Nonwoven Web Barrier Layer Segmentation for Basis Weight Reduction
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Solution Overview
Problem
There is a demand in the market for reducing the basis weight of nonwoven textiles while maintaining their barrier properties, which is challenging due to the need for a significant share of sub-micron fibers to enhance barrier properties in applications like hygiene products.
Innovation Solution
A nonwoven textile with two barrier layers, A and B, where the median fibre diameters have a theoretical fibre diameter coefficient x between 0.25 and 1, and the sum of their theoretical cover coefficients is greater than or equal to 50%, allowing for a combination of fibres with varying diameters to enhance barrier properties without requiring excessive fine fibres.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a significant share of sub-micron fibers is used to enhance barrier properties, then barrier properties are improved, but basis weight increases
Solution Approach 1:
The barrier layer is segmented into two distinct layers (A and B) with different fiber diameter ranges. Layer A contains finer fibers (0.5-2.0 μm median diameter) to provide primary barrier function, while layer B contains coarser fibers (2.0-5.0 μm median diameter) to provide structural support. This segmentation allows each layer to perform its specific function optimally, reducing the need for excessive fine fibers while maintaining barrier properties.
Solution Approach 2:
Different regions of the barrier layer have different fiber diameter characteristics. Layer A (closer to the liquid source) has finer fibers for immediate barrier protection, while layer B (outer region) has coarser fibers for mechanical strength. This local differentiation of fiber properties optimizes the overall barrier performance while reducing total material usage.
2Reliability
If finer fibers are used to reduce pore size and improve barrier capacity, then barrier capacity increases, but material consumption increases
Solution Approach 1:
The barrier function is segmented between two layers with different fiber fineness. Layer A with finer fibers provides the primary pore-blocking function, while layer B with coarser fibers provides structural framework. This segmentation reduces the total quantity of fine fibers needed compared to a single-layer structure, as the coarser fibers in layer B provide structural support that reduces the burden on layer A.
Solution Approach 2:
The barrier layer is constructed as a composite of two different fiber types with complementary properties. The combination of fine fibers (layer A) and coarser fibers (layer B) creates a synergistic structure where the fine fibers fill the pores created by coarser fibers, and the coarser fibers provide the structural framework. This composite approach improves barrier capacity while optimizing material consumption.
Data Source
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AI summary
Nonwoven textile with barrier properties containing a. a first barrier layer A with a theoretical cover coefficient TCC A, and consisting of fibres having a median fibre diameter in the layer of dAm; and b. a second barrier layer B with a theoretical cover coefficient TCC B, and consisting of fibres having a median fibre diameter in the layer of dBm; whilst i. the first barrier layer A and the second barrier layer B are together in direct contact; ii. the median diameters of fibres in the first and second layer have a theoretical fibre diameter coefficient x = (dBm-dAm)/dAm, where the theoretical fibre diameter coefficient x is less than or equal to 1 and where the theoretical fibre diameter coefficient x is greater than or equal to 0.25; and iii. the sum of the theoretical cover coefficient TCC A and TCC B is greater than or equal to 50%.