Microfiber-containing nonwoven fabrics

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Solution Overview

Problem

Traditional cleaning fabrics, especially disposable mopping wipes, are inadequate in picking up dirt and bacteria, leading to cross-contamination and limited cleaning areas due to their design and material limitations, which can result in ineffective cleaning and health concerns.

Innovation Solution

A nonwoven fabric comprising continuous fibers mechanically entangled with a blend of staple fibers, including polyester, bicomponent, microfiber, and wettable staple fibers, featuring a three-dimensional pattern with recessed portions to enhance dirt capture and a system with a mop frame and liquid reservoir for increased cleaning efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional cleaning fabrics are used, then they can clean surfaces, but they transfer dirt and grime from one area to another and fail to trap bacteria effectively

Engineering Contradiction:

Improvecleaning efficacyVSAvoidcross-contamination

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent uses a composite nonwoven fabric structure combining continuous fibers mechanically entangled with a blend of staple fibers including microfiber staple fibers. This composite structure creates a three-dimensional matrix with recessed portions that physically trap and hold dirt and bacteria, preventing their transfer to other surfaces and eliminating cross-contamination while maintaining effective cleaning capability.

Inventive Principle:

Principle #40Composite materials

2Area of stationary object

If traditional wet mops are used, then they can clean surfaces, but they are limited in the area that may be cleaned with a single mop due to liquid retention limitations

Engineering Contradiction:

Improvecleaning areaVSAvoidliquid retention

Core Design Contradiction:

Area of stationary objectVSQuantity of substance

Solution Approach 1:

The nonwoven fabric utilizes a porous three-dimensional structure formed by mechanically entangled continuous fibers and staple fiber blend. This porous matrix creates numerous recessed portions throughout the fabric that act as liquid reservoirs, significantly increasing the mop's liquid retention capacity and enabling cleaning of larger areas beyond the traditional 25 square meter limit without drying out.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent transforms the traditional two-dimensional cleaning surface into a three-dimensional structure with recessed portions extending into the fabric depth. This dimensional transformation creates additional liquid holding capacity within the fabric matrix, allowing the mop to retain sufficient cleaning solution across a much larger area without compromising cleaning efficacy.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If traditional cleaning fabrics are used, then they can be manufactured simply, but they lack the three-dimensional pattern structure needed for effective dirt capture

Engineering Contradiction:

Improvedirt capture capabilityVSAvoidfabric structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The three-dimensional pattern with recessed portions is formed as an integral part of the nonwoven fabric manufacturing process through mechanical entanglement of continuous fibers with the staple fiber blend. This preliminary formation of the three-dimensional structure during manufacturing, rather than as a post-processing step, enables effective dirt capture capability while avoiding excessive manufacturing complexity.

Inventive Principle:

Principle #10Preliminary action

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 solution effectively traps dirt and bacteria, allowing for larger cleaning areas (beyond 25 m²) with reduced risk of cross-contamination and improved cleaning efficacy, ensuring effective disinfection and dust removal.

Implementation Method 1

the continuous fibers are mechanically entangled (e.g., hydroentangled, needle-punched, air-entangled, etc.) with the blend of staple fibers

Methodology Applied

Scientific EffectHydroentanglement:

Implementation Method 2

the three-dimensional pattern may comprise a plurality of recessed portions configured to facilitate the capture of loose debris (e.g., dirt)

Methodology Applied

Scientific EffectPhysical confinement: Physical Containment

Data Source

PatentUS11708653B2Microfiber-containing nonwoven fabrics

Publication Date: 2023.07.25 MAGNERA CORP

AI summary

Nonwoven fabrics including (i) continuous fibers and (ii) a blend of staple fibers comprising polyester staple fibers, bicomponent staple fibers, microfiber staple fibers, and wettable staple fibers, in which the continuous fibers are mechanically entangled with the blend of staple fibers. The continuous fibers and the blend of staple fibers may be mechanically entangled via a hydroentangling process.