Patterned Nonwoven Webs for White-Look Texture Perception
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Solution Overview
Problem
Nonwoven webs, particularly white or non-colored ones, struggle to achieve high quality levels of texture, perceived absorbency, and softness, making it difficult to deliver premium products.
Innovation Solution
Incorporating a low level of a colorant, pigment, and/or dye as a melt additive during filament formation creates visually discernible three-dimensional patterns that enhance texture perception and softness without altering the web's color appearance, using regions of low-basis weight densification and fluffy high-basis weight areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If highly textured nonwoven webs are used to improve texture perception and softness, then texture and softness are enhanced, but skin marking and skin redness increase
Solution Approach 1:
The patent applies local quality by creating specific three-dimensional patterns (such as dots, lines, or geometric shapes) at localized regions of the nonwoven web rather than uniform texturing across the entire surface. This allows texture to be concentrated in specific areas that provide softness and comfort, while leaving other areas smoother to prevent skin marking and redness. The selective placement of textured regions optimizes both comfort and skin health.
2Shape
If white or non-colored nonwoven webs are used to maintain aesthetic appearance, then visual appeal is maintained, but texture perception and softness are reduced
Solution Approach 1:
The patent utilizes subtle color variations and optical effects to enhance texture perception in white or non-colored nonwoven webs. By incorporating slight shading differences, light reflection variations, or refractive index changes within the three-dimensional patterns, the texture becomes more visually discernible without adding obvious color. This allows the web to maintain its clean, aesthetic white appearance while providing enhanced texture perception through optical contrast rather than chromatic contrast.
3Shape
If three-dimensional patterns are added to enhance texture perception, then texture and softness are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by forming the three-dimensional patterns during the web formation process itself, before the nonwoven material undergoes subsequent manufacturing steps. By creating the textured patterns in the initial web structure using techniques such as patterned sieves, shaped fibers, or controlled fiber deposition, the texture is built-in from the start rather than added as a separate post-processing step. This integration reduces overall manufacturing complexity and eliminates the need for additional texturing equipment or processes.
Data Source
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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 have a first value of an average intensive property. The plurality second regions have a second value of the average intensive property. The first value and the second value are different and are both greater than zero. The nonwoven web has a Single Layer Chroma value in the range of about 1.0 to about 3.5, according to the Delta Chroma and Single Layer Chroma Test. The nonwoven web has a Delta Chroma value in the range of about + 0.1 to about + 3.5, according to the Delta Chroma and Single Layer Chroma Test.