Laminate Fibrous Structure for Bulk and Surface Softness
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Solution Overview
Problem
Existing fibrous structures face challenges in achieving bulkiness and softness simultaneously, with textured structures being rough and chemical softening agents only partially mitigating the rough feel, while non-textured structures lack bulk.
Innovation Solution
Laminate fibrous structures comprising a low basis weight nonwoven web with hydroxyl polymer fibers, such as polyvinyl alcohol or rayon, providing a basis weight of less than 5 gsm and specific fiber diameters, combined with a base fibrous structure to achieve bulk and softness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the fibrous structure is highly texturized to achieve bulkiness, then the volume and bulk increase, but the surface becomes rough and loses softness
Solution Approach 1:
The fibrous structure is divided into two distinct layers: a base layer that provides bulkiness through texturizing, and a separate top layer that provides surface softness. This segmentation allows each layer to independently fulfill its specific function without compromising the other.
Solution Approach 2:
Different regions of the fibrous structure are given different properties: the base layer is highly texturized for bulk, while the top layer is smooth and soft to the touch. This local differentiation of quality resolves the contradiction between overall bulkiness and surface softness.
2Ease of operation
If a chemical surface softening agent is applied to a highly texturized surface to improve softness, then the surface softness increases slightly, but the rough textured feel remains and bulkiness is compromised
Solution Approach 1:
Instead of applying chemical agents to a texturized surface, the structure is segmented into two layers: a texturized base layer for bulk and a separate smooth top layer for softness. This physical segmentation eliminates the need for chemical softening agents while maintaining both bulkiness and surface softness.
Solution Approach 2:
The fibrous structure uses a composite of two different fibrous layers with contrasting properties: a highly texturized base layer and a smooth non-textured top layer. This composite structure combines the bulkiness of the texturized layer with the surface softness of the smooth layer, resolving the contradiction between these two properties.
3Ease of operation
If the fibrous structure is made smooth and non-textured to achieve surface softness, then the surface softness improves, but the bulkiness is lost
Solution Approach 1:
The structure is segmented into two functional layers: a base layer that is highly texturized to provide bulkiness, and a top layer that is smooth to provide surface softness. This segmentation allows the smooth surface to exist without sacrificing the bulk provided by the texturized base layer.
Solution Approach 2:
Different layers of the fibrous structure have different local qualities: the base layer is texturized for bulk, while the top layer is smooth for surface softness. This local differentiation resolves the contradiction by allowing each property to dominate in its appropriate region.
Data Source
AI summary
Laminate fibrous structures, more particularly laminate fibrous structures containing a base fibrous structure associated with a low basis weight (less than 5 gsm) nonwoven web containing hydroxyl polymer fibrous elements, convolutely wound rolls of such laminate fibrous structures and methods for making such laminate fibrous structures and rolls are provided.