Needling-Bonded Absorption And Distribution Nonwoven Fabric
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Solution Overview
Problem
Existing methods for manufacturing nonwoven fabrics for personal hygiene products lack improved absorbent and distribution properties, intermediate storage capacity, and cushioning properties.
Innovation Solution
The nonwoven fabric is composed of specific percentages of support, distribution, and absorbent materials, with mechanical bonding achieved through needling, enhancing interlacing and capillarity, and thermal bonding to achieve improved thickness and distribution properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If water jet process is used for mechanical bonding, then nonwoven fabric can be produced with acceptable absorption and distribution properties, but the material thickness per weight per unit area is limited to a very narrow range between 0.12 mm-0.15 mm per 10 g/m2
Solution Approach 1:
The patent replaces the water jet bonding process with a needling process. Needles mechanically penetrate and interlace the fibers, creating a three-dimensional network structure that provides better thickness control and cushioning properties while maintaining absorption and distribution characteristics. This mechanical interlacing approach allows for broader material thickness ranges compared to water jet bonding.
2Reliability
If needling is used for mechanical bonding, then openness and capillarity are improved for better liquid distribution, but the interlacing is only achieved selectively via individual needles
Solution Approach 1:
The needling process creates localized interlacing points where needles penetrate the fiber mat and loop back to secure fibers in specific locations. This selective interlacing at key points maintains the overall openness and capillarity of the nonwoven fabric while providing sufficient structural stability for reliable liquid distribution across the entire surface.
3Strength
If higher material thicknesses per weight per unit area are produced, then cushioning properties and intermediate storage capacity are improved, but the thickness range is limited using previous methods
Solution Approach 1:
The needling process creates a dynamic three-dimensional fiber network with varying degrees of interlacing and void spaces. This dynamic structure allows the nonwoven fabric to achieve higher material thicknesses per weight per unit area while maintaining appropriate density and cushioning properties, expanding the usable thickness range compared to conventional water jet bonding methods.
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 produces nonwoven fabrics with enhanced absorption, distribution, and cushioning properties, achieving higher material thickness per weight, improved liquid distribution, and increased intermediate storage capacity.
Implementation Method 1
the stitch channels caused by the penetration of the needles surprisingly provide improved capillarity, which in particular improves the distribution properties of the nonwoven produced
Implementation Method 2
the nonwoven fabric is mechanically bonded and then thermally bonded by means of subsequent thermal activation, for example by hot-air bonding
Data Source
AI summary
The invention relates to a method for manufacturing an absorption and distribution nonwoven fabric made of staple fibers and absorbent material made of regenerated cellulose for personal hygiene products. The nonwoven fabric is composed of thermoplastic, synthetic staple fibers as support fibers, wherein the support fibers are homo- or bi-component, thermoplastic regenerated cellulose for personal hygiene products. The nonwoven fabric is composed of thermoplastic, synthetic staple fibers as supporting fibers, wherein the supporting fibers are homo- or bi-component, thermoplastic polymer fibers comprising fusible constituents, staple fibers of thermoplastic and/or duroplastic polymers as distribution fibers and absorbent material of regenerated cellulose. The nonwoven fabric is mechanically bonded and then thermally bonded by means of subsequent hot-air bonding. The invention also relates to an absorption and distribution nonwoven fabric produced by the method according to the invention and to a device for carrying out the method according to the invention.