Composite nonwoven sheet material
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional composite nonwoven sheet materials lack sufficient absorptive power and deep cleaning performance, especially when dealing with surfaces that require thorough cleaning and have small cavities or high hardness.
Innovation Solution
A composite nonwoven sheet material is developed, comprising a reinforcement layer of synthetic filaments, a pulp layer of cellulose fibers interposed between the reinforcement and surface layers, and a microfiber surface layer, which are entangled through hydroentangling to enhance absorption and release properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If microfibers are used in wiping material to achieve deep cleaning and quick liquid absorption, then cleaning performance and absorptive power are improved, but the material may lack sufficient structural strength and durability
Solution Approach 1:
The patent combines three distinct fiber types into a composite nonwoven structure: microfibers (1-20 μm) for deep cleaning and capillary absorption, cellulosic pulp fibers (1-6 mm) for bulk liquid absorption, and reinforcement filaments (10-100 μm) for structural strength. This composite approach allows each component to contribute its specific properties, resolving the contradiction between cleaning performance and structural strength.
Solution Approach 2:
The invention creates a layered structure with specific zonal functions: the microfiber surface layer provides deep cleaning capability at the contact surface, the intermediate pulp layer provides bulk absorption, and the reinforcement filaments provide structural support throughout. Each layer is optimized for its specific function while working together as an integrated system.
2Strength
If a combination of synthetic fibers and cellulosic pulp is used to achieve sufficient strength and absorptive power, then basic cleaning functionality is provided, but deep cleaning performance and liquid absorption speed are insufficient
Solution Approach 1:
The patent extends the conventional two-component blend (synthetic fibers and cellulosic pulp) to a three-component composite by adding microfibers as a distinct surface layer. This allows the material to achieve both structural integrity from the reinforcement filaments and pulp, while gaining deep cleaning capabilities from the microfiber surface layer with its high capillary forces.
Solution Approach 2:
The invention places microfibers specifically in the surface layer to provide localized deep cleaning functionality where it is most needed (at the contact surface), while the bulk material maintains its strength-providing composition of reinforcement filaments and pulp fibers. This spatial differentiation resolves the contradiction between strength and deep cleaning performance.
3Productivity
If conventional composite nonwoven structures are used to maintain simplicity and ease of manufacture, then production efficiency is high, but cleaning performance and liquid absorption capacity are limited
Solution Approach 1:
The patent segments the nonwoven structure into three distinct layers with different fiber compositions and functions, rather than using a homogeneous blend. This segmentation is achieved through a modified web formation process that deposits different fiber types in specific zones, allowing each layer to be optimized for its function while maintaining compatibility with conventional manufacturing approaches.
Solution Approach 2:
The invention creates a composite structure that can be manufactured using adapted conventional nonwoven processes. The multi-component composite is formed by controlling fiber deposition during web formation, allowing the complex three-layer structure to be produced efficiently without requiring entirely new manufacturing equipment or processes.
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 material exhibits improved cleaning performance, with increased liquid absorption and release capacities, allowing for effective deep cleaning of surfaces with small cavities and high hardness, while maintaining strength and versatility for various cleaning applications.
Implementation Method 1
the combination of capillary action provided by the microfibers at the surface of the sheet material
Implementation Method 2
the enhanced liquid absorption and release properties of the pulp layer
Data Source
AI summary
A composite nonwoven sheet material comprising a reinforcement layer comprising mainly reinforcement filaments, a pulp layer comprising mainly pulp fibers, and a surface layer comprising mainly microfibers, wherein the pulp layer is interposed between the reinforcement layer and the surface layer, and wherein the pulp fibers are entangled with the reinforcement filaments and the microfibers. A process of producing a composite nonwoven sheet material, comprising: forming a fibrous web comprising a reinforcement layer comprising mainly reinforcement filaments, a pulp layer comprising mainly pulp fibers, and a surface layer comprising mainly microfibers, wherein the pulp layer is interposed between the reinforcement layer and the surface layer; and hydroentangling the fibrous web to form the composite nonwoven sheet material.