Multi-layered Loop Material Embossing for Air Permeability Control
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Solution Overview
Problem
Existing multi-layer loop materials face challenges in balancing air permeability, stability, and cost-effectiveness while maintaining flexibility and hooking properties, particularly in applications requiring high holding forces and low stress duration.
Innovation Solution
A multi-layer loop material with a carrier layer and loop layer, both comprising nonwovens, where the carrier layer is reinforced by embossing with an area density between 10% and 95%, and the connection area density between the layers is lower, allowing for adjustable air permeability and stable hooking properties at reduced costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the carrier layer is made of nonwoven fabric to reduce costs and improve flexibility, then the material becomes more flexible and less expensive, but it becomes more difficult to process and position during production
Solution Approach 1:
The patent applies local quality by creating embossed regions with different properties (higher density, lower air permeability) in specific areas of the nonwoven carrier layer, while other areas maintain the original nonwoven properties. This allows the material to have locally enhanced processability where needed while maintaining overall flexibility and cost-effectiveness.
2Reliability
If the bonding area density between carrier layer and loop layer is increased to improve interlocking properties, then interlocking stability improves, but air permeability decreases and flexibility is compromised
Solution Approach 1:
The patent implements local quality by creating localized embossed regions in the carrier layer that provide concentrated bonding areas for the loop layer. These embossed regions have higher fiber density and create stable interlocking points, while the remaining non-embossed areas maintain high air permeability and flexibility. The bonding area density is controlled to be below the embossing area density, ensuring that not all areas are bonded.
Solution Approach 2:
The patent utilizes the porous structure of nonwoven fabric and controls the embossing process to maintain porosity in non-bonded regions. The embossed areas create localized density increases for bonding while preserving overall material porosity, achieving a balance between interlocking stability and air permeability through controlled porous structure management.
3Object-affected harmful factors
If embossing density is increased to reduce air permeability, then air impermeability improves, but flexibility and softness decrease
Solution Approach 1:
The patent applies local quality by limiting embossing to specific areas (embossing area density between 10% and 95% of total area) rather than embossing the entire carrier layer. This creates localized regions of reduced air permeability while preserving flexibility and softness in non-embossed areas, achieving a balance between air impermeability and material compliance.
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 configuration enables wide adjustment of air permeability, maintains sufficient fluffiness and flexibility, and ensures stable hooking properties, even at low air permeability, while minimizing adhesive usage and costs, thus addressing the limitations of prior materials.
Implementation Method 1
During embossing, the fibers are compacted in the area of a designated embossing point, potentially resulting in film formation
Implementation Method 2
the fibers are compacted in the area of a designated embossing point, potentially resulting in film formation—that is, a film-like development of the original fiber surface
Data Source
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AI summary
A multi-layered loop material comprising at least one carrier layer and a loop layer supported by the carrier layer, in which both the carrier layer and the loop layer comprise a non-woven fabric and the non-woven fabric of the carrier layer is reinforced by embossing, is, on the one hand, adaptable within large limits with regard to its air permeability and yet relatively stable with regard to its interlocking properties, and, on the other hand, relatively cost-effective and flexible, if the multi-layered loop material is characterized by the fact that the non-woven fabric of the carrier layer is reinforced by embossing with an embossing area density between 10% and 95%, and the loop layer and the carrier layer are intermittently connected to each other with a connection area density that is below the embossing area density.