Fibrous Structures with Patterned Linear Elements for Energy Absorption
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Solution Overview
Problem
Current fibrous structures do not meet consumer demand for cross machine direction total energy absorption (CDTEA) of greater than 8 cm-g/cm2 as measured by the TEA Test Method, while also maintaining a Dry Burst of less than 740 g as measured by the Dry Burst Test Method.
Innovation Solution
Development of fibrous structures with a CDTEA of greater than 8 cm-g/cm2 and a Dry Burst of less than 740 g, achieved through the use of co-formed structures comprising polypropylene filaments and wood pulp fibers, utilizing specific manufacturing processes such as wet-laid or air-laid papermaking, and employing deflection members with patterned ridges to create linear elements within the fibrous structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional fibrous structures are used, then manufacturing simplicity is maintained, but CDTEA is insufficient (less than or equal to 8 cm-g/cm2)
Solution Approach 1:
The fibrous structure is segmented into multiple plies (e.g., first ply, second ply, third ply) with distinct fiber compositions and orientations. Each ply contains specific types of fibers (cellulosic, synthetic, natural) arranged in particular directions to contribute differently to the overall CDTEA, allowing the structure to achieve high energy absorption through coordinated action of segmented components
Solution Approach 2:
Different regions of the fibrous structure have different local qualities - specific plies have higher concentrations of certain fiber types (e.g., synthetic fibers in one ply, natural fibers in another), and linear elements are positioned at specific orientations (e.g., 0 degrees, 45 degrees, 90 degrees) to create localized areas of enhanced energy absorption that collectively achieve the target CDTEA
2Strength
If fibrous structures with higher CDTEA are developed, then consumer preference is met, but Dry Burst increases (exceeding 740 g)
Solution Approach 1:
The invention changes multiple parameters simultaneously: fiber composition (ratios of cellulosic, synthetic, and natural fibers), fiber orientation (linear elements at various angles), ply structure (multi-ply configuration), and basis weight distribution. These parameter changes are optimized to achieve the specific performance window of CDTEA greater than 8 cm-g/cm2 while maintaining Dry Burst below 740 g
Solution Approach 2:
The fibrous structure uses composite materials combining different fiber types (cellulosic fibers, synthetic fibers, natural fibers) in specific ratios and arrangements. This composite approach allows tuning of both CDTEA and Dry Burst properties, as each fiber type contributes differently to energy absorption and burst strength, enabling simultaneous optimization of both parameters
Data Source
AI summary
Fibrous structures that exhibit a cross machine direction total energy absorption (CDTEA) of greater than 8 cm-g/cm2 as measured according to the TEA Test Method.