Soft Nonwoven Composite Resolving Softness-Abrasion Tradeoff
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Solution Overview
Problem
Conventional nonwoven webs for disposable diapers lack a soft, cloth-like feel while maintaining durability and strength, often requiring a tradeoff between softness and abrasion resistance.
Innovation Solution
A nonwoven composite comprising a first polyolefin web with ethylene polymer and a second polyolefin web containing rigid and ductile propylene polymers, along with a fatty acid derivative, which provides a soft feel and improved bonding without compromising durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If mechanical post treatments are used to improve softness of the nonwoven web, then softness is improved, but abrasion resistance deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the propylene polymer by incorporating specific additives (fatty acid derivatives, plasticizers, or waxes) to modify the material properties. This allows achieving softness without mechanical treatment that would compromise abrasion resistance
Solution Approach 2:
The patent creates a composite material system by combining propylene polymer with fatty acid derivatives, plasticizers, or waxes. This composite approach enables simultaneous achievement of softness and durability through chemical composition rather than mechanical modification
2Shape
If degree of thermal bonding is reduced to improve softness, then softness is improved, but strength deteriorates
Solution Approach 1:
The patent modifies the chemical parameters of the propylene polymer composition to inherently provide softness, eliminating the need to reduce thermal bonding degree. This allows maintaining strong bonding while achieving softness through material composition
3Strength
If polypropylene nonwoven web is used for backsheet, then strength is improved, but softness deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the propylene polymer by adding fatty acid derivatives, plasticizers, or waxes. This transforms the inherently rigid polypropylene into a soft yet strong material suitable for backsheet applications
Solution Approach 2:
The patent creates a composite propylene-based material that combines the strength of polypropylene with the softness-providing properties of fatty acid derivatives, plasticizers, or waxes, achieving both strength and softness in a single material system
Data Source
Figure 1
AI summary
A nonwoven composite that contains a first nonwoven web positioned adjacent to a second nonwoven web is provided. The first nonwoven web contains a plurality of fibers that are formed from a first poiyolefin composition, and the second nonwoven web contains a plurality of fibers that are formed from a second poiyolefin composition. The first poiyolefin composition contains an ethylene polymer, which and car; provide a soft feel to a surface of the first nonwoven web. The second poiyolefin composition likewise contains a rigid propylene polymer, which can provide good strength and durability to the second nonwoven web. The second poiyolefin composition also contains a ductile propylene polymer and a fatty acid derivative.