Nonwoven Material with Controlled Collapse Protrusions
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Solution Overview
Problem
Existing nonwoven materials for absorbent articles face challenges in maintaining well-defined three-dimensional features, especially when subjected to compressive forces, which can cause deformation and loss of visual signal, and require costly high-energy processes like hydroentangling for production.
Innovation Solution
Development of nonwoven materials with discrete three-dimensional deformations featuring protrusions and wide base openings that remain open even under compression, achieved through a mechanical deformation method using forming members with male and female elements, allowing for cost-effective high-speed production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If three-dimensional features are formed in nonwoven materials to improve softness and dryness, then liquid acquisition and visual signal are enhanced, but the features collapse or close when subjected to compressive forces
Solution Approach 1:
The nonwoven material is divided into multiple layers (first nonwoven layer, second nonwoven layer) with deformations formed in one layer while the other layer remains substantially planar. This segmentation allows the three-dimensional features to be isolated in a specific layer, preventing collapse when compression is applied to the composite structure.
Solution Approach 2:
The invention combines a first nonwoven layer with deformations and a second nonwoven layer without deformations into a laminate composite. This composite structure provides mechanical support from the planar layer that prevents the deformed layer from collapsing under compression, while maintaining the liquid acquisition benefits of the three-dimensional features.
2Manufacturing precision
If high-energy processes like hydroentangling are used to create three-dimensional features, then well-defined deformations are achieved, but production costs increase
Solution Approach 1:
The invention replaces high-energy hydroentangling processes with a mechanical deformation method using calibrated rollers that physically press the nonwoven material to create three-dimensional features. This mechanical approach achieves well-defined deformations without the high energy consumption of hydroentangling equipment.
Solution Approach 2:
The invention changes the physical parameters of the deformation process by using controlled compression force through calibrated rollers at specific temperatures and speeds. This allows precise control of the three-dimensional feature formation without requiring the extreme energy input of hydroentangling, achieving both definition and energy efficiency.
3Ease of manufacture
If mechanical deformation methods are used to create three-dimensional features, then production costs are reduced, but the features become less visible after compression
Solution Approach 1:
By segmenting the nonwoven material into multiple layers with deformations confined to one layer, the invention maintains visual visibility of the three-dimensional features after compression. The planar layer provides structural support that prevents complete collapse, preserving the visual signal while keeping production costs low through mechanical deformation.
Solution Approach 2:
The invention creates deformations that extend in the z-dimension (thickness direction) from the plane of the nonwoven material. This three-dimensional protrusion structure maintains visibility after compression because the height of the protrusions provides a visual indicator that persists even when the material is compressed, unlike flat two-dimensional features.
4Productivity
If high line speeds are used in manufacturing to increase productivity, then production efficiency improves, but three-dimensional features become difficult to maintain as well-defined
Solution Approach 1:
The invention optimizes processing parameters including temperature, pressure, and roller speed to maintain well-defined three-dimensional features at high line speeds. By adjusting these parameters dynamically, the mechanical deformation process achieves both high productivity and manufacturing precision simultaneously.
Solution Approach 2:
The nonwoven material is pre-conditioned (heated or moisture-treated) before deformation to increase its pliability and response to mechanical forming. This preliminary action allows the material to be deformed more effectively at high speeds while maintaining feature definition, as the pre-treated material responds more readily to the rapid mechanical action of the rollers.
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 preserves the three-dimensional structure and visual signal of the nonwoven materials under compression, enhancing liquid acquisition and providing a visible indication of absorbency, while being compatible with high-speed manufacturing lines and reducing production costs.
Implementation Method 1
mechanically deforming the precursor nonwoven web with the forming members to form a nonwoven web having a generally planar first region and a plurality of discrete deformations
Data Source
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AI summary
Nonwoven materials having discrete three-dimensional deformations therein forming protrusions that extend outward from the first surface of the nonwoven material and wide base openings adjacent to the second surface of the nonwoven material are disclosed. At least some of the three-dimensional deformations are configured to collapse in a controlled manner when compressive forces are applied on the nonwoven material.