Soft, Dry Double-Layer Composite With Protrusion-Assisted Wicking
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Solution Overview
Problem
Existing absorbent hygienic products face challenges in achieving a balance between softness, dryness, and skin-friendliness due to the use of fine fibers and weakly hydrophilic treatments, leading to issues like liquid retention, seepage, and leakage.
Innovation Solution
A soft and dry double-layer composite material is developed, comprising a bottom layer of finer fibers with weaker hydrophilicity and a surface layer of coarser fibers, featuring protrusions and openings, along with a preparation device using rollers and bonding mechanisms to create a structure that enhances liquid permeability and air permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If fine fibers are used to improve softness and comfort, then the fabric becomes softer and more comfortable, but the gaps between fibers reduce, slowing down liquid infiltration and increasing liquid holding amount, which increases wetness and affects dryness
Solution Approach 1:
The fabric is divided into two distinct layers: a surface layer made of coarse fibers for rapid liquid absorption and a bottom layer made of fine fibers for softness and comfort. This segmentation allows each layer to perform its specialized function without compromising the other, resolving the contradiction between softness and dryness.
Solution Approach 2:
Different regions of the fabric have different fiber characteristics tailored to their specific functions. The surface layer uses coarse fibers optimized for liquid wicking, while the bottom layer uses fine fibers optimized for skin comfort. This local differentiation enables the fabric to achieve both rapid drying and softness simultaneously.
2Reliability
If weakly hydrophilic treatment is applied to reduce seepage, then reverse infiltration is reduced, but liquid infiltration time is prolonged and slippage occurs, affecting the absorbent function
Solution Approach 1:
The fabric structure is segmented into two layers with different hydrophilic properties. The surface layer uses hydrophilic coarse fibers for rapid liquid uptake, while the bottom layer uses weakly hydrophilic fine fibers to prevent reverse infiltration and seepage. This segmentation resolves the time-seepage control contradiction by assigning different functional characteristics to different layers.
Solution Approach 2:
The hydrophilicity parameter is varied across different layers of the fabric. The surface layer has high hydrophilicity for fast liquid absorption, while the bottom layer has reduced hydrophilicity to prevent seepage. This parameter variation allows the fabric to achieve both rapid infiltration and effective seepage control.
3Quantity of substance
If natural fibers like spunlace pure cotton are used for liquid absorption, then absorption capacity increases, but the fabric cannot achieve good dryness
Solution Approach 1:
The fabric is segmented into a surface layer using hydrophilic natural fibers for high liquid absorption capacity and a bottom layer using fine synthetic or blended fibers for rapid moisture wicking and drying. This segmentation allows the fabric to achieve both high absorption and good dryness performance.
Solution Approach 2:
The fabric combines natural fibers (for absorption) with synthetic or blended fibers (for wicking and drying) in a composite structure. The surface layer uses natural fibers like cotton or viscose for high liquid uptake, while the bottom layer uses materials with different properties to facilitate rapid moisture transfer and evaporation, achieving both absorption capacity and dryness.
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 composite material ensures improved dryness and comfort by maximizing softness and reducing seepage while maintaining skin-friendliness, addressing the limitations of single-layer fabrics.
Implementation Method 1
the surface layer is provided with openings penetrating the surface layer; the bottom layer is provided with first protrusions protruding upwards, the first protrusions penetrate the openings respectively
Implementation Method 2
a bonding mechanism to bond the surface layer and the bottom layer
Data Source
AI summary
A soft and dry double-layer composite material includes a bottom layer and a surface layer arranged on the bottom layer. The surface layer has an upper surface and a lower surface. The surface layer is provided with openings penetrating the surface layer. The bottom layer is provided with first protrusions protruding upwards. The first protrusions penetrate the openings respectively. A top surface of each of the first protrusions is higher than the upper surface of the surface layer. The bottom layer is made of finer fibers than the surface layer.