Fibrous Nonwoven Coform Web Structure with Shaped Particles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current wet wipes substrates face challenges in balancing mechanical strength, absorbency, and surface friction, with hybrid pulp and polymer combinations often compromising on desired properties such as tensile strength, opacity, and consumer preference due to the inclusion of scrim layers.
Innovation Solution
A fibrous web structure with optimized proportions of pulp fibers and meltblown polypropylene filaments in scrim and core layers, where the allocation of filaments between these layers enhances tensile strength, opacity, and consumer preference, while maintaining absorbency and reducing linting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If scrim layers are added to enhance tensile strength and reduce linting, then mechanical strength improves, but surface friction and consumer preference deteriorate
Solution Approach 1:
The patent applies local quality by creating distinct layers with different functions: the core layer contains pulp fibers for absorbency and surface friction, while the scrim layer provides tensile strength. This localized functional differentiation allows each layer to optimize its specific property without compromising the other.
Solution Approach 2:
The patent uses composite materials by combining pulp fibers and polymer filaments in a coformed structure. The pulp fiber core layer provides natural hydrophilicity and surface texture for cleaning efficacy, while the polymer scrim layer adds mechanical strength, creating a composite that achieves both absorbency and structural integrity.
2Strength
If polymer filament content is increased to improve wet structural integrity, then tensile strength improves, but absorbency deteriorates
Solution Approach 1:
The patent segments the fibrous web structure into functionally distinct layers: a core layer rich in pulp fibers for absorbency and a separate scrim layer with polymer filaments for structural integrity. This segmentation allows each layer to specialize in its primary function without the negative effects of mixing materials throughout the entire structure.
Solution Approach 2:
The patent employs composite materials by creating a layered structure where pulp fibers and polymer filaments are distributed in specific proportions and locations. The core layer maintains high pulp content for absorbency, while the scrim layer provides polymer reinforcement for wet strength, achieving both properties through composite construction.
3Quantity of substance
If pulp fiber content is increased to enhance absorbency and surface friction, then cleaning efficacy improves, but tensile strength deteriorates
Solution Approach 1:
The patent segments the structure into a pulp-rich core layer for absorbency and a polymer-rich scrim layer for strength. This segmentation allows the pulp fiber content to be maximized in the core layer without compromising overall tensile strength, as the polymer scrim provides the mechanical reinforcement.
Solution Approach 2:
The patent uses composite materials to combine the advantages of pulp fibers (absorbency, hydrophilicity, surface friction) with polymer filaments (tensile strength, wet structural integrity) in a layered coformed structure, achieving a balance that neither material could provide alone.
4Strength
If hybrid pulp and polymer combinations are used to balance properties, then wet structural integrity improves, but manufacturing predictability deteriorates
Solution Approach 1:
The patent segments the fibrous web into distinct layers with controlled compositions: a core layer with specific pulp fiber content and a scrim layer with specific polymer filament content. This segmentation simplifies the manufacturing process by allowing independent control of each layer's properties, improving predictability of the final product's characteristics.
Solution Approach 2:
The patent applies composite materials in a structured, layered configuration that enables predictable manufacturing outcomes. By defining specific weight percentages and layer structures, the coforming process can consistently produce substrates with targeted properties for absorbency, strength, and surface characteristics.
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 optimized fibrous web structure achieves improved tensile strength, opacity, and consumer preference, while maintaining absorbency and reducing linting, thereby addressing the limitations of existing hybrid substrates.
Implementation Method 1
meltblown polypropylene filaments
Data Source
AI summary
A fibrous nonwoven structure formed of a blend of cellulose pulp fibers and melt spun polymer filaments is disclosed. The structure may include a distribution of a plurality of macroscopically visible shaped particles of substantially similar size and shape, included in the blend. The structure may also include outer scrim layers formed of melt spun polymer filaments. A method of manufacturing the fibrous nonwoven structure is also disclosed.