Method for producing polyester nonwoven fabric with improved impregnation property of fabric softener
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Solution Overview
Problem
Existing methods for producing nonwoven fabrics for dryer sheets face challenges in maintaining excellent impregnation properties when the fabrics are made lightweight, leading to reduced specific surface area and increased density deviations, which deteriorate the fabric softener's impregnation efficiency.
Innovation Solution
A method involving bicomponent-spinning of 70-90% high-melting-point polyester filaments and 10-30% low-melting-point polyester filaments, with controlled spinning conditions and calendering processes to adjust fiber density and spatial structure, increasing specific surface area and porosity while minimizing evenness deviation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the weight of nonwoven fabric is reduced to lower production costs, then productivity and cost competitiveness are improved, but the specific surface area is reduced and density deviation increases, leading to deteriorated impregnation property of fabric softener
Solution Approach 1:
The patent changes the physical and chemical parameters of the polyester filaments, specifically using a mixture of high-melting-point and low-melting-point polyester filaments with controlled weight ratios (70-90% high-melting-point and 10-30% low-melting-point). This parameter change allows the fabric to maintain proper impregnation properties even at reduced weights by controlling fiber density and spatial structure through differential melting behavior during calendering.
Solution Approach 2:
The patent creates a composite structure by combining two types of polyester filaments with different melting points in a single nonwoven fabric. The high-melting-point polyester provides structural integrity while the low-melting-point polyester facilitates bonding and controls spatial arrangement during calendering. This composite approach enables lightweight fabrics to maintain both mechanical properties and impregnation characteristics.
2Quantity of substance
If the specific surface area is reduced due to fabric weight reduction, then production cost is lowered, but the impregnation efficiency of fabric softener is deteriorated
Solution Approach 1:
The patent modifies the filament composition parameters by incorporating low-melting-point polyester (10-30% by weight) alongside high-melting-point polyester. During the calendering process, the low-melting-point fibers melt and re-solidify to create a controlled spatial structure that optimizes surface area utilization for impregnation, ensuring efficient fabric softener absorption even in lightweight fabrics.
3Adaptability or versatility
If the density deviation is increased due to fabric weight reduction, then production flexibility is improved, but the uniformity of fabric softener impregnation is reduced
Solution Approach 1:
The patent controls the melting point differential parameter between the two polyester components to achieve uniform impregnation. The low-melting-point polyester (melting point sufficiently lower than high-melting-point polyester) melts during calendering and creates a uniform bonding matrix that distributes fabric softener evenly across the fabric surface, compensating for variations in fabric weight and density.
Solution Approach 2:
The patent applies local quality by having different polyester components perform different functions: high-melting-point polyester maintains structural stability in regions requiring mechanical strength, while low-melting-point polyester creates bonding zones that facilitate uniform impregnation. This localized functional differentiation ensures even fabric softener distribution despite variations in overall fabric density.
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 enhances the impregnation properties of fabric softeners in lightweight nonwoven fabrics, ensuring uniform impregnation and maintaining mechanical properties, even when applied to thinner dryer sheets, thereby improving cost competitiveness.
Implementation Method 1
bicomponent-spinning of 70-90% high-melting-point polyester filaments and 10-30% low-melting-point polyester filaments, with controlled spinning conditions and calendering processes to adjust fiber density and spatial structure
Data Source
AI summary
The present disclosure relates to a method for producing a nonwoven fabric which improves the impregnation property of a fabric softener in the nonwoven fabric so as to apply the nonwoven fabric to a dryer sheet (sheet-type fabric softener). In a nonwoven fabric made of two types of polyester long fiber mixed filament yarns, by widening the specific surface area, adjusting the evenness deviation to be small and increasing the porosity, the impregnation property of a fabric softener is improved even when the nonwoven fabric is made lightweight, and the nonwoven fabric can be applied to a dryer sheet.