Layered Spunbond Nonwoven for Strength-Softness Balance
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Solution Overview
Problem
Existing spunbond nonwoven webs made from elastomeric materials lack sufficient strength and durability while maintaining a soft handfeel and drapeability.
Innovation Solution
A nonwoven web comprising a strength-building layer made from non-elastomeric spunbond fibers and a softness enhancing layer made from elastomeric fibers, with the latter forming the exterior surface, providing a balanced combination of strength and softness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If elastomeric materials are used to produce spunbond webs, then soft handfeel and drapeability are improved, but strength and durability deteriorate
Solution Approach 1:
The nonwoven web is divided into two distinct layers: a strength-building layer made from non-elastomeric spunbond fibers and a softness-enhancing layer made from elastomeric fibers. This segmentation allows each layer to perform its specialized function - the bottom layer provides structural strength while the top layer provides soft handfeel and drapeability.
Solution Approach 2:
Different regions of the nonwoven web have different properties tailored to specific functions. The bottom layer has high strength characteristics for durability, while the top layer has soft elastomeric characteristics for handfeel. This local differentiation resolves the contradiction by assigning opposite qualities to different parts of the same product.
2Strength
If non-elastomeric polymer fibers are used for the strength-building layer, then strength is improved, but soft handfeel deteriorates
Solution Approach 1:
The web is segmented into functional layers where the strength-building layer handles structural requirements and the softness-enhancing layer handles tactile requirements. This allows non-elastomeric fibers to be used in the bottom layer without compromising overall softness, since the elastomeric top layer provides the handfeel.
Solution Approach 2:
The elastomeric softness-enhancing layer acts as an intermediary between the user's touch and the non-elastomeric strength-building layer. It mediates the tactile interaction, providing soft handfeel while allowing the bottom layer to maintain structural strength without direct contact stress.
3Ease of operation
If elastomeric fibers are used for the softness-enhancing layer, then soft handfeel is improved, but strength deteriorates
Solution Approach 1:
By segmenting the web into layers with different fiber compositions, the elastomeric fibers are confined to the top softness-enhancing layer where they provide handfeel without being subjected to the full structural load. The bottom strength-building layer carries the mechanical stress, compensating for the lower strength of the elastomeric top layer.
Data Source
AI summary
A nonwoven material is disclosed having an excellent balance between strength and softness. The nonwoven material can be made from spunbond layers and can include at least one strength-building layer combined with at least one softness enhancing layer. In one aspect, the nonwoven material can be incorporated into an elastic laminate for use in absorbent articles.