Method and apparatus for making a nonwoven textile

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Solution Overview

Problem

Existing nonwoven fabrics face challenges in achieving a balance between mechanical strength, thickness/voluminosity, stiffness, drapability, and abrasion resistance, with current methods either compromising on aesthetics or process complexity.

Innovation Solution

A method involving the use of a calender roller and a hot-fluid main consolidater, such as a hot-air oven, to consolidate nonwoven webs, combined with preconsolidation using a hot-air knife, to create a nonwoven fabric with optimal mechanical properties and reduced stiffness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If nonwoven fabric is consolidated using a calender, then mechanical strength is improved, but thickness is reduced

Engineering Contradiction:

Improvemechanical strengthVSAvoidthickness

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

The consolidation process is divided into two separate stages: first calender consolidation to provide mechanical strength and embossing pattern, then additional hot-fluid consolidation to restore thickness. This segmentation allows each consolidation method to perform its optimal function without the negative effects of the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The calender consolidation is performed first as a preliminary action to establish mechanical strength and surface pattern, followed by the hot-fluid consolidation action to subsequently restore thickness. The sequence of actions ensures that the strength-building step precedes the thickness-restoring step.

Inventive Principle:

Principle #10Preliminary action

2Strength

If nonwoven fabric is consolidated using a calender, then mechanical strength is improved, but visual properties are adversely affected due to embossing patterns

Engineering Contradiction:

Improvemechanical strengthVSAvoidvisual properties

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The consolidation process is segmented into two stages: the first calender consolidation provides mechanical strength and embossing pattern, while the second hot-fluid consolidation step serves to reduce the visual prominence of the embossing pattern through thermal relaxation, thereby separating the strength-building function from the aesthetic restoration function.

Inventive Principle:

Principle #1Segmentation

3Volume of moving object

If nonwoven fabric is consolidated using hot-fluid consolidater, then thickness is improved, but stiffness increases and drapability decreases

Engineering Contradiction:

ImprovethicknessVSAvoiddrapability

Core Design Contradiction:

Volume of moving objectVSEase of operation

Solution Approach 1:

The consolidation process is divided into two stages: first calender consolidation to provide mechanical strength and initial thickness, then additional hot-fluid consolidation to further increase thickness while the calender's embossing pattern provides structural framework that prevents excessive stiffness, thereby maintaining drapability.

Inventive Principle:

Principle #1Segmentation

4Volume of moving object

If nonwoven fabric is consolidated using hot-fluid consolidater, then thickness is improved, but abrasion resistance is reduced

Engineering Contradiction:

ImprovethicknessVSAvoidabrasion resistance

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The consolidation process is segmented into two functional stages: the calender consolidation stage provides mechanical strength and abrasion resistance through compression and embossing pattern creation, while the subsequent hot-fluid consolidation stage independently increases thickness through thermal relaxation and fiber reorganization without compromising the abrasion-resistant structure established by the calender.

Inventive Principle:

Principle #1Segmentation

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 produces nonwoven fabrics with enhanced mechanical strength, thickness, drapability, and abrasion resistance while minimizing stiffness and visual imperfections, offering a flexible and efficient production process.

Implementation Method 1

the nonwoven web or the nonwoven fabric is consolidated with at least one calender roller

Methodology Applied

Scientific EffectHeat: Heating

Implementation Method 2

consolidated with at least one calender roller, in particular with at least one calender or calender roller pair comprising the calender roller

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 3

the nonwoven fabric is additionally consolidated or main consolidated with at least one hot-fluid main consolidater, in particular with at least one hot-air main consolidater

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS20250297415A1Method and apparatus for making a nonwoven textile

Publication Date: 2025.09.25 REIFENHAUSER GMBH & CO MASCHFAB

AI summary

The invention relates to a method for producing a nonwoven fabric comprising at least one nonwoven web composed of fibres. The fibres are produced by means of at least one fibre-producing device. Subsequently, the fibres are deposited on at least one depositing device in order to form the nonwoven web. The nonwoven web or nonwoven fabric is solidified with at least one calender roller, and the nonwoven fabric is also solidified or primarily solidified with at least one hot fluid primary solidification device.