Low-Density Hydroentangled Cleaning Substrate
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Solution Overview
Problem
Existing cleaning substrates with high basis weights are preferred for their absorption and effectiveness, but low basis weight substrates appear flimsy and are less accepted by consumers, and current methods for forming hydroentangled substrates with air laid natural fibers require expensive equipment and processes like wet laying or foam forming.
Innovation Solution
A method involving forming a carrier substrate, depositing an air laid layer of natural fibers, wetting it with low-pressure water, and hydroentangling it with the carrier substrate to create a low-density, integrated substrate with a basis weight of less than 100 gsm, which can be expanded for perceived bulk and thickness, using materials like meltblown, spunbond, and coform fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If high basis weight substrates are used, then absorption capacity and cleaning effectiveness are improved, but perceived flimsiness and consumer acceptance worsen
Solution Approach 1:
The patent combines synthetic fibers (providing strength and structure) with natural cellulosic fibers (providing absorbency) in a multi-layer hydroentangled substrate. This composite structure achieves high absorption capacity equivalent to heavier substrates while maintaining a lighter basis weight that appears less flimsy to consumers, thus resolving the contradiction between quantity of substance and consumer acceptance
Solution Approach 2:
The substrate employs different fiber types in different layers: the synthetic fiber layer provides structural integrity and strength, while the natural cellulosic fiber layer provides absorption capacity. This local differentiation of material properties allows the substrate to achieve both strength and absorbency without increasing overall basis weight, thereby improving consumer acceptance while maintaining effectiveness
2Ease of manufacture
If air laid natural fibers are hydroentangled with carrier substrate, then production cost is reduced, but equipment complexity increases
Solution Approach 1:
The substrate is formed in distinct stages with different fiber layers deposited separately and then integrated through hydroentangling. This segmentation allows each layer to be formed using simpler, more cost-effective equipment while the final integration provides the necessary structural integrity, thus reducing overall equipment complexity while maintaining ease of manufacture
Solution Approach 2:
The hydroentangling process uses water jets to entangle the fiber layers together. This hydraulic method provides a cost-effective alternative to more complex thermal or chemical bonding equipment, reducing production costs while the water jet system itself remains relatively simple in design and operation
3Volume of moving object
If low basis weight substrate is used, then perceived bulk and thickness are improved, but absorption capacity and cleaning effectiveness worsen
Solution Approach 1:
The patent uses a composite of synthetic and natural fibers where the natural cellulosic fibers provide high absorption capacity relative to their weight. This allows the substrate to achieve light basis weight (improving perceived bulk) while the highly absorbent natural fibers compensate for the reduced overall mass, maintaining sufficient absorption capacity for effective cleaning
Solution Approach 2:
The patent changes the physical and chemical parameters of the fiber assembly through hydroentangling, which creates a three-dimensional network structure with increased porosity and surface area. This structural transformation enhances the absorption capacity per unit weight, allowing low basis weight substrates to achieve adequate absorption performance while maintaining perceived bulk
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 method produces a strong and absorbent cleaning substrate suitable for hard surface cleaning with lower production costs and without the need for expensive equipment, providing a perceived thickness and effectiveness in cleaning applications.
Implementation Method 1
subjecting the intermediate substrate layers to a water curtain to saturate the cellulosic material with water
Implementation Method 2
hydroentangling the carrier web and air laid layer together to form a fully bonded dual layer substrate
Data Source
AI summary
The present invention is directed to a method for making a multiple layer substrate comprising the steps of: (1) forming a carrier substrate; (2) depositing an air laid layer comprising natural fibers on top of the carrier substrate; (3) wetting the air laid layer with a source of low pressure water; (4) hydroentangling the air laid layer with the carrier substrate to form an integrated substrate. Another aspect of the present invention is the creation of a low-density cleaning substrate with a basis weight of less than 100 gsm, which comprises at least one layer of a carrier web and at least one layer comprising an air laid cellulosic material which are hydroentangled together to form an integrated substrate. The substrate may be a pre-loaded wipe, which is either moistened by a consumer prior to use or moistened prior to packaging. The composition loaded onto the substrate may contain dry and/or liquid compositions preferably for cleaning hard or soft surfaces.