Hydroentanglement Pattern Formation via Movable Jet Blocking

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Solution Overview

Problem

Conventional hydroentanglement processes for producing nonwovens struggle to create clearly visible patterns without compromising the bulkiness of the material, and are costly due to the need for expensive patterned supports.

Innovation Solution

A process involving a fibrous web subjected to a first hydroentanglement process with discontinuous blocking of water jets using a movable blocking member, allowing for the formation of discrete areas in the machine direction, enabling cost-effective and patterned nonwoven production without compromising bulkiness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If conventional hydroentanglement process uses patterned support to create patterns, then patterns can be formed on nonwoven, but the manufacturing cost increases due to expensive patterned supports

Engineering Contradiction:

Improvepattern formationVSAvoidmanufacturing cost

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The water jet flow is segmented into discrete areas along the machine direction by using movable blocking members that create gaps. Instead of using a continuous patterned support, the water jets are divided into active (unblocked) and inactive (blocked) sections, allowing pattern formation without expensive patterned supports.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The blocking members are made movable along the machine direction, allowing dynamic adjustment of the patterned areas. This enables flexible pattern creation and modification without requiring different patterned supports for different designs, reducing manufacturing costs.

Inventive Principle:

Principle #15Dynamics

2Area of stationary object

If water flow is applied to entire surface of nonwoven in conventional hydroentanglement, then complete coverage is achieved, but clearly visible patterns cannot be formed due to insufficient thickness or density difference

Engineering Contradiction:

Improvewater flow coverageVSAvoidpattern visibility

Core Design Contradiction:

Area of stationary objectVSShape

Solution Approach 1:

Instead of uniform water flow across the entire nonwoven surface, the invention applies water jets selectively to specific discrete areas by blocking other regions. This creates local variations in fiber entanglement density and thickness, producing visible patterns with sufficient contrast between patterned and non-patterned areas.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention uses partial water jet application rather than complete surface coverage. By blocking portions of the water jets, only specific areas receive hydroentanglement treatment, creating distinct patterned regions with sufficient density differences for clear visibility against the background.

Inventive Principle:

Principle #16Partial or excessive action

3Adaptability or versatility

If patterned supports are used for different images, then various patterns can be produced, but the cost increases as switching to different patterns requires expensive patterned supports

Engineering Contradiction:

Improvepattern varietyVSAvoidcost to switch patterns

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The blocking members can be moved dynamically to create different patterns. By adjusting the position and configuration of the movable blocking members, various patterns can be produced without requiring different patterned supports, enabling cost-effective pattern switching and design flexibility.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The same water injection means with movable blocking members can produce multiple different patterns through dynamic reconfiguration. This universal system replaces the need for multiple specialized patterned supports, providing pattern variety without increasing manufacturing costs for pattern switching.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 effectively creates nonwovens with discrete patterns in the machine direction, maintaining bulkiness and providing a cost-effective solution for patterned nonwoven production, suitable for applications like absorbent articles.

Implementation Method 1

hydroentanglement (sometimes referred to as spunlacing, jet entanglement, water entanglement, hydroentanglement or hydraulic needling), is a mechanical bonding process whereby fibers of a fibrous web are entangled by means of high pressure water jets

Methodology Applied

Scientific EffectHydroentanglement:

Implementation Method 2

blocking at least one of the water jets from the water injection means discontinuously

Methodology Applied

Scientific EffectFluid flow blocking:

Data Source

PatentEP3802938B1Process for producing nonwoven and apparatus suitable therefor

Publication Date: 2024.10.30 PROCTER & GAMBLE CO

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Figure 3A~3B
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AI summary

Provided is a process and an apparatus for making a fibrous web comprising a plurality of first areas comprising hydroentangled fibers, the first areas being discrete in a machine direction and/or a counter-machine direction, wherein the process comprises subjecting a fibrous web to a first hydroentanglement process directing water jets from a water injection means comprising a plurality of orifices on to the fibrous web;blocking at least one water jet from the water injection means discontinuously by use of a first blocking member positioned between the water injection means and the fibrous web.