Five-Layer Non-Woven Fabric Wipe to Prevent Wood Pulp Linting
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Solution Overview
Problem
Existing melt-blown composite non-woven fabric wipes suffer from the issue of 'linting' due to short wood pulp fibers dropping from the melt-blown fiber layers, leading to poor cleaning performance.
Innovation Solution
A five-layer non-woven fabric wipe structure with melt-blown fiber webs and a wood pulp fiber web, where the melt-blown fibers of the second and fourth layers are partially interwoven with the wood pulp fibers, and the first and fifth layers are consolidated at 90° angles to form a protective layer, preventing fiber movement and enhancing abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wood pulp fiber layer is used as middle layer in melt-blown composite non-woven fabric, then cost-effectiveness and softness are improved, but linting occurs and cleaning performance deteriorates
Solution Approach 1:
The non-woven fabric is divided into five distinct layers with different functions: surface layers (first and fifth) provide fine fiber coverage, intermediate melt-blown layers (second and fourth) provide structural support, and the wood pulp layer (third) provides softness and absorbency. This segmentation allows each layer to optimize its function while preventing linting through the protective outer layers.
Solution Approach 2:
The invention uses a composite structure combining different fiber types (melt-blown fibers and wood pulp fibers) in a five-layer configuration. The melt-blown fiber layers serve as protective outer layers that prevent wood pulp fibers from shedding, while the wood pulp layer provides the desired softness and absorbency without causing linting issues.
2Ease of operation
If wood pulp fibers are used in melt-blown composite non-woven fabric, then softness and absorbency are improved, but fiber length is short and abrasion resistance deteriorates
Solution Approach 1:
By segmenting the fabric into five layers with the wood pulp confined to the middle layer (third layer) and protected by outer melt-blown fiber layers (first and fifth layers), the wood pulp fibers provide softness without being exposed to abrasion. The outer layers act as protective barriers that prevent the soft but weak wood pulp fibers from undergoing mechanical stress.
Solution Approach 2:
The outer melt-blown fiber layers are positioned beforehand to cushion and protect the inner wood pulp layer from mechanical stress and abrasion. This protective structure prevents the short wood pulp fibers from breaking or shedding during use, maintaining both softness and durability.
3Object-generated harmful factors
If five-layer structure with interwoven fibers is used, then linting is prevented and abrasion resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The five-layer structure is designed with clear functional segmentation where each layer has a specific role. The intermediate melt-blown fiber layers (second and fourth) are positioned adjacent to the wood pulp layer (third) to provide structural support and prevent fiber shedding, while the outer layers (first and fifth) provide fine fiber coverage. This segmentation achieves linting prevention through a systematic layering approach that can be manufactured using standard multi-layer non-woven fabric production techniques.
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 solution effectively prevents 'linting' and improves abrasion resistance, with reduced powder drop rates and enhanced cleaning performance, including hydrophilicity and skin-friendly properties through hydrophilic coatings.
Implementation Method 1
by using a melt-blowing process, a thermoplastic resin is heated, and enters the first and the second melt-blown spinning devices after melted; molten fine flows of the thermoplastic resin in the first and the second melt-blown spinning devices are ejected from melt-blown spinneret orifices of melt-blown spinneret plates and blown into fiber bundles each with a fiber diameter of ≤10 μm by using hot airflows
Implementation Method 2
a thermoplastic resin is heated, and enters the first and the second melt-blown spinning devices after melted
Implementation Method 3
performing a consolidation procedure, where the first layer, the second layer, the third layer, the fourth layer and the fifth layer of the non-woven fabric wipe are consolidated together via a heating apparatus
Data Source
AI summary
A non-woven fabric wipe having a layered fiber web structure. A first layer, a second layer, a fourth layer, and a fifth layer of the non-woven fabric wipe are all melt-blown fiber webs mainly composed of melt-blown fibers; a third layer of the non-woven fabric wipe is a wood pulp fiber web mainly composed of wood pulp fibers; the melt-blown fibers in the melt-blown fiber webs of the second layer and the fourth layer are partially interwoven in the adjacent wood pulp fiber web of the third layer, Because the non-woven fabric wipe of the present invention is composed of five layers of fiber webs, when the melt-blown fiber webs of the second layer and the fourth layer are consolidated, the portions interwoven with the wood pulp fibers are consolidated together with the interwoven wood pulp fibers, thereby forming a protective web that prevents the wood pulp fibers from moving.