Nonwoven Fibrous Structure With Compressed Weakness Lines
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Solution Overview
Problem
Existing nonwoven fibrous structures for disposable substrates, such as wipes, face challenges in balancing structural integrity during use with dispersability when flushed, as they often either lack sufficient strength or fail to break apart effectively in sewage systems, leading to potential blockages.
Innovation Solution
A nonwoven fibrous structure comprising compressed sites and molded elements, where the compressed sites form a line of weakness and the molded elements provide visual and tactile benefits, is created by conveying a fibrous web over a molding member and applying compressive stress, allowing the structure to fail along the lines of weakness when subjected to force, ensuring dispersability while maintaining integrity during use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the nonwoven fibrous structure is made stronger to maintain structural integrity during use, then it becomes more difficult to break apart when flushed, potentially causing blockages in sewage systems
Solution Approach 1:
The nonwoven fibrous structure is divided into multiple layers with different properties. The first layer provides structural integrity during use, while the second layer is designed to disintegrate rapidly in water. This segmentation allows the structure to maintain strength when needed and break apart when flushed, preventing blockages in sewage systems.
Solution Approach 2:
Different regions of the nonwoven structure have different properties tailored to specific functions. The first layer has higher strength and durability for structural support, while the second layer has lower strength and higher dispersibility for easy breakdown. This local differentiation resolves the contradiction between maintaining overall structural integrity and enabling localized disintegration for safe disposal.
2Object-generated harmful factors
If compressed sites are added to improve dispersability, then structural integrity may be compromised, affecting cleaning efficacy
Solution Approach 1:
The structure is segmented into two functional layers where the compression-induced weakness is localized to specific regions. The first layer maintains full structural integrity for cleaning efficacy, while the second layer contains compressed sites that create controlled weakness zones for dispersability without compromising the overall structural function.
Solution Approach 2:
Compressed sites are applied locally to specific areas of the nonwoven structure rather than uniformly throughout. This localized compression creates predetermined weakness zones that facilitate breakdown during flushing while leaving other areas intact to maintain structural integrity and cleaning effectiveness during use.
3Ease of operation
If hydromolding is applied to create molded elements for visual and tactile benefits, then the structural properties may be altered, affecting the balance between strength and dispersability
Solution Approach 1:
The molded elements are incorporated as a distinct third component in the layered structure. This segmentation allows the molded elements to provide visual and tactile benefits without fundamentally altering the structural properties of the first layer or the dispersibility characteristics of the second layer, maintaining the critical balance between strength and breakdown capability.
Solution Approach 2:
The molded elements are combined with the layered nonwoven structure in a way that integrates aesthetic and tactile functions while preserving the functional integrity of the underlying layers. The molding process creates surface features that enhance user experience without compromising the structural integrity needed for cleaning or the dispersibility needed for safe disposal.
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 structure achieves a balance between structural integrity for effective use and dispersability, preventing blockages by failing along designated lines of weakness, ensuring efficient passage through sewage systems while maintaining sufficient strength for cleaning purposes.
Implementation Method 1
conveying a fibrous web over a molding member
Implementation Method 2
applying a compressive stress to the web
Implementation Method 3
The plurality of compressed sites may form a line of weakness. The fibrous structure may at least partially fail along the line of weakness.
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
A nonwoven fibrous structure comprising compressed sites and molded elements. The combination of compressed sites and molded elements may provide for a fibrous structure comprising structural integrity in use, dispersability when flushed, and assistance to the user in cleansing.