Embossed Nonwoven Fabric Bonding Pattern for Abrasion Resistance
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Solution Overview
Problem
Spunbond nonwoven fabrics face a challenge in balancing abrasion resistance and softness, as bonding operations that enhance abrasion resistance often compromise the fabric's softness.
Innovation Solution
The development of embossed nonwoven fabrics with a bonding pattern featuring a plurality of icons defined by perimeter and internal bonding points, which improves abrasion resistance without sacrificing softness, achieved through an embossed bonding pattern and embossing rolls with specific protrusion patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bonding operations are performed on spunbond nonwoven fabrics to enhance abrasion resistance, then abrasion resistance is improved, but the fabric's softness deteriorates
Solution Approach 1:
The bonding pattern is segmented into multiple discrete icons distributed across the fabric surface. Each icon contains multiple bonding points (perimeter and internal) that are spatially separated. This segmentation allows bonding to occur at specific localized points rather than across the entire fabric surface, maintaining softness in unbonded regions while providing abrasion resistance at bonding locations.
Solution Approach 2:
The bonding characteristics are made local rather than uniform. Each icon has a specific geometry and bonding point configuration tailored to provide reinforcement where needed. The perimeter bonding points create a boundary structure while internal bonding points provide additional localized reinforcement. This local quality approach ensures that bonding strength is concentrated where it provides maximum benefit while minimizing impact on overall fabric softness.
2Reliability
If more bonding points are added to enhance abrasion resistance, then abrasion resistance is improved, but the fabric's softness and comfort deteriorate
Solution Approach 1:
Instead of bonding the entire fabric surface, the invention applies bonding action partially through discrete icons with specific numbers of bonding points. Each icon contains from 3 to 10 perimeter bonding points and 1 to 5 internal bonding points, which is sufficient to provide abrasion resistance and reduce linting at those locations without the excessive bonding that would compromise fabric softness and comfort across the entire surface.
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 embossed bonding pattern effectively enhances abrasion resistance and reduces linting while maintaining the fabric's softness, as demonstrated by the controlled placement and geometry of bonding points within the embossed icons.
Implementation Method 1
bonding operation to hold the individual filaments together
Implementation Method 2
embossing rolls with specific protrusion patterns
Data Source
AI summary
Fabrics having a desirable softness and exhibiting a low lint level are provided. The fabrics include an embossed bonding pattern, in which the embossed bonding pattern includes a plurality of icons (e.g., geometric shapes, caricatures, etc.). The plurality of icons may be defined by a plurality of perimeter bonding points. Additionally, from 1 to about 10 internal bonding points may be located within at least one of the plurality of icons.