SMS Laminated Nonwoven Fabric for Uniform Fluid Delivery
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Solution Overview
Problem
Laminated nonwoven fabrics with spunbonded and meltblown fibers exhibit poor absorption capacity and non-uniform fluid delivery due to large capillary structures and limited contact area, leading to streaky and inefficient liquid distribution.
Innovation Solution
A laminated nonwoven fabric structure with two layers of meltblown fibers sandwiching a layer of spunbonded fibers, where each layer is cooled below the polymer's melting point before lamination, maintaining the large void spaces in the spunbonded fibers and optimizing capillary action for improved fluid retention and uniform delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If meltblown fibers are sprayed directly onto spunbonded fibers, then the fabric structure is formed, but the large open void spaces in spunbonded fibers are filled in, reducing fluid holding capacity
Solution Approach 1:
The spunbonded fabric is pre-formed and cooled to below the polymer melting point before the meltblown layer is applied. This preliminary cooling action prevents the spunbonded fibers from collapsing when meltblown fibers are subsequently sprayed onto them, preserving the large open void spaces needed for fluid holding capacity.
Solution Approach 2:
The patent changes the temperature parameter of the spunbonded fabric from above melting point (during formation) to below melting point (before meltblown application). This parameter change maintains the structural integrity of spunbonded fibers and prevents void space collapse, resolving the contradiction between fabric formation and fluid holding capacity.
2Strength
If spunbonded fabric with large capillaries is used, then high strength is achieved, but wicking properties and liquid delivery uniformity deteriorate
Solution Approach 1:
The patent creates a composite structure combining spunbonded fabric (for strength) with a meltblown layer (for uniform liquid delivery). The meltblown layer with its fine capillary structure is applied onto the spunbonded fabric, providing excellent wicking characteristics and uniform liquid distribution while the underlying spunbonded layer maintains high strength.
Solution Approach 2:
Different regions of the fabric are assigned different functions: the spunbonded layer provides strength and structural support, while the outer meltblown layer provides wicking and uniform liquid delivery. This local differentiation of material properties resolves the contradiction between strength and delivery uniformity.
3Manufacturing precision
If meltblown fibers are used alone, then excellent wicking characteristics are achieved, but fabric strength and abrasion resistance deteriorate
Solution Approach 1:
The patent creates a composite structure where the meltblown layer (providing excellent wicking characteristics) is combined with the spunbonded layer (providing high strength and abrasion resistance). The resulting composite fabric exhibits both the superior wicking properties of meltblown fibers and the mechanical strength of spunbonded fibers.
Solution Approach 2:
The composite fabric structure performs multiple functions simultaneously: the meltblown layer handles fluid wicking and distribution, while the spunbonded layer provides mechanical strength and durability. This multi-functionality resolves the contradiction between wicking characteristics and fabric strength.
4Reliability
If spunbonded-meltblown-spunbonded laminated fabric is used, then barrier properties and strength are improved, but absorption capacity deteriorates
Solution Approach 1:
The spunbonded fabric is pre-formed and cooled to below the polymer melting point before the meltblown layer is applied. This preliminary action preserves the large open void spaces in the spunbonded fabric, maintaining absorption capacity while still providing the barrier properties and strength benefits of the laminated structure.
Solution Approach 2:
The temperature parameter of the spunbonded fabric is changed to below the polymer melting point before meltblown application, preventing collapse of the void spaces. This parameter change maintains absorption capacity while preserving the structural benefits of the laminated fabric for barrier properties and strength.
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 resulting fabric demonstrates enhanced fluid holding and uniform delivery characteristics, releasing 86% more solution on the first pass and 60% more after three passes compared to a pure meltblown fabric, with increased area coverage and effective solution utilization.
Implementation Method 1
The first and second layers of meltblown fibers are cooled to a temperature below the melting point of the polymer
Implementation Method 2
The large void spaces in the spunbonded fibers were kept open rather than filled in previously known processes which deposited meltblown fibers directly onto a layer of spunbonded fibers
Data Source
AI summary
There is disclosed a laminated, nonwoven fabric and a process for producing such a laminated, nonwoven fabric having desirable fluid holding and fluid release characteristics. The process provides that two sheets of meltblown fiber fabric are produced on forming wire assemblies, cooled at a cooling area, and are then laminated on opposite sides of a sheet of spunbonded fibers using to form the laminated, nonwoven fabric.