Unitary nonwoven material
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Solution Overview
Problem
Existing nonwoven materials for pre-moistened cleaning products, such as mopping cloths and wipes, quickly deplete their liquid content and lack effective scrubbing and scouring properties, necessitating frequent replacements and additional cleaning tools.
Innovation Solution
A unitary airlaid nonwoven material comprising three layers of fibers, including a top layer of synthetic fibers, a middle layer of cellulose and synthetic fibers, and a bottom layer of cellulose and high core bicomponent fibers, with hardwood bonded natural cellulosic fibers providing high capillary action and metered liquid release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If pre-moistened nonwoven materials are used for cleaning, then liquid absorption is achieved, but liquid retention is insufficient causing quick depletion
Solution Approach 1:
The nonwoven material is divided into three distinct layers with different fiber compositions and functions: a top layer for liquid absorption, a middle layer for liquid distribution, and a bottom layer for liquid retention. This segmentation allows each layer to optimize its specific function, preventing quick liquid depletion while maintaining effective retention.
Solution Approach 2:
Each layer of the nonwoven material is given different local qualities through specific fiber selections: the top layer uses hydrophilic fibers for rapid absorption, the middle layer uses a blend for distribution, and the bottom layer uses hydrophobic fibers for retention. This local differentiation enables the material to retain liquid longer while maintaining overall absorption capability.
2Ease of operation
If single-use pre-moistened materials are used, then cleaning is achieved, but scrubbing action is insufficient
Solution Approach 1:
The material incorporates fibers with varying physical parameters including different diameters, lengths, and stiffness values. The bottom layer specifically includes coarser fibers that provide mechanical scrubbing action, transforming the material from a soft cleaning cloth to one with reliable scrubbing capability while maintaining ease of operation.
3Area of stationary object
If liquid is released quickly from nonwoven material, then initial wetting is achieved, but coverage area is limited
Solution Approach 1:
The nonwoven material structure creates a periodic liquid release pattern where the top layer rapidly releases liquid for initial wetting, the middle layer distributes it, and the bottom layer provides sustained release. This periodic action extends the effective cleaning time and allows coverage of larger surface areas without requiring excessive initial liquid release speed.
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 material effectively retains and gradually releases liquid, enhancing cleaning efficiency over larger areas and providing improved scrubbing properties, thus reducing the need for frequent product replacements.
Implementation Method 1
hardwood bonded natural cellulosic fibers having a coarseness in a range of from 4.2 mg/100 m to 8.8 mg/100 m are contained in the second layer or the third layer
Implementation Method 2
the nonwoven materials of the presently disclosed subject matter provide relatively high liquid retention and a metered release of liquid
Data Source
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AI summary
Nonwoven materials having at least one layer comprising cellulose fibers are provided. The nonwoven materials comprise bonded natural cellulosic fibers having high capillary action. The nonwoven materials are suitable for use in a variety of applications, including absorbent products and pre-moistened cleaning materials with metered release of liquid.