Composite Structures With Inorganic Fillers For Bonding
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Solution Overview
Problem
Current polymeric nonwoven materials face challenges in achieving sufficient strength without compromising barrier performance, particularly in medical and hygiene applications where the meltblown layer's sensitivity to temperature affects bonding conditions.
Innovation Solution
A composite structure comprising at least two nonwoven polymeric layers, with the spunbond layers incorporating inorganic particulate fillers like calcium carbonate, which enhances strength while maintaining the barrier performance of the meltblown layer by allowing lower bonding temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermal bonding is used to bond nonwoven layers, then the layers are joined together, but the meltblown layer's barrier performance deteriorates due to fiber melting and deformation
Solution Approach 1:
The invention applies local quality by using inorganic particulate fillers specifically in the outer spunbond layers while keeping the inner meltblown layer free of fillers. This localized differentiation allows the outer layers to provide bonding strength through filler-containing material while the inner layer maintains its barrier performance through pure meltblown fibers, resolving the contradiction between bonding strength and barrier performance.
Solution Approach 2:
The invention employs composite materials by combining organic polymer fibers with inorganic particulate fillers in the spunbond layers. This composite structure enables the outer layers to achieve both mechanical strength from the filler-containing composite material and bonding capability, while the inner meltblown layer remains as a separate functional barrier layer, thus resolving the contradiction between bonding strength and barrier integrity.
2Strength
If bonding temperature is increased to improve bonding strength, then the layers bond better, but the meltblown fibers melt or deform reducing barrier performance
Solution Approach 1:
The invention applies local quality by using inorganic particulate fillers specifically in the outer spunbond layers while keeping the inner meltblown layer free of fillers. This localized differentiation allows the outer layers to provide bonding strength through filler-containing material while the inner layer maintains its barrier performance through pure meltblown fibers, resolving the contradiction between bonding strength and barrier performance.
Solution Approach 2:
The invention changes material parameters by incorporating inorganic particulate fillers with different thermal properties than the polymer fibers. These fillers modify the thermal behavior of the spunbond layers, enabling bonding at temperatures that do not degrade the meltblown barrier layer, thus resolving the contradiction between bonding strength and temperature control.
3Strength
If inorganic particulate filler is added to enhance strength, then tensile strength improves, but barrier performance may be adversely affected
Solution Approach 1:
The invention applies local quality by using inorganic particulate fillers specifically in the outer spunbond layers while keeping the inner meltblown layer free of fillers. This localized differentiation allows the outer layers to provide bonding strength through filler-containing material while the inner layer maintains its barrier performance through pure meltblown fibers, resolving the contradiction between bonding strength and barrier performance.
Solution Approach 2:
The invention employs composite materials by combining organic polymer fibers with inorganic particulate fillers in the spunbond layers. This composite structure enables the outer layers to achieve both mechanical strength from the filler-containing composite material and bonding capability, while the inner meltblown layer remains as a separate functional barrier layer, thus resolving the contradiction between bonding strength and barrier integrity.
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 structure exhibits improved tensile strength and elongation properties without adversely affecting barrier performance, specifically beneficial in medical applications by ensuring safety and functionality.
Implementation Method 1
the S layer or each of the S layers comprise inorganic particulate filler and the M layer or each of the M layers comprises less inorganic particulate filler than the S layers
Data Source
Figure 1~2
Figure 3a~3b
Figure 4a~4b
AI summary
Composite structure comprising at least two nonwoven, polymeric layers bonded to each other, articles and products comprising or formed from said composite structure, and a process for making said composite structure