Fluid-Entangled Laminate Web Hollow Projections
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Solution Overview
Problem
Existing methods for creating fibrous nonwoven materials with hollow projections and apertures fail to effectively balance thickness, softness, and fluid permeability, often resulting in materials that are either too stiff or prone to adhesive issues when used in absorbent products.
Innovation Solution
A process involving a projection forming surface with forming holes and protrusions, where pressurized fluid jets entangle fibers to form hollow projections and apertures, creating a laminate web with improved three-dimensionality and fluid management capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If embossing is used to create three-dimensionality, then thickness and surface area are improved, but the material becomes stiffer and loses softness
Solution Approach 1:
The patent uses hydroentangling (water jet entanglement) to form hollow projections by directing pressurized fluid streams through a forming surface with protrusions. This hydraulic approach creates three-dimensional structure without mechanical crushing, preserving fiber softness while achieving the desired topology.
Solution Approach 2:
The patent creates a porous structure with hollow projections and apertures through fluid entanglement. The porous configuration provides three-dimensionality and fluid management capabilities while maintaining material softness, as the hollow spaces prevent fiber densification that would otherwise occur with embossing.
2Shape
If embossing is used to create three-dimensionality, then thickness is improved, but material is lost due to crushing and bonding
Solution Approach 1:
The hydroentangling process uses water jets to entangle fibers and form hollow projections without mechanical compression that would crush and bond fibers. This preserves material integrity and reduces loss while achieving the desired thickness through three-dimensional fiber arrangement.
Solution Approach 2:
The patent changes the physical state and arrangement of fibers through fluid entanglement, transforming flat fiber layers into three-dimensional hollow projections. This parameter change in fiber configuration achieves thickness without material loss, as no fibers are removed or compressed into dense bonds.
3Reliability
If apertures are created in nonwoven web, then fluid permeability is improved, but adhesive penetration through apertures causes build-up and unintended bonds
Solution Approach 1:
The patent creates a controlled porous structure with apertures formed during hydroentangling. The aperture size and distribution are controlled to maintain fluid permeability while preventing adhesive penetration. The porous configuration allows fluid passage but the controlled geometry prevents adhesive build-up issues.
4Strength
If three dimensional shape is filled with fiber to maintain resilience, then softness is improved, but material usage increases and aesthetic appeal decreases
Solution Approach 1:
The patent creates hollow projections with controlled porosity that provide resilience through their three-dimensional geometry rather than fiber filling. The hollow spaces maintain structural integrity and softness while using less material, as the projection walls themselves provide the necessary mechanical properties without requiring complete fiber filling.
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 process generates a laminate web with hollow projections that enhance skin separation and fluid storage, reducing skin contact and contamination while maintaining softness and preventing adhesive issues, thus improving the performance of absorbent products.
Implementation Method 1
A projection fluid entangling device has a plurality of projection fluid jets capable of emitting a plurality of pressurized projection fluid streams of entangling fluid from the projection fluid jets in a direction towards the projection forming surface
Data Source
AI summary
The present invention is directed to a process and apparatus for formation of a fluid-entangled laminate web. The laminate web includes a support layer and a nonwoven projection web having a plurality of projections which are preferably hollow. The laminate web also includes a plurality of apertures interspersed with the projections. As a result of the fluid-entangling process, entangling fluid is directed through the support layer and into the projection web which is situated on a forming surface. The force of the entangling fluid causes the two layers to be joined to one another and the fluid causes a portion of the fibers in the projection web to be forced into openings present in a forming surface thereby forming the hollow projections. The force of the entangling fluid also causes the fibers of the two layers to be moved around protrusions present in the forming surface thereby forming the apertures.