Multilayered Nonwoven Fabric Structure for Dryness and Fluid Barriers
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Solution Overview
Problem
Existing nonwoven fabrics lack optimal combinations of abrasion resistance, water resistance, and softness, particularly in disposable absorbent articles, and do not effectively maintain surface dryness and fluid barrier properties.
Innovation Solution
A multilayered nonwoven fabric structure comprising outer spunbond layers and an inner meltblown layer with three or more sublayers, including at least two outer fine fiber layers and one or more inner coarse fiber layers, thermally bonded together, to enhance fluid barrier characteristics and maintain surface dryness and softness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a nonwoven fabric uses a simple single-layer or two-layer structure, then the manufacturing process is simple and cost is low, but the fabric cannot simultaneously achieve optimal abrasion resistance, water resistance, and softness
Solution Approach 1:
The nonwoven fabric is divided into multiple functional layers (spunbond layer, meltblown layer, and additional spunbond or meltblown layers) with each layer performing specific functions. The spunbond layers provide structural integrity and abrasion resistance, while the meltblown layers provide fluid barrier properties and softness. This segmentation allows each layer to be optimized for its specific function while maintaining overall performance consistency.
Solution Approach 2:
The fabric uses a composite structure combining different nonwoven materials (spunbond and meltblown fibers) with distinct properties. The spunbond fibers provide strength and durability, while the meltblown fibers provide hydrophobicity and softness. This composite approach enables the fabric to achieve multiple performance targets simultaneously that cannot be achieved with a single material type.
2Object-affected harmful factors
If the nonwoven fabric uses finer fibers to improve softness and surface dryness, then surface dryness is improved, but fluid barrier properties and abrasion resistance deteriorate
Solution Approach 1:
Different regions of the fabric have different fiber compositions and properties. The outer spunbond layers provide abrasion resistance and structural strength, while the inner meltblown layers with fine fibers (≤2 microns) provide surface dryness and fluid barrier properties. This local differentiation of fiber properties allows the fabric to achieve both softness and durability without compromise.
3Reliability
If the nonwoven fabric increases meltblown fiber content to improve fluid barrier properties, then water resistance is improved, but softness and surface dryness deteriorate
Solution Approach 1:
The fabric optimizes the fiber diameter parameter of the meltblown layers to ≤2 microns, which is finer than conventional meltblown fabrics. This parameter change enhances both the fluid barrier properties (by creating tighter fiber spacing) and the surface dryness (by providing a softer, more absorbent surface). The fine fiber diameter simultaneously improves multiple performance characteristics that were previously traded off against each other.
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 multilayered nonwoven fabric achieves improved fluid barrier properties and surface dryness while maintaining softness, with a Low Surface Tension Fluid Strikethrough Time of at least 25 seconds and air permeability below 35 m³/min/m³, suitable for disposable absorbent articles.
Implementation Method 1
the third nonwoven web is thermally bonded to the first and second nonwoven webs
Data Source
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AI summary
A nonwoven composite fabric including a first nonwoven layer composed substantially of meltblown fibers, the fibers within the first nonwoven layer having diameters that vary in accordance with a first distribution, a second nonwoven layer composed substantially of meltblown fibers, the fibers within the second nonwoven layer having diameters that vary in accordance with a second distribution, and a third nonwoven layer composed substantially of meltblown fibers, the third nonwoven layer disposed between the first and second nonwoven layers, the fibers within the third nonwoven layer having diameters that vary in accordance with a third distribution that is greater than the first and second distributions.