Nonwoven Forming Members With Texture For 3D Deformations
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need for improved nonwoven materials with three-dimensional features that remain well-defined and visible, even after compression, for use in absorbent articles, and for methods to produce these materials at high speeds and low costs, as existing methods often result in collapse or loss of three-dimensional structure under compressive forces.
Innovation Solution
A method and apparatus for forming nonwoven materials with discrete three-dimensional deformations, where protrusions extend from one surface and have a wide base opening on the opposing surface, using a pair of forming members with male and female elements to mechanically deform the precursor web, allowing for controlled collapse under compression while maintaining the visibility of the base opening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical deformation methods are used to form three-dimensional features in nonwoven materials, then production cost is reduced compared to hydroentangling and hydromolding, but the three-dimensional features tend to collapse or close under compression
Solution Approach 1:
The invention transitions from two-dimensional flat nonwoven material to three-dimensional features with protrusions and base openings. The forming members create depth in the Z-dimension, allowing the material to maintain visible three-dimensional structures that resist collapse under compression while keeping production costs lower than hydroentangling or hydromolding processes.
Solution Approach 2:
The invention changes physical parameters of the nonwoven material through controlled mechanical deformation. By adjusting forming member geometry, deformation depth, and material properties, the process creates stable three-dimensional features with wide base openings that maintain their structure under compression while reducing production costs compared to higher energy processes.
2Productivity
If high line speeds are used in manufacturing nonwoven materials, then productivity increases, but it becomes increasingly difficult to form three-dimensional features that remain well-defined
Solution Approach 1:
The forming members are pre-configured with specific geometric profiles and surface textures that determine the final three-dimensional feature shape. This preliminary setup allows the nonwoven material to be deformed into well-defined protrusions and base openings even at high manufacturing line speeds, maintaining feature definition without sacrificing productivity.
3Reliability
If the nonwoven material is compressed during packaging or product manufacturing, then the material is protected and integrated into the absorbent article, but the three-dimensional character of the features is lost and they become much less visible
Solution Approach 1:
The forming members create three-dimensional features with wide base openings and specific geometric configurations that pre-resist collapse under subsequent compression. The protrusions and base openings are formed with sufficient structural integrity to maintain visibility and three-dimensional character even when the material is compressed during packaging or integrated into absorbent articles, counteracting the harmful effect of compression before it occurs.
4Adaptability or versatility
If wide base openings are formed in the nonwoven material, then liquid acquisition is improved and a visual signal is provided, but the structural integrity of the material may be compromised
Solution Approach 1:
The invention creates controlled porosity through wide base openings in the three-dimensional features, improving liquid acquisition capability. The porous structure allows rapid liquid penetration while the surrounding nonwoven matrix and forming member geometry maintain overall material strength and structural integrity, enabling both high adaptability for liquid handling and sufficient mechanical strength.
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 enables nonwoven materials with well-defined three-dimensional features that remain visible and functional after compression, improving liquid acquisition and providing a visual signal of softness and dryness, while being compatible with high-speed manufacturing and cost-effective production.
Implementation Method 1
mechanically deforming the precursor nonwoven web with the forming members
Implementation Method 2
Certain prior three dimensional structures have a tendency to collapse or close and become much less visible after compression
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
An apparatus for forming deformations in a nonwoven web is disclosed. The apparatus includes a pair of forming members that form a nip therebetween. The forming members include: a first forming member having a surface comprising a plurality of discrete, spaced apart male forming elements; and a second forming member having a surface comprising a plurality of recesses in the second forming member, wherein the recesses are aligned and configured to receive the male forming elements therein, wherein the recesses have a plan view periphery that is larger than, and may completely surround, the plan view periphery of the male elements. At least one of the forming members has a plurality of discrete surface texture elements thereon.