Laminate Absorbent Structure for High Strength at Low MD Stretch
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Solution Overview
Problem
Existing absorbent structures, such as disposable paper towels and wipes, face challenges in achieving high strength, absorbency, and softness while minimizing machine direction (MD) stretch, which is typically associated with increased production costs and reduced productivity due to the need for high levels of rush transfer and chemical strength additives.
Innovation Solution
The development of a laminate absorbent structure using a structuring fabric in a Through Air Drying (TAD) process, which includes embossed plies adhered with a water-soluble adhesive, resulting in a product with high ball burst strength, absorbency, and softness at low MD stretch levels, achieved through a unique combination of channel spacing, embossment patterns, and adhesive application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high levels of rush transfer and chemical strength additives are used to achieve high strength, then strength is improved, but productivity decreases and production costs increase
Solution Approach 1:
The patent changes the physical parameters of the fabric structure (thread count, stitch type, channel spacing) to achieve high strength without requiring high rush transfer rates or chemical additives. Specifically, using a tighter knit structure with smaller stitch length and appropriate channel spacing allows the web to maintain strength at lower MD stretch levels, thereby improving productivity.
2Strength
If high levels of rush transfer are used to achieve high strength, then strength is improved, but energy consumption increases
Solution Approach 1:
The patent modifies fabric parameters (thread count, stitch length, channel spacing) to achieve the desired strength level at reduced rush transfer rates, thereby lowering energy consumption while maintaining product performance.
3Strength
If chemical strength additives are used to achieve high strength, then strength is improved, but product cost increases
Solution Approach 1:
The patent achieves high strength through optimized fabric physical parameters (thread count, stitch type, channel spacing) rather than relying on chemical strength additives, thereby reducing raw material costs and simplifying the manufacturing process.
4Strength
If MD stretch is increased to achieve high strength, then strength is improved, but absorbency and softness decrease
Solution Approach 1:
The patent decouples the relationship between MD stretch and strength by optimizing fabric structure parameters. The specific channel spacing and stitch configuration allow the web to achieve high ball burst strength at lower MD stretch levels, preserving the compressibility and void space necessary for absorbency and softness.
5Strength
If MD stretch is increased to achieve high strength, then strength is improved, but product cost increases
Solution Approach 1:
The patent reduces production cost by optimizing fabric parameters to achieve high strength at lower MD stretch levels, eliminating the need for expensive chemical additives and reducing energy consumption during the drying process.
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
This approach allows for the production of absorbent products with enhanced strength, absorbency, and softness without the need for high MD stretch, thereby improving productivity and reducing costs by minimizing the use of chemical additives and energy consumption.
Implementation Method 1
embossed plies adhered with a water-soluble adhesive
Implementation Method 2
absorbent structures with high strength and low md stretch
Data Source
AI summary
Absorbent product including a laminate of at least two plies, wherein the absorbent product has a measured Y-Connected Area parameter greater than 20 and a Surface Channel Spacing of less than 2.5 mm. The absorbent product has high strength and low machine direction stretch.