygiene wipes at reduced costs by utilizing cost-effective natural short fibers, while maintaining the quality and integrity of the composite nonwoven web.

Implementation Method 1

This device can, for example, be a water jet bonding unit. In this unit, the fibers of each layer are intertwined, and at least over a thickness zone adjacent to the interface between the two layers, the fibers of the two layers are swirled together.

Methodology Applied

Scientific EffectWater jet: Jet

Data Source

PatentEP4301919B1Assembly of a device, and method and device for producing a composite nonwoven fabric

Publication Date: 2025.10.29 ANDRITZ KUESTERS GMBH & CO KG

Figure 1
Figure 2
Figure 3

AI summary

The invention relates to an assembly of a device for producing a composite nonwoven fabric comprising at least two layers, said assembly being provided in order to apply natural short fibers, in particular pulp (17), onto a first layer (4) and being designed to be usable as a substitute for a device (carding unit 5) in order to provide long fibers in the device.