Methods for making three-dimensional webs
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Solution Overview
Problem
Existing methods for manufacturing intricate and complex nonwoven webs are costly and complex, failing to meet consumer demand for three-dimensional features in products like absorbent articles.
Innovation Solution
Utilizing a rotating collection surface with cavities and land areas to collect continuous filaments, creating regions with varying properties such as basis weight, volumetric density, caliper, and air permeability, and bonding the intermediate web to form a final three-dimensional web.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional three-dimensional nonwoven making belts are used, then intricate and complex three-dimensional nonwoven webs can be produced, but the manufacturing process becomes expensive and complex
Solution Approach 1:
The invention employs a rotating collection surface that dynamically forms three-dimensional structures through rotation, replacing static complex belts. The rotating surface creates varied surface areas (raised areas and cavities) that dynamically collect filaments to form regions with different basis weights, achieving three-dimensional complexity through rotational motion rather than complex static structure
Solution Approach 2:
The invention transitions from two-dimensional flat web formation to three-dimensional structured webs by utilizing the rotating collection surface with varying surface heights. The raised areas and cavities create vertical dimensionality, forming regions with different basis weights and volumetric densities without requiring complex multi-layer stacking or additional processing steps
2Manufacturing precision
If traditional three-dimensional nonwoven making belts are used, then intricate and complex three-dimensional nonwoven webs can be produced, but manufacturing costs increase
Solution Approach 1:
The invention uses a simple rotating collection surface with varying surface areas (raised areas and cavities) that can be easily manufactured and replaced, rather than investing in expensive complex three-dimensional making belts. The basic rotating surface structure is cost-effective and can be maintained at lower operational costs
Solution Approach 2:
The invention changes the basis weight parameter spatially by using the rotating collection surface with raised areas and cavities. This creates regions of different basis weights (first regions on raised areas, second regions in cavities) without requiring multiple separate processing steps or expensive equipment, thereby reducing manufacturing costs while achieving three-dimensional complexity
3Ease of manufacture
If a rotating collection surface with cavities and land areas is used, then cost-effective production is achieved, but the device structure becomes more complex
Solution Approach 1:
The rotating collection surface is segmented into distinct functional regions: raised areas and cavities. This segmentation creates zones with different filament collection characteristics, allowing formation of regions with different basis weights. The segmentation is achieved through simple surface geometry rather than complex mechanical structures, maintaining cost-effectiveness
4Manufacturing precision
If filaments are collected on raised areas and cavities, then regions with different basis weight are formed, but the process requires precise control of fluid pressure
Solution Approach 1:
The rotating collection surface self-regulates filament distribution through its geometric features. The raised areas and cavities naturally guide filament deposition patterns based on their surface areas and exposure to the filament stream, reducing the need for complex external fluid pressure control systems while still achieving controlled basis weight distribution
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
Produces high-quality, consumer-desirable three-dimensional nonwoven webs efficiently and simply, with improved properties and reduced manufacturing costs.
Implementation Method 1
applying a fluid pressure to the collection surface and collecting the filaments on the collection surface
Implementation Method 2
bonding the intermediate three-dimensional web using a bonding operation, such as air-through bonded, to form a final three-dimensional web
Data Source
AI summary
A method of making a three-dimensional web is provided. The method comprises spinning continuous filaments from a spinneret, moving the spun continuous filaments along a travel path having an end, and rotating a collection surface at or proximate to the end of the travel path. The collection surface comprises cavities and land areas. The land areas are tangentially planar with an outer surface of the collection surface. The cavities are recessed with respect to the outer surface of the collection surface. The method comprises applying a fluid pressure to the collection surface and collecting the filaments on the collection surface to create an intermediate three-dimensional web having first regions formed in the cavities and second regions formed on the land areas. The first and second regions differ in at least one intensive property. The method comprises bonding the intermediate web using a bonding operation to form a final three-dimensional web.