Multi-Layer Nonwoven Interlining With Single-Line Point Bonding
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Solution Overview
Problem
Existing multi-layer nonwoven interlining production processes require a second joining process, increasing costs and complexity, and there is a need for a method to integrate various fiber types and improve strength while being environmentally friendly.
Innovation Solution
A single-process production line integrates carded web and additional layers through point bonding using thermal treatment and embossing calendering, eliminating the need for a meltblown layer and enabling the use of natural and recyclable materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a second joining process is used to produce multi-layer nonwoven interlining, then bonding strength is improved, but production complexity and cost increase
Solution Approach 1:
The patent combines multiple functions (forming, bonding, and finishing) into a single thermal bonding step. The thermal bonding process simultaneously bonds the carded web to the additional layer while applying the necessary pressure and heat, eliminating the need for a separate second joining process and reducing production complexity while maintaining bonding strength
Solution Approach 2:
The thermal bonding apparatus performs multiple operations in one step: it bonds the layers together, applies pressure to consolidate the structure, and provides thermal treatment to activate the bonding. This multi-functional approach replaces what would traditionally require separate processes, reducing both complexity and cost
2Strength
If traditional multi-layer production process is used, then layer bonding is achieved, but production cost increases
Solution Approach 1:
The patent merges the bonding operation with the forming operation into a single thermal bonding step. By applying heat and pressure simultaneously during the formation process, the need for separate bonding equipment and operations is eliminated, directly reducing production costs while achieving effective layer bonding
Solution Approach 2:
The thermal bonding process is integrated into the continuous production line, allowing bonding to occur without interrupting the flow of material. This continuous operation eliminates downtime between forming and bonding operations, improving productivity and reducing per-unit production cost
3Device complexity
If meltblown layer is used in multi-layer structure, then production is simplified, but environmental recyclability deteriorates
Solution Approach 1:
The patent changes the material composition parameter by replacing synthetic meltblown layers with natural fiber-based additional layers. This substitution maintains the structural and functional requirements of the interlining while improving environmental recyclability, as natural fibers are biodegradable and more easily recycled compared to synthetic materials
4Adaptability or versatility
If diverse fiber types are combined, then material properties are improved, but processing difficulty increases
Solution Approach 1:
The patent applies different fiber types in specific layers with specific functions. The carded web layer uses fibers optimized for bonding, while the additional layer uses natural fibers for the desired interlining properties. This localized assignment of fiber types based on functional requirements simplifies the overall processing by avoiding the need to handle highly diverse fiber mixtures throughout the entire 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
This approach reduces costs, enhances strength, and improves recyclability and energy efficiency, allowing for the production of high-strength multi-layer nonwoven interlinings with diverse fiber combinations.
Implementation Method 1
leveling the additional layer by means of a thermal treatment
Implementation Method 2
the carded web and the additional layer are joined by means of point bonding
Implementation Method 3
passed between a hot embossing calender and a hot smooth calender
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a new multi-layer nonwoven interlining and the production process thereof. The invention also relates to a process that allows a multi-layer nonwoven interlining to be obtained simultaneously with a single process on a single production line. The process of the present invention comprises the fiber opening step (100), the fiber feeding step (110), the carding step (120), the levelling step of the additional layer by the thermal treatment (130), and the point bonding step of the carded web and additional layer (140). As a result of the process of the invention, a structure is obtained where the carded web (1a) is point-bonded onto the additional layer (1b).