Nonwoven fabric
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Solution Overview
Problem
Existing nonwoven fabrics for human cleansing and cosmetic applications face challenges with poor liquid retention, insufficient bulkiness, and skin irritation due to lack of rigidity and irregular fiber cross-sections, which affect their absorption, wiping ability, and softness.
Innovation Solution
A nonwoven fabric comprising 20-80% by weight of polyester fibers with an oblate multilobal cross-section and 20-80% by weight of cellulose fibers, where the polyester fibers have a specific oblate cross-section with at least 6 lobes, and the cellulose fibers have a preferred oblate shape with lobes and recesses, enhancing liquid retention and absorption without sacrificing softness or causing skin irritation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If polyester fiber and polyolefin fiber are used to achieve soft texture, then softness is improved, but liquid retention and bulkiness deteriorate
Solution Approach 1:
The patent combines polyester fiber (providing softness and rigidity) with polyolefin fiber (providing bulkiness and liquid retention) in a composite nonwoven fabric structure. The polyester component contributes to the fabric's structural integrity and soft texture, while the polyolefin component provides hydrophobic properties that enhance liquid retention and prevent saturation, thereby resolving the contradiction between softness and liquid retention capability.
Solution Approach 2:
The patent applies different fiber types in specific proportions (40-77% polyester, 23-60% polyolefin) to create local functional zones within the fabric. The polyester-rich areas provide softness and rigidity for skin contact, while the polyolefin-rich areas provide bulkiness and liquid retention, allowing different regions of the fabric to perform specialized functions that collectively resolve the softness-liquid retention contradiction.
2Quantity of substance
If fiber with irregular cross-section is used to improve liquid holding, then liquid holding is improved, but skin damage risk increases due to pointed cross-section
Solution Approach 1:
The patent specifies that the polyester fiber should have an irregular cross-section with rounded contours and no sharp points or protrusions. This local modification of the fiber geometry allows the fiber to maintain liquid-holding capability through its irregular shape while eliminating the harmful pointed features that could damage skin, thereby resolving the contradiction between liquid holding and skin safety.
3Quantity of substance
If hollow cross-section fiber is used to improve liquid holding, then liquid holding is improved, but shape retention deteriorates due to collapse
Solution Approach 1:
The patent combines hollow cross-section polyester fibers (providing liquid holding capacity) with rigid polyolefin fibers (providing structural support). The polyolefin component acts as a structural framework that prevents the hollow polyester fibers from collapsing, thereby maintaining both the liquid-holding advantage of the hollow structure and the shape retention required for fabric integrity.
4Ease of manufacture
If degree of oblateness is increased to improve anti-transparency, then anti-transparency is improved, but softness deteriorates
Solution Approach 1:
The patent specifies that the polyester fiber should have a degree of oblateness of 2.0 or more to achieve anti-transparency through diffuse reflection, while simultaneously maintaining a degree of irregularity of 0.4 or more to ensure softness and flexibility. This local optimization of fiber geometry parameters allows the fabric to achieve both anti-transparency and softness by balancing two different geometric characteristics of the same fiber.
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 fabric achieves high absorption, retention, and release of liquids, maintaining bulkiness and softness, while reducing skin irritation, thus being suitable for cosmetic and cleansing applications with improved wiping performance.
Implementation Method 1
a nonwoven fabric comprising 20 to 80% by weight of a polyester fiber having an oblate multilobal cross-section and 20 to 80% by weight of a cellulose fiber wherein the polyester fiber having an oblate multilobal cross-section has an oblate cross-section with at least 6 lobes on its periphery
Implementation Method 2
when the cross-section of the polyester fiber having a multilobal oblate cross-section has maximum length A, maximum width B, length C of line connecting adjacent lobe apexes in the section with largest lobes, and length D of perpendicular between the line C connecting the adjacent lobe apexes and the bottom of recess between the adjacent lobes
Data Source
Figure 1
AI summary
A nonwoven fabric suitable for human cleansing and cosmetic wiper application is provided. This nonwoven fabric exhibits high absorption, retention and release of liquid such as water and chemical solution, excellent bulkiness and softness with good texture and reduced skin irritation, and high wiping ability. The nonwoven fabric comprises 20 to 80% by weight of a polyester fiber having an oblate multilobal cross-section and 20 to 80% by weight of a cellulose fiber, and the polyester fiber has an oblate multilobal cross-section with an oblate cross-section having at least 6 lobes on its periphery. The polyester fiber has predetermined degree of oblateness and degree of irregularity.