Composite Non-Woven Fabric Layering for Softness and Stable Carding
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Solution Overview
Problem
Existing non-woven fabrics with fiber denier less than 1.0 denier face challenges in fiber carding during production, leading to uneven web surfaces, while fabrics with larger denier offer improved breathability but lack softness and skin-friendliness.
Innovation Solution
A composite non-woven fabric comprising an upper layer of side-by-side bi-component crimped spunbond long fibers with a fiber denier of 0.6 to 1.0 denier and a lower layer of coarse denier fibers, bonded through differing shrinkage stresses of high- and low-melting-point resins, enhancing softness and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If fiber denier is reduced to less than or equal to 1.0 denier to achieve finer texture and softness, then skin-friendliness and smoothness are improved, but fiber carding becomes difficult resulting in uneven web surfaces
Solution Approach 1:
The invention divides the non-woven fabric into two distinct layers: an upper layer with fine denier fibers (≤1.0) for skin-friendliness and a lower layer with coarse denier fibers (2.0-12.0) for manufacturing stability. This segmentation allows each layer to fulfill its specific function without compromising the other, resolving the contradiction between softness and carding difficulty.
Solution Approach 2:
The invention uses composite materials by combining fine denier spunbond fibers with coarse denier support fibers in a layered structure. The fine fibers provide the desired soft texture while the coarse fibers provide structural support that facilitates carding and web formation, thus resolving the manufacturing difficulty associated with ultra-fine fibers.
2Productivity
If fiber denier is increased to improve breathability and liquid absorption, then porosity and fluffiness are enhanced, but softness and skin-friendliness are reduced
Solution Approach 1:
The invention applies local quality by assigning different fiber deniers to different layers based on their functional requirements. The upper layer uses fine denier fibers for softness and skin contact, while the lower layer uses coarse denier fibers for breathability and absorption. This localized differentiation allows both contradictory properties to coexist in different regions of the same product.
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 fabric achieves a fine and smooth texture with improved tensile strength, reduced bonding points, and enhanced fluffiness, addressing carding issues and providing superior skin-friendliness and comfort.
Implementation Method 1
adjacent side-by-side bi-component crimped spunbond long fibers being bonded to each other through surface melting
Implementation Method 2
the high-melting-point resin and the low-melting-point resin having different shrinkage stresses
Implementation Method 3
under action of hot air at a temperature of 100° C. to 110° C., the side-by-side bi-component spunbond long fibers, due to differing shrinkage stresses of the high-melting-point resin and the low-melting-point resin, begin to crimp
Implementation Method 4
the overlapping composite mesh is passed through a heating device where the upper layer fine denier unbonded fiber web is bonded
Data Source
AI summary
A fine denier composite non-woven fabric comprising an upper layer fine denier fiber web composed of fibers with a fiber denier less than or equal to 1.0 denier and a lower layer coarse denier fiber web composed of fibers with a fiber denier of 2.0 deniers to 12.0 deniers; the upper layer fine denier fiber web being composed of side-by-side bi-component crimped spunbond long fibers, and adjacent fibers being bonded to each other through surface melting to form a fiber web.