High Loft Spunbond Nonwoven Fabric with Crimped Multicomponent Fibers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing nonwoven fabrics with high loft spunbond layers made from crimped multicomponent fibers do not achieve sufficient loft and stability, particularly in hygiene products, where they are desired for softness and barrier properties.
Innovation Solution
A nonwoven fabric comprising a high loft spunbond layer with crimped multicomponent fibers, where the second component comprises a blend of polymer A with a polymer B having a melt flow rate at least 25% different from polymer A, and the second component constitutes at least 40 wt.-% of the fiber, enhancing crimp and loft while maintaining stability and barrier properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If multicomponent fibers with different melt flow rates are used to achieve crimp, then loft is improved, but stability and liquid barrier properties deteriorate
Solution Approach 1:
The invention uses multicomponent fibers comprising polymer A and polymer B with different melt flow rates to create crimped structures that provide high loft while maintaining stability and liquid barrier properties through the synergistic combination of different polymer materials
Solution Approach 2:
The invention optimizes the melt flow rate difference between polymer A and polymer B (at least 25% difference) and the composition ratio (at least 40 wt.-% polymer B in the second component) to achieve the desired balance between loft and stability
2Volume of stationary object
If the second component comprises a blend of polymer A and polymer B with significant polymer B content, then crimp and loft are enhanced, but manufacturing complexity increases
Solution Approach 1:
The invention defines specific parameter ranges for the blend composition (at least 40 wt.-% polymer B) and melt flow rate difference (at least 25%) to optimize loft while providing clear manufacturing guidelines that reduce complexity
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 improved loft, softness, and stability of the nonwoven fabric, reducing glue bleed-through during manufacturing and enhancing the barrier properties of hygiene products, such as diapers and sanitary napkins, by increasing the crimp and bulk of the fibers.
Implementation Method 1
The crimp of the fibers is thereby achieved upon using multicomponent fibers where the two components have different melt flow rates
Data Source
AI summary
The invention relates to a fabric comprising at least one high loft spunbond nonwoven layer having crimped multicomponent fibers, wherein a first component of the multicomponent fibers comprises a first polymer A and a second component of the multicomponent fibers comprises a blend of the first polymer A and a second polymer B, wherein the melt flow rate of polymer A is at least 25% higher than the melt flow rate of polymer B and wherein the second component comprises at least 40 wt.-% of polymer B.