Meltblown Nonwoven Fabric Spacers for Stackability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Voluminous meltblown nonwoven fabrics used as acoustic damping materials or oil absorbers are highly ductile and prone to deformation under compressive loads, making them difficult to stack without unwanted deformation and preserving their thickness-specific acoustic properties.
Innovation Solution
Incorporating spacers that extend partially or fully through the thickness of the fabric, made from dimensionally stable materials or compressed nonwoven fabric, to achieve a compressibility of less than 10% under applied pressure, allowing for easy stacking and maintaining acoustic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If voluminous meltblown nonwoven fabric is used for acoustic damping applications, then acoustic absorption properties are improved, but compressibility increases leading to deformation under stacking loads
Solution Approach 1:
The patent applies parameter changes by modifying the physical state of specific regions within the nonwoven fabric. The spacer fibers are melted at controlled temperatures (between 100-200°C for polyethylene, 200-300°C for polypropylene) to transform from a solid, space-maintaining state to a liquid state that flows and consolidates, ultimately forming a compressed, dimensionally stable structure that resists deformation while preserving acoustic properties
Solution Approach 2:
The invention utilizes phase transitions of the spacer fiber material as the core mechanism. The spacer fibers undergo melting (solid to liquid phase transition) when exposed to controlled thermal energy, allowing them to collapse and fuse with surrounding fibers. This phase change enables the fabric to transition from a highly compressible, voluminous state to a stable, deformation-resistant state that maintains acoustic absorption capabilities
2Reliability
If high voluminosity is achieved for acoustic damping, then acoustic absorption coefficient is improved, but stackability deteriorates due to poor relaxation
Solution Approach 1:
The patent applies segmentation by dividing the nonwoven fabric structure into distinct functional regions: acoustic-active regions containing the spacer fibers that provide volume and sound absorption, and stabilization regions where the spacer material is selectively melted and compressed to provide dimensional stability. This segmentation allows different parts of the fabric to perform different functions simultaneously
Solution Approach 2:
The invention uses parameter changes by applying controlled thermal energy to specific regions containing spacer fibers, transforming them from a soft, compressible state to a rigid, stable state. This localized parameter change enables the fabric to maintain high voluminosity in acoustic regions while achieving stackability in stabilized regions
3Stability of the object's composition
If spacers are added to improve stackability, then compressibility is reduced, but device complexity increases
Solution Approach 1:
The patent applies merging by combining the spacer fiber stabilization function with the existing nonwoven fabric structure. The spacer fibers are integrated during the fabric formation process, and their stabilization through melting merges them with the surrounding fiber matrix, creating a unified structure rather than adding separate, discrete components
Solution Approach 2:
The invention employs self-service by using the spacer fibers themselves to provide the stabilization function. The spacer material, already present in the fabric structure, serves dual purposes: maintaining volume during manufacturing and providing compression resistance during stacking when melted. This eliminates the need for separate stabilization components or complex assembly processes
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 use of spacers enables the nonwoven fabric to be stacked without deformation and retains its acoustic properties, ensuring easy storability and preventing appreciable compression, thus maintaining its thickness-specific absorption coefficient.
Implementation Method 1
the meltblown nonwoven fabric has a compressibility of less than 10% when a pressure of 50 Pa is applied to its surface
Data Source
AI summary
The present invention relates to a meltblown nonwoven in the form of a sheet-like formation with a weight per unit area of 100 to 600 g/m2 and with a density of 5 to 50 kg/m3, wherein the meltblown nonwoven (10) has at least one spacer (12), extending at least on one of the surfaces thereof and/or at least partially in the direction of the thickness of the meltblown nonwoven (10) and arranged in such a way that the meltblown nonwoven (10) has a compressibility of less than 10% when a pressure of 50 Pa is applied to its surface.