Hydroentangled Nonwoven Fabric for Wet-State Skin Conformability
Solution Overview
Problem
Existing face masks impregnated with liquid do not adequately conform to the skin in a wet state, lacking sufficient flexibility and adherence.
Innovation Solution
A hydroentangled nonwoven fabric composed of spunbonded nonwoven fabric with heat-fused fibers and a fiber web bonded by hydroentangling, using natural or regenerated cellulose fibers, with embossed parts in an irregular pattern or without embossed parts, and a basis weight ratio of 0.35 to 1.60, incorporating extensible long fibers like thermoplastic polyurethane-based elastomer long fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a laminated nonwoven fabric with regular embossed parts is used, then manufacturing precision and structural stability are improved, but conformability to skin in wet state deteriorates
Solution Approach 1:
The patent applies asymmetry by changing the embossed parts arrangement from a regular pattern to an irregular pattern. This irregular arrangement reduces the fabric's overall rigidity while maintaining local bonding strength, allowing the face mask to conform better to skin contours in wet state without compromising structural integrity during manufacturing and use.
2Strength
If the spunbonded nonwoven fabric has regular embossed parts, then bonding strength between layers is improved, but flexibility and conformability in wet state deteriorate
Solution Approach 1:
The patent applies local quality by creating localized bonding zones through irregularly distributed embossed parts rather than uniform bonding across the fabric. This allows certain areas to maintain flexibility while other areas provide sufficient bonding strength, enabling the fabric to adapt to skin contours while maintaining structural coherence.
3Strength
If hydroentangling is performed with high water pressure, then fiber bonding strength is improved, but fabric softness and conformability deteriorate
Solution Approach 1:
The patent applies parameter changes by optimizing the hydroentangling process parameters, specifically controlling water pressure within a moderate range (0.1-30 MPa) rather than using high pressure. This moderate pressure regime achieves sufficient fiber bonding strength while preserving the softness and conformability of the fabric structure, particularly when combined with the irregular embossed pattern that distributes bonding stresses.
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 fabric provides excellent conformability to the skin in a wet state, maintaining tight fit and impregnation properties, with improved flexibility and reduced elastic force.
Implementation Method 1
a fiber web bonded to at least one main surface of the spunbonded nonwoven fabric by hydroentangling
Implementation Method 2
a high-pressure water jet used in the hydroentangling has a water pressure of from 0.1 MPa to 30 MPa
Implementation Method 3
a spunbonded nonwoven fabric containing heat-fused fibers
Implementation Method 4
performing an embossing treatment on the spunbond web to prepare a spunbonded nonwoven fabric precursor that contains heat-fused fibers
Data Source
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AI summary
The hydroentangled nonwoven fabric of the disclosure includes a spunbonded nonwoven fabric, and a fiber web bonded to at least one main surface of the spunbonded nonwoven fabric by hydroentangling. The fiber web is composed of natural fibers or regenerated cellulose fibers. The hydroentangled nonwoven fabric of the disclosure satisfies the following (a) or (b): (a) the spunbonded nonwoven fabric has plural embossed parts in which some of the plural fibers contained in the spunbonded nonwoven fabric are fused, and the plural embossed parts are arranged in an irregular pattern; or (b) the spunbonded nonwoven fabric does not have the embossed parts.