3D Textured Coform Nonwoven Web for Softness and Flexibility
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Solution Overview
Problem
Coform nonwoven webs used in absorbent applications lack improved softness and flexibility, which are essential characteristics for various applications.
Innovation Solution
A coform nonwoven web is developed with a matrix of meltblown fibers and an absorbent material, featuring a continuous region and offset regions that create uninterrupted portions, using a propylene/α-olefin copolymer and pulp fibers, with specific dimensions and weight ratios to enhance softness and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If coform nonwoven webs are made with traditional uniform structure, then manufacturing is simpler, but softness and flexibility are insufficient
Solution Approach 1:
The nonwoven web is segmented into continuous regions and offset regions, where the continuous regions provide flexibility and the offset regions provide softness. This segmentation allows different parts of the web to have different functions, resolving the contradiction between softness/flexibility and structural simplicity.
Solution Approach 2:
Different regions of the web are given different properties: continuous regions have higher flexibility while offset regions have higher softness. This local differentiation allows the web to achieve both softness and flexibility simultaneously without requiring complex overall restructuring.
2Ease of operation
If offset regions are added to create uninterrupted portions, then softness and flexibility improve, but manufacturing complexity increases
Solution Approach 1:
The forming surface is pre-configured with a pattern of openings that defines where offset regions will form. This preliminary structuring of the forming surface automates the creation of the complex web structure, reducing manufacturing complexity while maintaining the desired softness and flexibility properties.
Solution Approach 2:
The web structure self-organizes during formation as fibers are deposited on the patterned forming surface. The continuous and offset regions emerge naturally from the deposition process, reducing the need for complex post-processing or manual structuring operations.
3Ease of operation
If continuous regions are made wider to improve flexibility, then flexibility increases, but the ratio of uninterrupted to offset region width must be maintained
Solution Approach 1:
The web structure parameters (continuous region width, offset region width, and their ratio) are optimized to achieve the desired flexibility while maintaining manufacturability. By controlling the width ratio between 0.3 and 2.0, the web achieves adequate flexibility without requiring excessive precision that would complicate manufacturing.
Data Source
AI summary
A flexible coform nonwoven web that contains a matrix of meltblown fibers and an absorbent material is provided. The meltblown fibers may constitute from about 2 wt % to about 40 wt % of the coform web. The absorbent material may constitute from about 60 wt % to about 98 wt % of the coform web. The Cup Crush Energy/Thickness ratio of the nonwoven structure is desirably less than about 600. The coform web may be imparted with a three-dimensional texture by, for example, using a three-dimensional forming surface. The coform web is suitable for forming absorbent articles such as wipers and personal care absorbent products.