Nonwoven Web Irregular 3D Texture Pattern
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Solution Overview
Problem
Nonwoven webs used in absorbent articles lack the tactile and visual properties of traditional woven materials, resulting in a less appealing texture and feel for consumers.
Innovation Solution
The development of nonwoven webs with visually discernible three-dimensional patterns featuring irregular varying regions and substantially linear segments, which mimic the natural variation found in woven materials, providing a clothlike or woven-like appearance and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If embossing process is used to create texture patterns on nonwoven webs, then the texture pattern is visually discernible and regular, but the texture appears engineered and less appealing compared to traditional woven materials
Solution Approach 1:
The patent applies asymmetry by creating irregular varying regions within the texture pattern, where the three-dimensional features have non-uniform dimensions and orientations. This irregularity mimics the natural variation found in woven materials, making the texture appear more organic and less engineered, thereby improving appearance quality while maintaining manufacturability through controlled pattern formation processes.
Solution Approach 2:
The patent implements local quality by incorporating regions of substantially linear segments that vary in orientation and spacing across different areas of the nonwoven web. Each region has locally distinct characteristics that contribute to the overall clothlike appearance, with linear segments oriented at different angles creating a natural, varied texture pattern that is both visually appealing and manufacturable.
2Manufacturing precision
If regular embossed texture is applied to nonwoven webs, then the texture pattern is consistent and defined, but the tactile properties and softness are reduced compared to traditional woven materials
Solution Approach 1:
The patent uses asymmetry in the varying dimensions and orientations of three-dimensional features within irregular regions. This creates tactile variation that mimics natural woven materials, improving softness and comfort against the skin while maintaining manufacturing precision through controlled embossing or forming processes that replicate the desired irregular pattern consistently across the web.
Solution Approach 2:
The patent incorporates three-dimensional features with varying heights, depths, and orientations on the surface of the nonwoven web. This dimensional variation creates a clothlike tactile feel by adding depth and complexity to the texture, making it feel softer and more natural to the touch while maintaining manufacturing precision through multi-dimensional forming or embossing techniques.
3Ease of operation
If traditional woven materials are used, then the tactile properties and softness are superior, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent copies the essential characteristics of traditional woven materials by creating irregular varying regions with three-dimensional features that mimic the appearance and tactile properties of woven fabrics. This copying approach allows nonwoven webs to achieve clothlike feel and appearance without requiring actual woven construction, thereby maintaining tactile comfort while reducing manufacturing complexity and cost.
Solution Approach 2:
The patent creates composite texture patterns by combining regions of three-dimensional features with regions of substantially linear segments in a single nonwoven web. This composite approach integrates multiple textural elements to achieve a clothlike appearance and tactile feel, while the entire structure can be manufactured using a single nonwoven forming process, avoiding the complexity of combining separate woven and nonwoven layers.
Data Source
AI summary
A nonwoven web for an absorbent article is provided. The nonwoven web includes a first surface and a second surface. The nonwoven web includes a repeat unit comprising a visually discernible pattern of three-dimensional features on the first surface or the second surface. The three-dimensional features comprise one or more first regions and a plurality of second regions. The one or more first regions are different than the plurality of second regions. The one or more first regions comprise a plurality of substantially linear segments. A first group of the plurality of substantially linear segments intersects with a second group of the plurality of substantially linear segments at angles of intersection. The angles of intersection are in the range of about 70 degrees to about 110 degrees.