Nonwoven Material With Multi-Height Protuberances For Absorbent Products
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Solution Overview
Problem
Existing nonwoven materials for absorbent products face challenges in achieving good liquid receiving characteristics, comfort for the wearer, and clear decorative surface structures due to issues with thermal embossing and previous hydroentangling methods that compromise material strength and visibility.
Innovation Solution
A nonwoven material produced by hydroentangling a substrate web with synthetic, regenerated, or natural fibers, featuring protuberances of different heights and areas on one side, where the second protuberances occupy at least four times the area of the first, enhancing liquid distribution and absorption while maintaining softness and visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If thermal embossing is used to produce images or decorations on nonwoven material, then the image is produced as a depression, but the fibres are compressed and melted which reduces surface softness and impairs strength characteristics
Solution Approach 1:
The patent replaces thermal embossing with hydroentangling technology. Instead of using heat and pressure to create embossed images, the invention uses high-pressure liquid jets to hydroentangle fibers, forming three-dimensional surface structures with images or decorations. This substitution eliminates thermal damage to fibers while achieving the desired surface patterning effect.
Solution Approach 2:
The invention changes the fundamental parameters of the surface treatment process from thermal-mechanical (thermal embossing) to hydraulic-mechanical (hydroentangling). By using liquid jets at controlled pressures to create surface structures, the process achieves image formation without the fiber damage caused by thermal compression and melting.
2Shape
If thermal embossing is used to produce images or decorations on nonwoven material, then the image is produced, but the fibres are compressed and melted which reduces surface softness
Solution Approach 1:
The patent replaces thermal embossing with hydroentangling technology. Instead of using heat and pressure to create embossed images, the invention uses high-pressure liquid jets to hydroentangle fibers, forming three-dimensional surface structures with images or decorations. This substitution eliminates thermal damage to fibers while achieving the desired surface patterning effect.
3Shape
If hydroentangling is used against an image transfer surface to produce images, then the nonwoven material receives an image on both sides, but the contact surface with subjacent material is poor which makes it more difficult to glue in place
Solution Approach 1:
The invention creates localized three-dimensional surface structures (protuberances) with varying heights and areas on the nonwoven material surface. These structured regions provide enhanced mechanical interlocking and adhesive bonding surfaces, improving gluing ease while maintaining the decorative image function. The local quality enhancement through 3D structuring solves the poor contact surface problem.
4Quantity of substance
If hydroentangling is used to produce depressions on one side of nonwoven material, then the depressions retain liquid, but this is not good for the distribution of liquid
Solution Approach 1:
The invention segments the liquid retention function across multiple protuberances of different heights and areas distributed across the surface. Instead of single large depressions that trap liquid, the segmented 3D structure creates numerous smaller retention zones that work together to both retain and distribute liquid effectively across the nonwoven material surface.
Solution Approach 2:
The invention transitions from two-dimensional surface patterns to three-dimensional protuberances with varying heights. This dimensional change creates volume-based liquid retention zones that facilitate both liquid holding and distribution through the vertical dimension, improving upon flat depression structures that only retain liquid on the surface plane.
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 results in a nonwoven material with improved liquid absorption, distribution, and comfort, as well as a textile-like appearance that is soft, strong, and discreetly visible, reducing skin contact and enhancing airflow and absorption of viscous substances.
Implementation Method 1
The protuberances form at least a first and a second surface structure respectively in the form of first and second protuberances from the base level, wherein the first protuberances have a height h1 from the base level and the second protuberances have a height h2 from the base level
Implementation Method 2
a substrate web of fibres is laid on the image transfer surface, wherein the substrate web is hydroentangled, that is to say it is sprayed with jets of liquid
Data Source
AI summary
The present invention relates to a nonwoven material intended for use in absorbent products produced by the hydroentangling of a substrate web comprising at least one layer of fibers selected from amongst synthetic fibers, regenerated fibers and natural fibers, wherein the nonwoven material (1) has a base level h0 with protuberances (2, 3) on one side, wherein the protuberances (2, 3) form at least a first and a second surface structure respectively in the form of first (2) and second (3) protuberances from the base level h0, wherein the first protuberances (2) have a height h1 from the base level and the second protuberances (3) have a height h2 from the base level h0, where h2 is higher than h1, and each of the second protuberances (3) occupies an area of the surface of the base level at least 4 times greater than each of the first protuberances (2).The invention also relates to an absorbent product containing a nonwoven material in accordance with the above.