Hydraulic Patterning of Sided Nonwoven Web
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Solution Overview
Problem
Existing methods for producing patterned nonwoven materials, such as hydroentangling, do not efficiently create sided nonwovens with distinct fiber compositions and patterns on both surfaces, which are preferred for wiping substrates.
Innovation Solution
A reflective patterning process using high-pressure water jets to push fibers against a patterned support, with the reflected water creating a pattern on the opposing side, allowing for the integration of short and continuous fibers to produce sided nonwovens with enhanced thickness and drapeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional hydroentangling processes are used with highly porous support members, then fluid can pass through the nonwoven web for collection, but the process cannot produce sided nonwovens with distinct fiber compositions and patterns on both surfaces
Solution Approach 1:
The patent inverts the conventional approach by using a non-porous support member that reflects fluid back through the web rather than allowing fluid to pass through. This inversion enables the formation of distinct patterns on both surfaces and allows production of sided nonwovens with different fiber compositions on each side, directly resolving the limitation of conventional porous support members
2Strength
If high pressure fluid jets are used to entangle fibers, then fiber entanglement is achieved, but distinct surface patterns on both sides cannot be created
Solution Approach 1:
The patent applies local quality by using a non-porous support member with specific reflective properties that concentrate fluid energy at particular locations. This creates distinct surface patterns on both sides of the nonwoven web while maintaining fiber entanglement, as the reflected fluid jets locally entangle fibers in patterned arrangements rather than uniform entanglement
3Manufacturing precision
If conventional patterning methods are used, then patterned nonwovens are produced, but the methods do not efficiently create sided nonwovens with enhanced thickness and drapeability
Solution Approach 1:
The patent merges the entanglement function and patterning function into a single hydroentangling pass using a non-porous support member. This combination efficiently produces sided nonwovens with distinct patterns, enhanced thickness, and improved drapeability in one process step, eliminating the need for separate patterning operations and improving production efficiency
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 results in nonwovens with improved thickness, softness, and drapeability, along with distinct surface patterns, making them suitable for wiping substrates and offering enhanced tactile and visual appearances.
Implementation Method 1
A reflective patterning process using high-pressure water jets to push fibers against a patterned support
Implementation Method 2
with the reflected water creating a pattern on the opposing side
Data Source
Figure 1~3
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AI summary
Disclosed herein is a reflectively patterned, fibrous, sided nonwoven material comprising a first set of fibers hydraulically needled with a web of a second set of fibers, the first set of fibers primarily containing short fibers and the second set of fibers primarily containing one of (a) substantially continuous filaments, (b) long fibers, and (c) short fibers having an average fiber length at least twice the average fiber length of the first set of fibers. The material has a first surface predominately comprising the first set of fibers and an opposing second surface predominately comprising the second set of fibers. The first surface is reflectively patterned to have a visual and tactile appearance depending on a support pattern on which the patterning is performed.