Structured Outer Wire Forming for Bulk and Surface Smoothness

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Solution Overview

Problem

Existing methods for producing absorbent structures using structured fabrics face limitations in achieving high bulk and absorbency while preserving smoothness, as they often require fabric crepe, vacuum, or pressing, which compromise the quality attributes.

Innovation Solution

A method that forms a nascent web directly through a structured fabric using centrifugal force from a forming roll, allowing deep penetration without fabric crepe, vacuum, or pressing, utilizing a highly viscous web with up to 99.5% water, and employing a structured fabric with woven monofilaments and overlaid resin.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of stationary object

If a coarse structured fabric with thick monofilament polymeric fibers is used to create deep valleys for fiber penetration, then bulk and absorbency are improved, but surface smoothness is negatively impacted

Engineering Contradiction:

ImprovebulkVSAvoidsurface smoothness

Core Design Contradiction:

Volume of stationary objectVSShape

Solution Approach 1:

The patent changes the physical state and composition parameters of the nascent web by maintaining it as a highly viscous slurry with up to 99.5% water content during formation. This allows the web to penetrate deeply into the structured fabric valleys without requiring coarse fabric structures, thereby achieving high bulk while preserving surface smoothness.

Inventive Principle:

Principle #35Parameter changes

2Length of moving object

If vacuum pressure or speed differential is used to force fibers into the structured fabric, then fiber penetration is achieved, but maximum penetration depth and bulk are limited

Engineering Contradiction:

Improvepenetration depthVSAvoidbulk

Core Design Contradiction:

Length of moving objectVSVolume of stationary object

Solution Approach 1:

The patent replaces the conventional mechanical systems (vacuum pressure, speed differential) with a centrifugal force-based system. The forming roll rotates to generate centrifugal force that drives the highly viscous nascent web directly through the structured fabric, achieving much deeper penetration and greater bulk without the limitations of vacuum or speed differential methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If the structured fabric is placed in the inner position in an ATMOS process, then the absorbent structure is formed directly between wire and structured fabric, but fiber penetration into the structured fabric is limited due to centrifugal force directing water and fiber towards the outer wire

Engineering Contradiction:

Improveformation processVSAvoidfiber penetration

Core Design Contradiction:

Ease of manufactureVSLength of moving object

Solution Approach 1:

The patent inverts the conventional ATMOS configuration by placing the structured fabric in the outer position rather than the inner position. This reversal allows the centrifugal force to drive the highly viscous nascent web through the structured fabric valleys, achieving deep fiber penetration and high bulk while maintaining the direct formation process between wire and structured fabric.

Inventive Principle:

Principle #13The other way round (Inversion)

4Length of moving object

If the absorbent structure is pressed into the structured fabric in the NTT process, then fiber penetration is achieved, but compaction limits absorbency and softness potential

Engineering Contradiction:

Improvepenetration depthVSAvoidabsorbency and softness

Core Design Contradiction:

Length of moving objectVSStrength

Solution Approach 1:

The patent replaces the pressing mechanism with a centrifugal force-based system. The rotating forming roll generates centrifugal force that drives the highly viscous nascent web through the structured fabric without compression. This eliminates compaction while achieving deep penetration, thereby preserving absorbency and softness potential.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Achieves high bulk and softness with a smooth surface by enabling deep penetration of the web into the structured fabric, maintaining absorbency and softness without compromising smoothness.

Implementation Method 1

the highly viscous nascent web can, therefore, penetrate deeply into the structured fabric using the centrifugal force from the forming roll

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Data Source

PatentEP3510196B1Former of water laid asset that utilizes a structured fabric as the outer wire

Publication Date: 2026.04.22 STRUCTURED I LLC

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AI summary

A method of forming a fibrous web including the steps of providing a fiber slurry, depositing the fiber slurry between an inner forming wire and an outer forming wire, wherein the outer forming wire comprises a structured fabric and the inner forming wire contacts a segment of a forming roll, and rotating the forming roll so that the fiber slurry moves into contact with the structured fabric.