Nonwoven Web Quilted Texture via Local Basis Weight Variation
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Solution Overview
Problem
Existing nonwoven webs for absorbent articles lack the desired tactile properties and visual appearance of high quality, such as softness and a quilted fabric texture, which are sought by consumers.
Innovation Solution
The development of nonwoven webs with visually discernible patterns of three-dimensional features, comprising low-basis weight, densified regions that mimic stitching and fluffy, high-basis weight areas, creating a quilted texture and appearance through the use of structured forming belts and specific fiber arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If nonwoven webs use conventional uniform structures, then manufacturing is simple and cost-effective, but they lack desired tactile properties and visual appearance of high quality
Solution Approach 1:
The nonwoven web is divided into multiple regions with different basis weights (first regions with lower basis weight and second regions with higher basis weight), creating distinct tactile zones that mimic quilted stitching patterns while maintaining manufacturability through controlled variations in fiber density
Solution Approach 2:
Different regions of the nonwoven web are assigned different local properties through variation in basis weight, where first regions provide a smoother appearance and second regions provide softer, fluffier textures, allowing each area to contribute specific tactile characteristics to the overall high-quality appearance
2Device complexity
If nonwoven webs increase basis weight uniformly, then softness and texture improve, but visual appearance of quilted fabric and tactile differentiation are compromised
Solution Approach 1:
The invention creates visually discernible patterns by varying basis weight locally across different regions, where higher basis weight areas provide softness and lower basis weight areas provide structural definition, together creating the quilted fabric appearance that would be difficult to achieve with uniform weight
Solution Approach 2:
The nonwoven web incorporates three-dimensional features through variation in basis weight across different regions, creating visual depth and tactile differentiation that mimics the raised and recessed areas of traditional quilted fabric, adding a dimensional aspect to the texture
Data Source
AI summary
A nonwoven web for an absorbent article is provided. The nonwoven web comprises a first surface, a second surface, and 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 in a value of an average intensive property. The one or more first regions comprise a first line, a second line, and a third line extending at least partially intermediate the first line and the second line. The first line and the second line extend in substantially the same direction. The third line extends in a direction transverse to the first line and the second line.