Patterned Nonwoven Forming Surface for Fluid Control and Flexibility
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Solution Overview
Problem
Existing nonwoven materials struggle to balance liquid absorbency, fluid handling, flexibility, and material efficiency, particularly in absorbent articles and wiping products, necessitating improvements in substrate formation processes.
Innovation Solution
The process involves forming nonwoven webs with regions of high and low basis weight and thickness using a unique forming surface with distinct porosity zones, creating elongated fluid control canals and enhancing flexibility, while allowing for efficient slitting and faster converting speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If nonwoven materials are designed to have good liquid absorbent properties, then fluid absorbency is improved, but fluid handling properties deteriorate
Solution Approach 1:
The forming surface is divided into zones of different porosity: high porosity zones (first zones) that allow rapid fluid intake and distribution, and low porosity zones (second zones) that provide structural integrity and control fluid flow. This local differentiation enables the substrate to simultaneously achieve good fluid absorbency in specific areas while maintaining overall fluid handling properties through the patterned structure.
2Strength
If nonwoven materials are made with higher basis weight to improve strength, then strength is improved, but flexibility deteriorates
Solution Approach 1:
The patterned forming surface creates regions of varying basis weight: high basis weight areas corresponding to low porosity zones provide strength and structural support, while low basis weight areas corresponding to high porosity zones provide flexibility and conformability. This spatial variation in basis weight allows the substrate to simultaneously achieve both strength and flexibility.
3Loss of substance
If nonwoven materials are made from as little material as possible to reduce waste, then material efficiency is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patterned forming surface with distinct high and low porosity zones enables precise control over fiber deposition and fluid drainage at different locations. This allows the creation of a lightweight, material-efficient substrate with optimized local properties: high porosity zones use less material to achieve fluid intake functions, while low porosity zones provide structural control, overall improving material efficiency without sacrificing manufacturing precision.
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 nonwoven substrates with improved fluid intake and distribution capabilities, increased flexibility, and reduced wear on slitting equipment, offering enhanced comfort and functionality in absorbent articles and wiping products.
Implementation Method 1
The forming surface includes a pattern of porous first zones and porous second zones. The first zones have a porosity greater than a porosity of the second zones.
Implementation Method 2
Fluids are drained from the forming surface causing a continuous nonwoven substrate to form
Data Source
AI summary
A process and system for producing nonwoven substrates are disclosed. Also disclosed is a forming surface or forming wire for producing the substrates. The forming surface includes a pattern of high porosity zones and low porosity zones. The low porosity zones have a non-zero but low porosity. A wet suspension of fibers is deposited onto the forming surface to form nonwoven substrates having areas of high basis weight and low basis weight. The low porosity zones have a width dimension that is greater than the average fiber length of at least some of the types of fibers contained in the fiber furnish to form substrates having exceptional properties, especially with respect to fluid control properties.