Nonwoven Web Bond Pattern for Fastener Receiving Component
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Solution Overview
Problem
Conventional nonwoven web bond patterns in receiving components of mechanical fastening systems experience pressure fluctuations during processing, leading to reduced strength and quality, as well as increased likelihood of overbonding or underbonding, which affects the performance of the fastening system.
Innovation Solution
A nonwoven web with a bond pattern featuring zigzag unit patterns in the machine direction, overlapping adjacent patterns to form a bond zone, and sweep regions with a bond ratio between 1 and 20, which reduces pressure fluctuations and maintains sufficient unbonded areas for effective engagement with engaging components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional nonwoven web bond patterns are used, then the receiving component can be manufactured, but pressure fluctuations occur during processing leading to reduced strength and quality
Solution Approach 1:
The patent applies local quality by creating a bond pattern with varying bond ratios across different regions. Specifically, the pattern includes high-bond-ratio regions (first regions) and low-bond-ratio regions (second regions) within the same web, allowing different areas to serve different functions: high-bond areas provide structural strength while low-bond areas maintain flexibility and engagement capability. This spatial variation in bond quality resolves the contradiction between overall strength and consistent processing reliability.
Solution Approach 2:
The bond pattern is segmented into distinct regions with different bond ratios. The web is divided into first regions with higher bond ratios and second regions with lower bond ratios, creating a heterogeneous structure. This segmentation allows the receiving component to have both strong bonded areas for structural integrity and less bonded areas that reduce pressure fluctuations during processing, thereby improving both strength and reliability simultaneously.
2Ease of manufacture
If conventional bond patterns are used, then processing can be completed, but overbonding or underbonding occurs affecting fastening system performance
Solution Approach 1:
By implementing local quality through region-specific bond ratios, the patent enables the manufacturing process to accommodate natural pressure fluctuations. The high-bond regions can tolerate higher pressures without overbonding, while low-bond regions prevent underbonding by requiring less pressure. This local differentiation maintains manufacturing precision across the entire web despite variations in processing conditions.
Solution Approach 2:
The segmentation of the bond pattern into multiple regions with different bond ratios provides a buffer against manufacturing variations. Each region is designed with an appropriate bond ratio that ensures proper bonding under a range of processing conditions, thereby maintaining consistent bond quality and fastening performance throughout the web without requiring extremely precise control of processing parameters.
3Ease of manufacture
If uniform bond patterns are used, then manufacturing is simplified, but sufficient unbonded areas cannot be maintained for effective engagement
Solution Approach 1:
The patent segments the bond pattern into first regions with higher bond ratios and second regions with lower bond ratios. The second regions with lower bond ratios specifically provide sufficient unbonded areas that maintain flexibility and engagement effectiveness. This segmentation allows the web to have both bonded areas for structural support and unbonded areas for hook engagement, resolving the contradiction between manufacturing simplicity and operational effectiveness.
Solution Approach 2:
By applying local quality principles, the patent creates specific zones (second regions) with lower bond ratios that are optimized for engagement functionality. These local areas with reduced bonding provide the necessary unbonded fibers and flexibility for effective hook engagement, while other areas (first regions) provide structural support. This localized differentiation maintains ease of manufacture through a systematic pattern while ensuring operational effectiveness.
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 proposed bond pattern enhances the mechanical strength and fastening performance of the receiving component by stabilizing pressure during processing, ensuring consistent bond quality and strength in both machine and cross-machine directions.
Implementation Method 1
The fiber-to-fiber bonds are typically formed by fusing portions of fibers together via, for example, heat, pressure, or sound (e.g., ultrasonic) energy
Implementation Method 2
A constant force is generally applied to one of the calendering rolls such that as the nonwoven web passes between the calendering rolls, the protrusions apply pressure to the nonwoven web
Implementation Method 3
The fiber-to-fiber bonds are typically formed by fusing portions of fibers together via, for example, heat, pressure, or sound (e.g., ultrasonic) energy
Data Source
Figure 1A
Figure 1B
Figure 2A~2B
AI summary
A nonwoven web (100) for a mechanical fastening system comprising: (i) engaging component comprising a plurality of engaging elements; and (ii) a receiving component having a longitudinal axis (160) and a lateral axis (162); and (iii) optionally at least 1 layer of fibers; wherein the plurality of engaging elements are capable of engaging the receiving component.