Nonwoven Textile With Discrete Embossments for Less Visible Patterns
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Solution Overview
Problem
Existing nonwoven fabrics face issues where the consolidation process using calender rollers with embossing elements impairs the thickness and visual aesthetics, creating an optically perceptible embossing pattern that affects mechanical properties and handling.
Innovation Solution
A nonwoven fabric with an embossing pattern composed of small, non-interconnected embossments, each with an embossing area of 0.05 to 0.3 mm², which minimizes visual impairment while maintaining mechanical strength and thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If calender rollers with embossing elements are used to consolidate the nonwoven fabric, then mechanical strength and consolidation are improved, but the thickness and visual aesthetics deteriorate
Solution Approach 1:
The embossing pattern is segmented into discrete, isolated embossments rather than continuous or interconnected patterns. Each embossment is a separate element with specific dimensions (0.05-0.3 mm²), creating individual compression zones that provide mechanical reinforcement without creating continuous deformation paths that would compromise overall thickness.
Solution Approach 2:
The embossing pattern applies localized compression only at specific points rather than uniformly across the entire fabric surface. This local quality approach concentrates the consolidating effect where needed for mechanical strength while preserving the thickness and aesthetic appearance of the majority of the fabric surface.
2Strength
If calender rollers with embossing elements are used to consolidate the nonwoven fabric, then mechanical strength is improved, but visual aesthetics deteriorate
Solution Approach 1:
The embossing pattern is divided into small, discrete embossments (0.05-0.3 mm²) rather than large continuous patterns. This segmentation creates numerous small visual elements that are less perceptible to the human eye compared to large embossments, reducing visual impairment while maintaining the mechanical strength benefits of the embossing pattern.
Solution Approach 2:
The dimensions of the embossments are carefully controlled within the range of 0.05-0.3 mm², which is a specific parameter change from traditional larger embossments. This parameter optimization reduces the visual perceptibility of the embossing pattern while preserving the mechanical reinforcement effect.
3Strength
If traditional embossing patterns are used, then mechanical properties are improved, but handling and treatment are compromised
Solution Approach 1:
The embossing pattern consists of isolated, non-interconnected embossments that do not create continuous constraints on the fabric. This segmentation allows the fabric to be handled and treated more easily compared to traditional continuous embossing patterns that may create rigidity or handling difficulties.
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 effectively reduces the optical perceptibility of the embossing pattern while preserving advantageous mechanical properties and thickness, offering improved handling and aesthetic appeal.
Implementation Method 1
wherein the embossments each have an embossing area of 0.05 to 0.3 mm2, preferably of 0.06 to 0.2 mm2, preferably of 0.07 to 0.18 mm2, particularly preferably of 0.08 to 0.15 mm2 and quite particularly preferably of 0.09 to 0.12 mm2
Implementation Method 2
The embossments of the embossing pattern according to the invention are preferably made by at least one calender roller with a complementary embossing pattern of embossing elements
Data Source
AI summary
The invention relates to a nonwoven fabric comprising at least one nonwoven web composed of fibres. The nonwoven fabric has an embossed pattern. The embossed pattern consists of a plurality of embossments—preferably not connected to one another. The embossments each have an embossing area of 0.05 to 0.3 mm2.