Spunbonded Nonwoven Laminate Balancing Drapability and Delamination Resistance
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Solution Overview
Problem
Existing spunbonded nonwoven laminates face a conflict between satisfactory drapability and sufficient mechanical stability, often lacking optimal compromise and experiencing undesirable delamination and poor abrasion resistance.
Innovation Solution
A spunbonded nonwoven laminate comprising at least two layers, one with crimped multicomponent filaments and one with less crimped reinforcing filaments, where the filaments have a controlled melting temperature difference and binder component, enhancing binding properties to prevent delamination and improve abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If spunbonded nonwoven laminates are designed to have satisfactory drapability, then softness and flexibility are improved, but mechanical stability and longitudinal stiffness deteriorate
Solution Approach 1:
The spunbonded nonwoven laminate is divided into multiple layers with different properties: a crimped spunbonded nonwoven layer providing drapability and softness, and a reinforcing spunbonded nonwoven layer providing mechanical stability and longitudinal stiffness. This segmentation allows each layer to fulfill its specific function optimally.
Solution Approach 2:
Different regions of the laminate have different structural characteristics - the crimped layer provides local softness and flexibility where needed, while the reinforcing layer with noncrimped filaments provides local mechanical strength and stiffness. This local differentiation resolves the contradiction between overall drapability and overall mechanical stability.
2Adaptability or versatility
If multilayer spunbonded nonwoven laminates are provided with different properties for softness and strength, then target parameters are adjusted, but abrasion resistance deteriorates and delamination occurs
Solution Approach 1:
The patent carefully controls the melting temperature parameter of the binder component in the reinforcing layer, setting it to be within 15°C (preferably within 12°C, 8°C, 5°C, or 3°C) of the low-melting plastic component in the crimped layer. This precise parameter control ensures the binder melts at the right temperature to prevent delamination during processing while maintaining abrasion resistance.
Solution Approach 2:
The laminate uses composite material construction with the crimped spunbonded nonwoven layer containing low-melting plastic components and the reinforcing layer containing noncrimped filaments with binder components. This composite structure, with carefully matched melting temperatures, achieves both abrasion resistance and delamination prevention.
3Reliability
If the melting temperature difference between binder component and low-melting plastic component is small, then binding properties are improved and delamination is prevented, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies a melting temperature difference range (within 15°C, preferably within 12°C, 8°C, 5°C, or 3°C) that balances binding performance with manufacturability. This parameter specification provides clear manufacturing guidelines while achieving reliable binding properties that prevent delamination.
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 a balance between drapability and mechanical stability, with reduced delamination and improved abrasion resistance, while maintaining low flexural stiffness.
Implementation Method 1
the continuous filaments of the reinforcing spunbonded nonwoven layer comprise at least one binder component on their surface
Implementation Method 2
the melting temperature difference between the binder component of the continuous filaments of the reinforcing spunbonded nonwoven layer and the first, preferably low-melting, plastic component of the continuous filaments of the at least one crimped spunbonded nonwoven layer is less than 15° C.
Data Source
AI summary
A spunbonded nonwoven laminate comprising at least two spunbonded nonwoven layers made of continuous filaments, wherein at least one crimped spunbonded nonwoven layer comprising bulked continuous filaments is present. The bulked continuous filaments of the at least one crimped spunbonded nonwoven layer are multicomponent filaments comprising at least one first polymer component and at least one second polymer component. At least one reinforcing spunbonded nonwoven layer which consists or substantially consists of non-bulked continuous filaments and/or continuous filaments that are less bulked in comparison with the continuous filaments of the at least one crimped spunbonded nonwoven layer is present. The continuous filaments of the reinforcing spun-bonded nonwoven layer comprise at least one binder component arranged at their surface. The melting temperature difference between the binder component of the continuous filaments of the reinforcing spunbounded nonwoven layer and the first polymer component of the continuous filaments of the at least one crimped spunbounded nonwoven layer is less than 15° C. The laminate has a maximum cantilever flexural strength of at most 100 mm.