3D Shaped Nonwoven Structure for Compression-Resistant Softness

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Solution Overview

Problem

There is a need for nonwoven fabrics with improved three-dimensional surface features that maintain physical integrity and softness, minimize fuzzing, and retain aesthetics when packaged and unpackaged, while also providing enhanced absorbency and reduced in-bag stack height for absorbent articles.

Innovation Solution

A nonwoven fabric with a visually discernible pattern of three-dimensional features and apertures, formed on a shaped forming belt, featuring differential intensive properties within microzones and regions, produced through melt spinning and continuous filament deposition, which retains shape and functionality under compression.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If nonwoven fabric is compressed to reduce in-bag stack height, then packaging efficiency and handling convenience are improved, but the three-dimensional surface features and aesthetics are degraded

Engineering Contradiction:

Improvein-bag stack heightVSAvoidthree-dimensional surface features

Core Design Contradiction:

Volume of moving objectVSShape

Solution Approach 1:

The patent employs parameter changes by creating nonwoven fabrics with variable basis weight and density through controlled fiber deposition patterns. The forming belt applies differential pressure to deposit fibers at varying densities, creating regions of different compactness that can withstand compression while retaining three-dimensional surface features. This allows the fabric to be compressed for packaging while maintaining aesthetic properties when unpacked.

Inventive Principle:

Principle #35Parameter changes

2Ease of operation

If nonwoven fabric is made softer to improve comfort, then softness is improved, but physical integrity and structural stability are worsened

Engineering Contradiction:

ImprovesoftnessVSAvoidphysical integrity

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The patent applies local quality by creating nonwoven fabrics with spatially varying fiber density and basis weight. The forming belt deposits fibers at different rates in different regions, creating soft, low-density areas for comfort against the skin, while maintaining sufficient fiber density and bonding in structural areas to preserve physical integrity. This gradient structure allows simultaneous optimization of softness and strength.

Inventive Principle:

Principle #3Local quality

3Productivity

If nonwoven fabric has three-dimensional surface features to improve aesthetics and absorbency, then functional properties are improved, but manufacturing complexity is worsened

Engineering Contradiction:

ImproveabsorbencyVSAvoidmanufacturing process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent applies universality by designing the forming belt to simultaneously achieve multiple functions: creating three-dimensional surface features for aesthetics, establishing variable basis weight zones for absorbency control, and forming aperture patterns for fluid permeability. The single forming belt process integrates these functions without requiring separate manufacturing steps, thereby improving productivity while controlling manufacturing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Strength

If nonwoven fabric is made with higher basis weight to improve strength, then physical integrity is improved, but softness and absorbency are worsened

Engineering Contradiction:

Improvephysical integrityVSAvoidsoftness

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent resolves this contradiction by applying local quality through spatially varying basis weight. The forming belt deposits fibers at different densities in different regions, creating low-basis weight areas that remain soft and absorbent, while maintaining sufficient basis weight in structural areas for physical integrity. This non-uniform distribution allows the fabric to simultaneously exhibit both softness and strength.

Inventive Principle:

Principle #3Local quality

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 fabric maintains significant caliper and functional properties post-compression, offering improved absorbency, softness, and reduced leakage, with reduced in-bag stack height for convenient handling and lower distribution costs.

Implementation Method 1

formed on a shaped forming belt, featuring differential intensive properties within microzones and regions, produced through melt spinning and continuous filament deposition

Methodology Applied

Scientific EffectMelt spinning:

Implementation Method 2

The fabric maintains significant caliper and functional properties post-compression

Methodology Applied

Scientific EffectCompression resistance: Compression

Data Source

PatentUS20260035837A1Shaped Nonwoven

Publication Date: 2026.02.05 PROCTER & GAMBLE CO

AI summary

A nonwoven fabric. The nonwoven fabric can include a first surface and a second surface and a visually discernible pattern of three-dimensional features on one of the first or second surface. Each of the three-dimensional features can define a microzone comprising a first region and a second region. The first and second regions can have a difference in values for an intensive property.