Wet Nonwoven Screen Printing With Puffing Paste for Raised Abrasives
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Solution Overview
Problem
Existing methods for creating non-woven fabrics with abrasive elements are costly and inefficient due to the need for post-processing and the use of substantial material, limiting their economic viability and manufacturing speed.
Innovation Solution
An in-line process using a specialized paste with a puffing agent, rheology modifiers, and cross-linking agents is applied to wet non-woven fabrics during the manufacturing process, allowing for controlled deposition of abrasive elements with varying height and density without the need for additional processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If abrasive elements are applied to finished dry non-woven fabric, then the fabric gains cleaning functionality, but the process becomes expensive and time-consuming due to post-processing requirements
Solution Approach 1:
The patent applies the preliminary action principle by depositing abrasive elements on the non-woven fabric while it is still wet during the manufacturing process, rather than after drying. This allows the abrasive application to occur in-line during production, eliminating post-processing steps and maintaining high manufacturing speed while simplifying the overall process.
2Reliability
If substantial amounts of abrasive material are deposited to achieve required physical effects, then the fabric gains sufficient abrasiveness, but the process becomes economically unviable due to high material consumption
Solution Approach 1:
The patent applies parameter changes by utilizing the physical state of the fabric (wet vs. dry) and the rheological properties of the paste formulation to control material deposition. The wet fabric provides a controlled substrate that requires less material for effective abrasive performance, while the paste's rheology ensures proper distribution and adhesion, reducing overall material consumption while maintaining reliable abrasive performance.
3Manufacturing precision
If abrasive elements are created on finished fabric, then the fabric achieves desired cleaning properties, but additional processing steps are required increasing complexity and cost
Solution Approach 1:
The patent applies the merging principle by combining the abrasive element deposition with the existing wet fabric handling process in the manufacturing line. The paste application and drying occur as integrated steps within the continuous manufacturing process, merging what would otherwise be separate post-processing operations into the main production flow, thereby reducing device complexity while maintaining precision control over abrasiveness and pattern characteristics.
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
This method enables the production of high-quality non-woven fabrics with controlled abrasive properties, reducing material usage and processing time while maintaining chemical stability and aesthetic appeal, thus enhancing both industrial and cosmetic cleaning applications.
Implementation Method 1
a paste that expands under heating by virtue of a puffing agent contained therein
Implementation Method 2
The printed paste is then dried and cross-linked to provide chemical stability to the printed elements
Data Source
AI summary
A process for manufacturing a non-woven fabric having on its surface distributed elements having a physical dimension, comprises screen printing on wet fabric a desired shape using a paste that expands under heating by virtue of a puffing agent contained therein.