Methods for producing through-fluid bonded nonwoven webs

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Solution Overview

Problem

Current methods for producing continuous fiber nonwoven webs struggle to achieve optimal loft, strength, and softness due to excessive self-crimping of fibers before final bonding, leading to non-uniformity and reduced integrity.

Innovation Solution

The method involves intermittently applying vacuum to portions of a moving porous member where continuous fibers are laid down, allowing fibers to reorient and entangle, followed by through-fluid bonding to produce a strong, lofty, and soft web.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If continuous fiber strands are allowed to self-crimp extensively before final bonding, then loft and softness are improved, but web integrity and uniformity are reduced

Engineering Contradiction:

ImproveloftVSAvoidweb integrity

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent applies preliminary bonding actions (heating and pressing) to specific zones of the web before final through-fluid bonding. This preliminary action stabilizes the web structure early in the process, preventing excessive self-crimping from compromising web integrity, while still allowing controlled loft development in subsequent processing stages.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent divides the web processing into multiple zones with different vacuum forces applied sequentially. By segmenting the bonding process into zones of varying vacuum intensity, the web can develop loft in lower-vacuum zones while maintaining structural integrity in higher-vacuum zones, resolving the contradiction between loft and web integrity.

Inventive Principle:

Principle #1Segmentation

2Shape

If continuous fiber strands are allowed to self-crimp extensively before final bonding, then loft and softness are improved, but uniformity and strength are reduced

Engineering Contradiction:

ImproveloftVSAvoidweb uniformity

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The patent employs dynamic control of vacuum forces that vary over time and space during web processing. By dynamically adjusting vacuum intensity in different zones and at different times, the system optimizes fiber entanglement and crimping to achieve uniform web properties while maintaining desired loft characteristics.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent applies periodic vacuum cycling with multiple on/off cycles in different zones. This periodic action allows controlled periods of fiber entanglement followed by stabilization periods, creating uniform web structure with consistent loft and strength properties across the entire web.

Inventive Principle:

Principle #19Periodic action

3Reliability

If vacuum force is continuously applied to the moving porous member, then web structural integrity is improved, but fiber entanglement and reorientation are reduced

Engineering Contradiction:

Improveweb structural integrityVSAvoidfiber entanglement

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent implements periodic vacuum cycling with multiple on/off cycles in different zones. This periodic action allows controlled periods of fiber entanglement followed by stabilization periods, creating uniform web structure with consistent loft and strength properties across the entire web.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

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

This approach enhances continuous fiber entanglement, leading to improved z-direction resilience, loft, and softness of the nonwoven web, while maintaining structural integrity.

Implementation Method 1

Intermittently applying vacuum (e.g., turn on/off, apply/reduce) to portions of a moving porous member where the continuous fibers are laid down

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 2

flowing a fluid intermediate the spinneret and a moving porous member

Methodology Applied

Scientific EffectFluid flow: Convection

Implementation Method 3

the intermediate continuous fiber nonwoven web may also be intermittently heated and/or cooled with air or other mechanisms to again promote further reorienting of the continuous fibers within the web

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 4

the continuous fibers may be deposited on the moving porous member, they may be formed into an intermediate continuous fiber nonwoven web and may be conveyed downstream facilitated by various methods

Methodology Applied

Scientific EffectFluid flow: Convection

Data Source

PatentUS12320046B2Methods for producing through-fluid bonded nonwoven webs

Publication Date: 2025.06.03 PROCTER & GAMBLE CO

AI summary

A method of creating a soft and lofty continuous fiber nonwoven web is provided. The method includes providing first and second, different molten polymers to a spinneret defining a plurality of orifices and flowing a fluid intermediate the spinneret and a moving porous member. The method includes using the fluid to draw the first and second molten polymers, in a direction toward the porous member, through at least some of the plurality of orifices to form a plurality of individual continuous fiber strands. The method includes depositing the continuous fiber strands onto the porous member at a first location to produce an intermediate continuous fiber nonwoven web, and varying, in at least two different zones, a vacuum force applied to the moving porous member and to the intermediate web downstream of the first location and without any heat applied.