Nonwoven cloth
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Solution Overview
Problem
Existing methods for producing nonwoven fabrics struggle to achieve a balance between improved flexibility, sufficient thickness, and specific volume, as pressure applied in the thickness direction reduces bulkiness and absorption rates.
Innovation Solution
A nonwoven fabric comprising heat-fusible conjugate fibers that intersect and overlap with heat-fused constriction parts, where the distance between fiber axes at these constriction points is greater than the fiber radius, and the proportion of constriction parts to total heat-fused parts is between 1/10 to 9/10, allowing for a thickness of 0.5 to 3.0 mm and specific volume of 6 to 300 cm^3/g.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If hot air is applied to the nonwoven fabric by an air-through method to restore bulkiness, then the bulkiness of the nonwoven fabric is restored, but pressure is applied in the thickness direction which reduces the liquid absorption rate and flexibility
Solution Approach 1:
The patent applies local quality by creating heat-fused constriction parts only at specific intersection regions of fibers rather than uniformly across the entire nonwoven fabric. This localized heat fusion at constriction parts allows bulkiness restoration while preserving flexibility in other areas, as the fusion is concentrated where fibers intersect rather than throughout the entire fabric structure.
Solution Approach 2:
The patent inverts the conventional approach by applying heat from the lateral direction (parallel to the fabric surface) rather than from the thickness direction (perpendicular to the fabric). This lateral heat application method restores bulkiness without applying compressive pressure in the thickness direction, thereby maintaining flexibility and liquid absorption rate.
2Ease of manufacture
If pressure is applied in the thickness direction to compress the nonwoven fabric for storage, then the nonwoven fabric can be stored in a compact form, but the bulkiness and thickness are reduced
Solution Approach 1:
The patent applies preliminary action by restoring bulkiness through lateral heat fusion before the nonwoven fabric is wound into a roll for storage. The heat-fused constriction parts are formed in advance, creating a stable three-dimensional structure that maintains bulkiness even during subsequent compression in storage, allowing the fabric to be stored compactly while retaining its bulk properties when deployed.
3Ease of operation
If the distance between fiber axes at heat-fused constriction parts is larger than the fiber radius, then flexibility is improved, but the strength of the heat-fused bonds may be reduced
Solution Approach 1:
The patent applies parameter changes by precisely controlling the distance between fiber axes at heat-fused constriction parts to be larger than the fiber radius. This specific parameter range optimizes the balance between flexibility and bond strength, allowing the heat-fused bonds to maintain sufficient strength while preserving the flexibility of the nonwoven fabric structure.
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 provides a nonwoven fabric with enhanced flexibility, compression deformation properties, and increased specific volume, addressing the limitations of previous methods by maintaining bulkiness and absorption efficiency.
Implementation Method 1
heat-fusible conjugate fibers intersecting and overlapping with each other and heat-fused constriction parts at the intersection regions
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3~4
AI summary
In order to address the problem of providing a nonwoven cloth provided with both improved softness and adequate thickness and specific volume, the present invention provides a nonwoven cloth having thermally fused composite fibers (F1, F2) that are mutually intersecting and overlapping, and a constricted thermally adhesive section (B1) in which the thermally fused composite fibers (F1, F2) are thermally fused in the intersection region (R1); wherein the constricted thermally adhesive section (B1) has a recessed surface facing a center line (A1) extending in a direction (Z1) overlapping with the thermally fused composite fibers across the center (P1) of the intersection region (R1), the distance between the thermally fused composite fibers (F1, F2) being larger than the sum of the radii of the thermally fused composite fibers, the thickness under a load of 3.0 gf/cm2 being 0.5-3.0 mm, and the specific volume being 6-300 cm3/g.