High-Loft Nonwoven Material With Core-Sheath Fiber Bonding

Solution Overview

Problem

Existing high loft nonwoven materials do not effectively balance loftiness, softness, and compression strength, particularly in applications requiring high airflow and absorbency, such as filter media and absorbent pads.

Innovation Solution

Incorporating multicomponent fibers with a core/sheath configuration, where the sheath melts during bonding while the core remains intact, combined with monocomponent fibers of higher melting temperature, to create a nonwoven material with enhanced loft, softness, and increased compression strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of stationary object

If less compression force is applied during bonding, then loftiness is increased, but compression strength decreases

Engineering Contradiction:

ImproveloftinessVSAvoidcompression strength

Core Design Contradiction:

Volume of stationary objectVSStrength

Solution Approach 1:

The bonding process is segmented into two distinct stages: first, low compression force is applied to bond the high-loft nonwoven material and maintain its loftiness; second, a separate low melting temperature polymer is applied and melted to provide additional bonding that increases compression strength without compromising the loft structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the bonding parameters by using a two-stage process with different compression forces and temperatures. The first stage uses low compression force to preserve loft, while the second stage introduces a low melting temperature polymer that can be bonded at lower temperatures and pressures, thereby maintaining loftiness while achieving adequate compression strength.

Inventive Principle:

Principle #35Parameter changes

2Strength

If compression force is increased during bonding, then compression strength is improved, but loftiness is reduced

Engineering Contradiction:

Improvecompression strengthVSAvoidloftiness

Core Design Contradiction:

StrengthVSVolume of stationary object

Solution Approach 1:

The bonding process is segmented into two distinct stages: first, low compression force is applied to bond the high-loft nonwoven material and maintain its loftiness; second, a separate low melting temperature polymer is applied and melted to provide additional bonding that increases compression strength without compromising the loft structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the bonding parameters by using a two-stage process with different compression forces and temperatures. The first stage uses low compression force to preserve loft, while the second stage introduces a low melting temperature polymer that can be bonded at lower temperatures and pressures, thereby maintaining loftiness while achieving adequate compression strength.

Inventive Principle:

Principle #35Parameter changes

3Temperature

If high melting temperature polymers are used, then thermal stability is improved, but bonding efficiency decreases

Engineering Contradiction:

Improvethermal stabilityVSAvoidbonding efficiency

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The invention uses a composite bonding approach where a low melting temperature polymer (for easy bonding) is combined with the high melting temperature base polymer of the nonwoven material (for thermal stability). This composite strategy allows the material to achieve both ease of manufacture through low-temperature bonding and thermal stability through the presence of the high melting temperature polymer.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention changes the bonding parameters by using a two-stage process with different compression forces and temperatures. The first stage uses low compression force to preserve loft, while the second stage introduces a low melting temperature polymer that can be bonded at lower temperatures and pressures, thereby maintaining loftiness while achieving adequate compression strength.

Inventive Principle:

Principle #35Parameter changes

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 results in a nonwoven material with improved loftiness, softness, and void spaces for air passage, along with enhanced compression strength, suitable for various applications including filter media and absorbent pads.

Implementation Method 1

The melting temperatures of the first and second polymers are selected such that the first polymer substantially melts during the heat bonding process, but the second polymer does not substantially melt.

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS20250320644A1High loft nonwoven material

Publication Date: 2025.10.16 DELSTAR TECHNOLOGIES INC

AI summary

Nonwoven materials are provided that comprise multicomponent and monocomponent fibers. The multicomponent fibers comprise first and second polymers and the monocomponent fibers comprise the second polymer or a third polymer. The second and/or third polymer has a higher melting temperature than the first polymer. The fibers are selected to provide increased loft to the materials and are suitable for a variety of different applications and products, such as filter media for air or liquid filters and absorbent pads for bandages, wound dressings, diapers, adult incontinence products, feminine hygiene products and the like. Absorbent pads are provided comprising high loft nonwoven material that increases the absorbency of the pad. Filter media is provided comprising high loft nonwoven material that increases the dust holding capacity of the media.