3D Shaped Nonwoven Microzones for Compression-Resistant Softness
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Solution Overview
Problem
There is a need for improved nonwoven fabrics with three-dimensional surface features that maintain physical integrity, softness, and reduced fuzzing properties, while being able to be packaged in a compressed form without losing these features, and for absorbent articles that offer hydrophilic and hydrophobic regions within microzones.
Innovation Solution
A nonwoven fabric with a visually discernible pattern of three-dimensional features, where microzones have differing intensive properties such as thickness and basis weight, and is produced using a forming belt and melt spinning process to create continuous filaments with varying densities and hydrophilic/hydrophobic regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If nonwoven fabrics are compressed for packaging, then distribution costs are reduced and handling is easier, but the three-dimensional surface features are lost
Solution Approach 1:
The nonwoven fabric is pre-formed with three-dimensional surface features during the manufacturing process using a shaped forming belt, so that the desired shape is established before packaging. This preliminary shaping ensures that even when compressed for distribution, the fabric retains its functional and aesthetic three-dimensional characteristics upon use.
Solution Approach 2:
The invention changes the physical parameters of the nonwoven fabric by creating regions with varying thickness, basis weight, and volumetric density. These parameter variations throughout the fabric structure provide mechanical integrity and shape retention, allowing the fabric to maintain its three-dimensional features even when subjected to compression during packaging and distribution.
2Ease of operation
If nonwoven fabrics are made softer, then comfort is improved, but physical integrity and fuzzing resistance are reduced
Solution Approach 1:
The nonwoven fabric incorporates microzones with locally varied properties, including regions of different thickness, basis weight, and fiber composition. This local quality variation allows certain areas to be softer and more comfortable while other areas maintain greater strength and structural integrity, preventing fuzzing while preserving comfort.
Solution Approach 2:
The invention uses composite nonwoven structures combining different fiber types, densities, and bonding characteristics within a single fabric. This composite approach enables the fabric to simultaneously exhibit softness for comfort and sufficient strength for physical integrity and fuzzing resistance.
3Ease of manufacture
If uniform nonwoven fabric is used, then manufacturing is simpler, but functional versatility for different applications is limited
Solution Approach 1:
The nonwoven fabric is segmented into multiple microzones with different properties during a single manufacturing process. This segmentation creates functionally distinct regions (e.g., more absorbent areas, more breathable areas, different softness levels) without requiring multiple separate manufacturing steps, thus maintaining ease of manufacture while achieving functional versatility.
Solution Approach 2:
By implementing local quality variations in the form of microzones with different thickness, basis weight, and material composition, the fabric can be tailored for specific applications or different functional regions within a single product, greatly enhancing adaptability and versatility while using standard manufacturing processes.
Data Source
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, and wherein in at least one of the microzones the first region exhibits a Contact Angle of greater than 90 degrees, as measured by the Contact Angle Test Method detailed herein.