Low-Basis-Weight Nonwoven Web Winding Without Handling Defects

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Solution Overview

Problem

Existing nonwoven webs, particularly those made from hydroxyl polymer filaments like polyvinyl alcohol, face challenges in achieving basis weights below 5 gsm due to handling issues during processing and winding, leading to difficulties in forming convolutely wound rolls.

Innovation Solution

The production of low basis weight nonwoven webs is achieved by forming hydroxyl polymer filaments, such as polyvinyl alcohol, at speeds below 500 feet per minute and using controlled vacuum conditions to prevent damage, enabling the creation of webs with basis weights as low as 0.25 gsm to 5 gsm, which are then wound into rolls without defects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If nonwoven webs are produced at high speeds, then productivity is improved, but the webs become difficult to handle and cannot be wound into rolls

Engineering Contradiction:

Improveproduction speedVSAvoidhandling ease

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The patent applies parameter changes by controlling the production speed within a specific range (50-500 fpm) and adjusting vacuum parameters (300-400 SCFM) to optimize both productivity and handling characteristics. This resolves the contradiction by finding the optimal parameter range that enables both efficient production and ease of operation.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If vacuum is increased to draw fibrous elements onto collection device, then web formation is improved, but holes and defects are created in the web

Engineering Contradiction:

Improveweb formation qualityVSAvoidholes and defects

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent resolves this contradiction by precisely controlling the vacuum parameter within the range of 300-400 SCFM. This optimized vacuum level is sufficient to draw fibrous elements onto the collection device for quality web formation while avoiding excessive vacuum that would create holes and defects in the web structure.

Inventive Principle:

Principle #35Parameter changes

3Quantity of substance

If basis weight is reduced below 5 gsm, then material usage is reduced, but web strength becomes insufficient for handling

Engineering Contradiction:

Improvematerial usageVSAvoidweb strength

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The patent resolves this contradiction by changing multiple parameters simultaneously: producing the web at controlled speeds (50-500 fpm), using optimized vacuum (300-400 SCFM), and controlling basis weight within the specific range of 0.25-5 gsm. These coordinated parameter changes enable low material usage while maintaining sufficient web strength for handling.

Inventive Principle:

Principle #35Parameter changes

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 method allows for the production of low basis weight nonwoven webs with enhanced tensile strength and energy absorption, supporting handling and processing without tears or holes, facilitating the formation of high-quality convolutely wound rolls.

Implementation Method 1

any vacuum that functions to assist in drawing the fibrous elements, for example filaments, of the low basis weight nonwoven web onto a surface of the collection device

Methodology Applied

Scientific EffectVacuum suction: Suction

Data Source

PatentUS20260071365A1Low basis weight nonwoven webs and methods for making same

Publication Date: 2026.03.12 PROCTER & GAMBLE CO

AI summary

Low basis weight, for example less than 5 gsm, nonwoven webs, rolls thereof, and methods for making same are provided.