3D Composite Nonwoven Structure for Loft and Softness
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Solution Overview
Problem
Existing nonwoven materials used in absorptive devices, such as diapers and feminine napkins, struggle to achieve a balance between cost-effectiveness and softness, with spun bonded nonwovens being less lofty and less soft than spunlace nonwovens, and synthetic hydrophilic fibers being rigid and uncomfortable.
Innovation Solution
A composite material comprising a nonwoven layer with fibers and a polymer film layer featuring extended cells and apertures, where fibers extend into these cells, creating a three-dimensional pattern that enhances loft and softness, while using less costly spun bonded nonwovens and incorporating a surfactant for hydrophilicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If spunlace process is used to create high loft nonwoven materials, then softness and loft are improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent applies the copying principle by replicating the beneficial three-dimensional structure and loft characteristics of spunlace nonwovens through a spunbonded manufacturing process. Instead of using the complex and expensive spunlace hydro-entanglement method, the invention creates a copied version of the desired structure using simpler, more cost-effective spunbonded techniques, thereby achieving similar softness and loft properties without the high manufacturing costs and process complexity associated with spunlace production
Solution Approach 2:
The patent employs parameter changes by modifying key manufacturing parameters of the spunbonded process, including jet pressure (1.379-5.516 MPa), jet diameter (0.05-0.20 cm), jet spacing, and water-to-web ratio, to achieve high loft and softness characteristics typically associated with spunlace materials. By optimizing these parameters, the invention transforms the normally low-loft spunbonded output into a high-loft material that copies spunlace performance while maintaining cost-effectiveness
2Ease of manufacture
If spun bonded process is used to reduce manufacturing cost, then ease of manufacture is improved, but loft and softness deteriorate
Solution Approach 1:
The patent applies the dynamics principle by introducing a dynamic hydroforming step after the static spunbonded web formation. The web is subjected to dynamic water jet impingement that actively reshapes and expands the fiber structure, creating loft and three-dimensional architecture. This dynamic treatment transforms the flat, low-loft spunbonded web into a lofty, soft material, effectively adding a functional stage that bridges the gap between cost-effective manufacturing and desired material properties
Solution Approach 2:
The patent employs dimensionality change by transitioning the spunbonded web from a two-dimensional flat structure to a three-dimensional lofty structure through hydroforming. The water jet process lifts and separates fibers in the vertical dimension, creating air pockets and three-dimensional cell structures that provide loft and softness. This dimensional transformation allows the material to achieve spunlace-like softness while maintaining spunbonded cost-effectiveness
3Reliability
If synthetic hydrophilic fibers are used to improve fluid absorption, then absorptive capability is improved, but comfort and softness deteriorate due to fiber rigidity
Solution Approach 1:
The patent applies the flexible shells and thin films principle by using a polymer film layer with extended cells that provides a soft, flexible matrix surrounding the synthetic hydrophilic fibers. This film structure envelops the rigid fibers,柔化 their harshness while maintaining their absorptive functionality. The thin film acts as a cushioning matrix that allows the synthetic fibers to perform their absorption duty without directly contacting the skin, thereby eliminating the comfort issue while preserving absorptive capability
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 composite material achieves higher loft and softness comparable to spunlace nonwovens, with improved air permeability and hydrophilicity, maintaining comfort and functionality in absorptive devices.
Implementation Method 1
The spunlacing process may create relatively high lofted soft nonwoven materials that are soft and cool to the touch by using high pressure water jets that are essentially in the shape and diameter of needles to hydro-entangle the fibers
Implementation Method 2
incorporating a surfactant for hydrophilicity
Data Source
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AI summary
A composite material includes a nonwoven layer having a plurality of fibers and a polymer film layer with a plurality of extended cells. Each of the extended cells are contemplated to include continuous sidewalls extending away from the nonwoven layer. At least one of the fibers extends into one or more of the extended cells.