Double-Sided Embossed Non-Woven Fabric Suction Method

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Solution Overview

Problem

Existing methods for making double-sided embossed fibrous webs often result in hardened and shrunk material in embossed regions, with thinner thickness compared to non-embossed regions, due to melting, pressurizing, and cooling during the embossing process.

Innovation Solution

A method involving a screen assembly with suction holes and elements arranged in specific patterns, where semi-molten fibers are drawn into the holes to form a non-woven fabric with raised and recessed patterns, facilitating fiber bonding and maintaining even thickness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If conventional embossing rollers with pressure and heat are used, then embossing effect is achieved, but material hardening and shrinkage occur

Engineering Contradiction:

Improveembossed patternVSAvoidmaterial hardness

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The patent replaces the conventional mechanical embossing system (pressure rollers with mechanical pressure and heat) with a suction-based embossing system. The suction device creates negative pressure that draws the fibrous web into contact with the embossing pattern on the screen assembly, achieving embossing through atmospheric pressure differential rather than direct mechanical compression. This substitution eliminates the hardening and shrinkage caused by high pressure and heat while maintaining the embossed shape.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs pneumatic principles by using a suction device that generates negative pressure to emboss the fibrous web. The suction holes in the screen assembly create localized vacuum zones that pull the semi-molten fibers into contact with the embossing pattern. This pneumatic approach replaces mechanical pressure with pressure differential, achieving embossing without the harmful effects of compression and heat.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Shape

If conventional embossing rollers are used, then embossing is achieved, but thickness reduction occurs

Engineering Contradiction:

Improveembossed patternVSAvoidfabric thickness

Core Design Contradiction:

ShapeVSVolume of moving object

Solution Approach 1:

The patent replaces mechanical compression with pneumatic suction to achieve embossing. The suction device creates negative pressure that draws fibers into the embossing pattern without compressing them. This maintains the original thickness of the fibrous web while still creating the desired embossed shape, avoiding the thickness reduction caused by conventional pressure-based embossing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If suctioning method is used, then material hardening and thickness reduction are avoided, but device complexity increases

Engineering Contradiction:

Improvematerial flexibilityVSAvoidsuction device structure

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The screen assembly incorporates a porous structure with suction holes that allow atmospheric pressure to act on the fibrous web. The porous design enables the suction device to create localized vacuum zones without requiring complex sealing mechanisms. The holes in the screen assembly facilitate uniform suction distribution across the web surface, achieving embossing while maintaining material flexibility and avoiding excessive device complexity.

Inventive Principle:

Principle #31Porous materials

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

This method produces a double-sided embossed non-woven fabric that avoids material hardening and thickness reduction, achieving a stable and uniform embossed structure with improved air permeability and versatility for applications like diapers and filtering media.

Implementation Method 1

embossing the stack of the semi-molten fibers on the screen assembly by suctioning the stack of the semi-molten fibers using the suctioning device such that the stack of the semi-molten fibers is drawn into the holes

Methodology Applied

Scientific EffectSuction: Suction

Implementation Method 2

forming a stack of semi-molten fibers on a screen assembly... embossing the stack of the semi-molten fibers... thereby forming the stack of the semi-molten fibers into a non-woven fabric

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS9175428B2Method of making a double-sided embossed non-woven fabric

Publication Date: 2015.11.03 HUANG CHEN CHENG

AI summary

A method of making a double-sided embossed non-woven fabric includes: forming a stack of semi-molten fibers on a screen assembly, the screen assembly including a first layer structure that has a plurality of suction holes arranged into a first pattern, and a second layer structure that is disposed on the first layer structure and that has a plurality of elements arranged into a second pattern; and embossing the stack of the semi-molten fibers on the screen assembly by suctioning the stack of the semi-molten fibers using a suctioning device such that the stack of the semi-molten fibers is drawn into the holes to wrap the elements.