Composite Velcro Element with Knitted Loops and Nonwoven Softness
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Solution Overview
Problem
Existing composite elements for Velcro fasteners in disposable diapers face challenges in achieving a soft, pleasant surface with low basis weight, which is often associated with high production costs, and have an undesirable appearance and feel due to their open structure.
Innovation Solution
A composite element with a knitted basic structure from polyamide threads and loop threads formed from textured multifilament yarns, specifically polyester or polyamide, which provides a softer, more even surface with a lower basis weight, and a method involving adhesive patterns for bonding with a carrier film to maintain low production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a nonwoven material is used as the basic textile structure to achieve a soft surface, then the surface softness and pleasant feel are improved, but the basis weight increases to 40-50 g/m² resulting in higher production costs
Solution Approach 1:
The patent combines a nonwoven material (for softness) with a knitted fabric layer (for low weight) to create a composite textile structure. The knitted layer with loops provides the Velcro attachment function while the nonwoven layer contributes to surface softness, achieving both requirements without needing high weight nonwoven alone
Solution Approach 2:
The patent applies different material properties to different regions/layers of the textile: the knitted fabric provides structural integrity and loop formation for Velcro attachment, while the nonwoven material provides surface softness. This localized functional differentiation allows optimization of each property independently
2Weight of stationary object
If the knitted fabric has an open structure to reduce basis weight and production costs, then manufacturing cost is reduced, but the appearance and feel become less soft and more undesirable
Solution Approach 1:
The patent creates a composite structure where an open-knit fabric (low weight) is combined with a nonwoven material layer. The nonwoven layer fills in the gaps of the open knit structure, providing surface softness and a more pleasant appearance while maintaining the low basis weight advantage of the open knit structure
Solution Approach 2:
The nonwoven material acts as an intermediary layer that mediates between the open knit structure and the external environment. It provides the missing surface softness and aesthetic quality without requiring the knit structure itself to be dense, thus preserving the low-weight advantage
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 solution results in a composite element with a soft, textile-like appearance and feel, reduced risk of skin irritation, and sufficient strength for Velcro hooks, while maintaining low production costs and a basis weight between 15 and 45 g/m², achieving a high-quality appearance and functional performance.
Implementation Method 1
The carrier and the textile material are connected to one another in a pattern of adhesive areas and areas without adhesive
Implementation Method 2
the loop threads are formed from a textured multifilament yarn, in particular a multifilament yarn based on polyester or polyamide
Implementation Method 3
a basic structure knitted from threads and loop threads knitted into the basic structure
Data Source
Figure 1~2
AI summary
The invention relates to a composite element for hook and loop fasteners, in particular for a diaper fastener, comprising a carrier (1) and a textile material (2) laminated onto the carrier (1), which has a base structure formed from threads or fibers and loop threads (S) incorporated into the base structure by knitting, which form loops intended for connection with hook and loop hooks. The loop threads (S) are formed from a textured multifilament yarn based on polyester or polyamide.