Soft Absorbent Coform Nonwoven Web via Bicomponent Fiber Distribution
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Solution Overview
Problem
Conventional coform webs made from meltblown thermoplastic fibrous material and secondary fibrous material face challenges in achieving a balance between softness and strength, with polyethylene homopolymers increasing softness but reducing strength.
Innovation Solution
A nonwoven web material comprising meltblown polymer fibers with bicomponent fibers formed from a first and second polymer component, and monocomponent fibers, along with absorbent fibers, is developed. This configuration allows for specific distribution of fibers in different regions of the web, optimizing softness and strength values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If polyethylene homopolymer is used to increase softness, then softness is improved, but strength deteriorates
Solution Approach 1:
The patent uses bicomponent fibers consisting of a polyethylene homopolymer component (for softness) and a polypropylene homopolymer component (for strength). This composite fiber structure allows the web to simultaneously achieve both softness and strength properties that neither component could provide alone, directly resolving the technical contradiction between softness and strength.
Solution Approach 2:
The patent implements a stratified web structure where different regions have different fiber compositions. The first and second outer regions contain bicomponent fibers with both polyethylene and polypropylene components, while the central region contains only polyethylene homopolymer fibers. This local differentiation allows the web to have high softness in the central region while maintaining strength through the bicomponent fibers in the outer regions.
2Strength
If bicomponent fibers are distributed throughout the web, then strength is improved, but softness deteriorates
Solution Approach 1:
The patent creates a stratified web structure where bicomponent fibers are concentrated in the first and second outer regions, while the central region contains only monocomponent polyethylene fibers. This local distribution allows the web to achieve high strength through the bicomponent fibers in the outer regions while maintaining softness in the central region, resolving the contradiction between strength and softness.
Data Source
AI summary
Soft and strong nonwoven web materials and methods of formation are described. In one embodiment, a nonwoven web material may comprise meltblown polymer fibers comprising bicomponent fibers formed of a first polymer component and a second polymer component, and monocomponent fibers formed only of the first polymer component, or a third polymer component that is different than either of the first polymer component and the second polymer component, and absorbent fibers, wherein the nonwoven web material has a TS7 Softness value of less than or equal to 3.9, according to the TS7 Softness Test Method.