Frothed Benefit Agent Coating for Softer, Bulkier Nonwoven Substrates
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Solution Overview
Problem
Current methods for applying additive compositions to nonwoven substrates, such as tissue products, face inefficiencies due to low chemical mass efficiency and clogging issues with larger particles, which hinder the enhancement of softness and bulk properties.
Innovation Solution
A method involving the application of a frothed, aqueous benefit agent to a hot drying surface, allowing it to form an adhesive film, and then bonding the nonwoven substrate to this film, enabling improved softness and bulk through creping, while incorporating micro-particles and fibers for enhanced tactile benefits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If spray particles are applied to the dryer surface, then additive composition is deposited on the substrate, but chemical mass efficiency is low due to air boundary layer and high dryer temperatures
Solution Approach 1:
The invention changes the physical state of the additive composition from liquid spray to froth (foam). The froth form allows the composition to be applied at lower temperatures and adheres better to the dryer surface, overcoming the air boundary layer barrier and improving chemical mass efficiency from 40-70% to significantly higher levels.
Solution Approach 2:
The additive composition undergoes a phase transition from liquid to froth (gas-liquid mixture). This phase change enables the composition to be applied as a stable foam that can withstand the air boundary layer and high dryer temperatures without decomposing or being blown away, thereby improving deposition efficiency.
2Strength
If larger particles and short fibers are added to enhance softness, then substrate softness is improved, but spray nozzles become clogged
Solution Approach 1:
The invention changes the application form from liquid spray to froth. In froth form, larger particles and short fibers can be suspended within the foam structure without clogging nozzles, as the froth delivery system accommodates these larger components. This allows softness-enhancing particles to be applied effectively while maintaining manufacturing ease.
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
This approach increases chemical mass efficiency, reduces energy consumption, and enhances the softness and bulk of nonwoven substrates by maintaining entrapped air within the coated layer, providing a more efficient and effective application process.
Implementation Method 1
allowing the frothed, benefit agent to form an adhesive film onto the drying surface; directly bonding the nonwoven substrate to the adhesive film positioned on the drying surface
Implementation Method 2
positioned an applicator adjacent to a hot, non-permeable drying surface
Implementation Method 3
allowing the frothed, benefit agent to form an adhesive film onto the drying surface; directly bonding the nonwoven substrate to the adhesive film
Data Source
AI summary
The present invention provides a nonwoven substrate comprising a fibrous web defining a surface; and a layer of a benefit agent wherein said benefit agent is selected from an additive composition, an enhancement component and combinations thereof; wherein said benefit agent is frothed and bonded to the fibrous web surface through a creping process. Additionally, the present invention provides for a method of creping a nonwoven substrate and also provides for a nonwoven substrate comprising an adhesive film of an aqueous, frothed, benefit agent.