Method for producing a nonwoven element for hygiene articles
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Solution Overview
Problem
Existing methods for producing nonwoven elements for hygiene articles, such as sanitary wipes, lack flexibility and effective cleaning performance while maintaining stability, particularly when used in different applications and conditions.
Innovation Solution
A method involving a multi-ply nonwoven material with a carded staple fiber layer and a storage layer containing cellulose and thermoplastic staple fibers, where the fibrous web is treated with liquid jets for entanglement and embossing, followed by heat application for fusion and consolidation, creating a three-dimensional structure with varying surface density and increased roughness for enhanced strength and cleaning efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a multi-ply nonwoven material with carded staple fiber layer and storage layer is used, then cleaning performance and flexibility are improved, but manufacturing complexity increases
Solution Approach 1:
The nonwoven material is divided into multiple functional layers: a carded staple fiber layer for structure and strength, a storage layer containing cellulose and thermoplastic fibers for liquid absorption and release, and potentially additional functional layers. Each layer performs a specific cleaning function, allowing optimization of overall cleaning performance while managing manufacturing complexity through modular layer construction.
Solution Approach 2:
The invention combines different fiber types (cellulose, thermoplastic staple fibers, carded staple fibers) into a composite nonwoven structure. This composite material approach enables simultaneous achievement of flexibility from natural fibers, structural integrity from thermoplastic fibers, and enhanced cleaning performance through the synergistic interaction of different material properties within the multi-layer configuration.
2Strength
If liquid jets are applied to entangle fibers and emboss surface structure, then strength and cleaning efficiency are improved, but energy consumption increases
Solution Approach 1:
Liquid jets are utilized as a hydraulic mechanism to entangle fibers and create surface embossing. The kinetic energy of the liquid jets provides the force necessary for fiber interlocking and surface structuring, achieving enhanced strength and cleaning efficiency. The liquid medium transfers energy efficiently to the fibrous web, reducing overall energy consumption compared to purely mechanical or thermal methods.
3Stability of the object's composition
If heat is applied to fuse thermoplastic fibers, then stability and structure are improved, but temperature control complexity increases
Solution Approach 1:
Heat is applied to induce phase transition in the thermoplastic staple fibers within the storage layer, causing them to melt and fuse with adjacent fibers. This phase change process creates strong bonds that stabilize the multi-layer nonwoven structure. The thermoplastic fibers act as natural binding agents, and the controlled heating process achieves structural stabilization through melting and bonding, simplifying temperature control requirements compared to chemical bonding methods.
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 a nonwoven element with improved flexibility, stability, and cleaning performance, allowing for versatile use in various applications, including wet and dry conditions, by creating a structured surface with increased strength and roughness through the entanglement and fusion of fibers.
Implementation Method 1
the fibrous web is subsequently acted upon on both sides by liquid jets, as a result of which the fibers of the multi-ply nonwoven material are intermingled and entangled
Implementation Method 2
The fibrous web is then acted upon by heat, as a result of which the thermoplastic staple fibers at least partially fuse
Implementation Method 3
a surface structure is embossed into the fibrous web at the same time... characterized by a three-dimensional structure characterized by highly compressed areas and less compressed or non-compressed areas
Data Source
AI summary
A method for producing a nonwoven element for hygiene articles is accomplished by the steps of: forming a fibrous web from a multi-ply nonwoven material with at least one carded staple fiber layer and a storage layer which is arranged on the staple fiber layer and which has cellulose fibers, wherein at least a portion of the staple fibers of the staple fiber layer are formed from a thermoplastic; applying liquid jets to the fibrous web, as a result of which the fibers of the multi-ply nonwoven material are intermingled and entangled, and the fibrous web is embossed with a surface structure; applying heat to the fibrous web, as a result of which the thermoplastic staple fibers at least partially fuse and the fibrous web is bonded to form a nonwoven web, and severing individual nonwoven elements from the nonwoven web.