Polyester Mixed Nonwoven Structure for Lightweight Dryer Sheet Impregnation
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Solution Overview
Problem
Existing nonwoven fabrics for dryer sheets face challenges in maintaining excellent impregnation properties when made lightweight, leading to reduced fabric softener distribution and increased density deviations, which affect wear resistance and productivity.
Innovation Solution
A long-fiber mixed nonwoven fabric comprising 70-90% polyester filaments with a high melting point and 10-30% filaments with a lower melting point, produced through bicomponent-spinning and drawing to achieve specific surface areas and evenness deviations that enhance impregnation properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the weight of nonwoven fabric is reduced to lower production costs, then cost competitiveness is improved, but impregnation property of fabric softener deteriorates
Solution Approach 1:
The patent changes the physical parameters of the nonwoven fabric by controlling specific surface area (0.080-0.150 m²/g) and evenness deviation (200-300), which allows lightweight fabric to maintain good impregnation properties through optimized spatial structure rather than increased weight
Solution Approach 2:
The patent uses a composite fiber composition mixing polyester fibers (70-90 wt%) with polyamide fibers (10-30 wt%), combining the cost-effectiveness and softness of polyester with the absorbency and impregnation capability of polyamide, achieving both cost reduction and maintained fabric softener impregnation
2Reliability
If the weight of nonwoven fabric is reduced, then production cost is reduced, but density deviation increases
Solution Approach 1:
The patent optimizes the evenness deviation parameter to a specific range (200-300) and controls specific surface area (0.080-0.150 m²/g), which stabilizes the density distribution in lightweight nonwoven fabric and prevents excessive density deviation even at reduced weights
3Manufacturing precision
If polyester short-fiber nonwoven fabric is used to improve impregnation property, then impregnation and delamination properties are improved, but productivity decreases and wear resistance is reduced
Solution Approach 1:
The patent creates a composite nonwoven fabric combining polyester and polyamide fibers, where polyester provides cost-effectiveness and basic durability, while polyamide enhances impregnation properties, achieving a balance between productivity, wear resistance, and fabric softener absorption without requiring complex short-fiber processing
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 method improves impregnation rates and maintains mechanical properties even at reduced weights, ensuring effective fabric softener distribution and cost competitiveness by adjusting fiber density and spatial structure.
Implementation Method 1
A long-fiber mixed nonwoven fabric comprising 70-90% by weight of a first polyester filament having a melting point of 250°C or higher and 10-30% by weight of a second polyester filament having a melting point of 235°C or lower
Implementation Method 2
it is liquefied by heating and then coated onto a nonwoven web through a gravure roll to be solidified at room temperature
Data Source
AI summary
The present disclosure relates to a method for producing a nonwoven fabric which improves the impregnation property of a fabric softener in the nonwoven fabric so as to apply the nonwoven fabric to a dryer sheet (sheet-type fabric softener). In a nonwoven fabric made of two types of polyester long fiber mixed filament yarns, by widening the specific surface area, adjusting the evenness deviation to be small and increasing the porosity, the impregnation property of a fabric softener is improved even when the nonwoven fabric is made lightweight, and the nonwoven fabric can be applied to a dryer sheet.