Elastomeric Nonwovens with Slip Agents
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Solution Overview
Problem
Elastic nonwoven materials used in personal care products have a 'rubbery' feel that is undesirable for consumer contact, and modifying these materials to improve feel often compromises their physical and elastic properties.
Innovation Solution
A nonwoven fabric structure comprising inelastic or partially elastic facing layers made from propylene-based polymers thermally bonded with elastic inner layers containing slip agents, where the facing layers have a permanent set above 30% and the inner layers have a permanent set below 28%, ensuring a dry touch and maintaining elastic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If elastic nonwoven materials are modified to improve feel, then the feel is improved, but the physical and elastic properties are compromised
Solution Approach 1:
The nonwoven fabric is divided into multiple layers with distinct functions: an inelastic facing layer providing acceptable feel and an elastic inner layer maintaining stretchability and elasticity. This segmentation allows each layer to optimize its specific property without compromising the other, resolving the contradiction between feel and elastic properties.
Solution Approach 2:
Different regions of the nonwoven fabric are assigned different material properties: the facing layer uses inelastic or partially elastic propylene-based polymers for acceptable feel, while the inner layer uses elastic propylene-based polymers with slip agents for stretchability. This local differentiation allows the fabric to simultaneously achieve good feel and elastic properties.
2Object-affected harmful factors
If inelastic facing layers are added to improve feel, then the feel is improved, but the elastic properties may be compromised
Solution Approach 1:
The fabric structure is segmented into facing layers and inner layers, with the facing layers being inelastic or partially elastic for improved feel, and the inner layers being elastic for maintained stretchability. The thermal bonding between layers ensures structural integrity while allowing each layer to fulfill its specific function.
Solution Approach 2:
The nonwoven fabric uses composite construction combining inelastic propylene-based polymers in the facing layer with elastic propylene-based polymers containing slip agents in the inner layer. This composite structure allows the fabric to exhibit both acceptable feel and elastic properties simultaneously.
3Reliability
If propylene-based polymers with specific properties are used, then the elastic properties are maintained, but the manufacturing complexity increases
Solution Approach 1:
The patent specifies particular parameters for the propylene-based polymers including isotactic arrangement, heat of fusion less than 45 J/g, and specific permanent set values. By controlling these parameters, the fabric achieves good elastic properties while maintaining compatibility with conventional spunmelt equipment, thus managing manufacturing complexity.
Solution Approach 2:
Different propylene-based polymer formulations are used in different layers: the facing layer uses inelastic or partially elastic polymers while the inner layer uses elastic polymers with slip agents. This local differentiation optimizes elastic properties where needed without requiring complex manufacturing processes throughout the entire fabric.
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 proposed structure provides a nonwoven fabric with improved feel and retained elastic properties, preventing delamination and enhancing mechanical properties such as tensile strength and elasticity.
Implementation Method 1
the inner layers are elastic nonwoven webs comprising one or more propylene-based polymers and one or more slip agents, the inner layer having a permanent set below 28%
Implementation Method 2
one or more facing layers thermally bonded to one or more inner layers
Data Source
AI summary
A nonwoven fabric and disposable articles comprising the same are provided. The nonwoven fabric can include one or more facing layers thermally bonded to one or more inner layers. The facing layers are inelastic or partially elastic nonwoven webs comprising one or more propylene-based polymers. The facing layer has a permanent set above 30%. The inner layers are elastic nonwoven webs comprising one or more propylene-based polymers and one or more slip agents. The inner layer has a permanent set below 28%, and the one or more propylene-based polymers have (i) 60 wt % or more units derived from propylene, (ii) isotactically arranged propylene derived sequences, and (iii) a heat of fusion less than 45 J/g.