Spunbond laminate

Solution Overview

Problem

Spunbond nonwoven laminates with crimped continuous filaments face a conflict between achieving high thickness and softness, which compromises their strength and abrasion resistance, while also lacking optimal opacity.

Innovation Solution

A spunbond nonwoven laminate composed of multiple layers with crimped multicomponent or bicomponent filaments, where the first layer consists of polyolefin with a lower melting point and a higher melting point plastic, and the second layer has a higher polyolefin portion, providing enhanced strength, abrasion resistance, and opacity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If crimped continuous filaments are used to achieve high thickness and softness, then thickness and softness are improved, but tensile strength and abrasion resistance deteriorate

Engineering Contradiction:

ImprovethicknessVSAvoidtensile strength

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The nonwoven fabric is divided into multiple layers (at least two layers) where different layers serve different functions: some layers provide thickness and softness while others provide strength. This segmentation allows each layer to be optimized for its specific purpose without compromising the overall fabric properties.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite filament structures including multicomponent filaments (e.g., polyethylene/polypropylene combinations) and combines different filament types (crimped and straight) within and across layers. This composite approach allows the fabric to simultaneously achieve softness from crimped filaments and strength from straight filaments with high tenacity.

Inventive Principle:

Principle #40Composite materials

2Volume of moving object

If crimped continuous filaments are used to achieve high thickness and softness, then thickness and softness are improved, but abrasion resistance deteriorates

Engineering Contradiction:

ImprovethicknessVSAvoidabrasion resistance

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The nonwoven fabric is divided into multiple layers (at least two layers) where different layers serve different functions: some layers provide thickness and softness while others provide strength. This segmentation allows each layer to be optimized for its specific purpose without compromising the overall fabric properties.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite filament structures including multicomponent filaments (e.g., polyethylene/polypropylene combinations) and combines different filament types (crimped and straight) within and across layers. This composite approach allows the fabric to simultaneously achieve softness from crimped filaments and strength from straight filaments with high tenacity.

Inventive Principle:

Principle #40Composite materials

3Volume of moving object

If conventional nonwoven structures are used to achieve thickness, then thickness is improved, but opacity deteriorates

Engineering Contradiction:

ImprovethicknessVSAvoidopacity

Core Design Contradiction:

Volume of moving objectVSIllumination intensity

Solution Approach 1:

Different layers are assigned different qualities: some layers use crimped filaments for thickness and softness, while other layers use straight filaments with high basis weight for opacity. This local optimization ensures that each layer contributes its specific property to the overall fabric performance.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention uses composite filament structures including multicomponent filaments (e.g., polyethylene/polypropylene combinations) and combines different filament types (crimped and straight) within and across layers. This composite approach allows the fabric to simultaneously achieve softness from crimped filaments and strength from straight filaments with high tenacity.

Inventive Principle:

Principle #40Composite materials

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 laminate achieves high softness, thickness, and strength with excellent abrasion resistance and opacity, along with a homogeneous surface, making it suitable for various applications while being cost-effective and productive to manufacture.

Implementation Method 1

a first component on the outer surface of the filaments of the first layer consisting or substantially consisting of at least one polyolefin, in particular of polyethylene... a second component of the filaments of the first layer consisting or substantially consisting of a plastic having a higher melting point than the polyolefin or polyethylene

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS11318712B2Spunbond laminate

Publication Date: 2022.05.03 REIFENHAUSER GMBH & CO MASCHFAB

AI summary

A spunbond nonwoven laminate has a first spunbond nonwoven layer having crimped filaments formed by a first component on an outer surface of the filaments of the first layer consisting or substantially consisting of a polyolefin and a second component consisting or substantially consisting of a plastic having a higher melting point than the polyolefin of the first component of the filaments of the first layer. A second outermost spunbond nonwoven layer on the first layer having filaments as a cover layer and formed by a first component on an outer surface of the filaments of the second layer consisting or substantially consisting of a polyolefin, and a second component consisting or substantially consisting of a plastic having a higher melting point than the polyolefin of the first component of the filaments of the second layer.