Topographical Support Member for Nonwoven Patterning
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Solution Overview
Problem
Existing nonwoven product manufacturing processes require separate and costly calendaring steps for patterning, leading to high material content, low bulk, and dimensionally unstable raised portions that lose structure when handled or laundered.
Innovation Solution
A support member with a series of raised land areas and corresponding depressions, and through voids for air and water permeability, integrated into the production process to impart texture and bulk to nonwoven products, eliminating the need for separate patterning and reducing material content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a separate calendaring process is used to impart patterns or marks on nonwoven products, then the desired design is achieved, but the manufacturing cost increases and processing time is extended
Solution Approach 1:
The patent combines the patterning function directly into the support member used during hydroentanglement processing. The support member incorporates raised land areas and depressed areas that transfer their topography to the fibrous web, eliminating the need for a separate calendaring process. This integration merges two previously distinct operations (support during processing and pattern imparting) into a single unified component.
Solution Approach 2:
The pattern is pre-formed on the support member before the hydroentanglement process begins. The raised and depressed areas are created in advance on the support member surface, so that when the fibrous web passes over it during processing, the pattern is automatically transferred without requiring subsequent patterning operations.
2Shape
If calendar rolls are used for patterning nonwoven products, then design is achieved, but material content increases and bulk decreases
Solution Approach 1:
The patent replaces the mechanical compression system of calendar rolls with a hydroentanglement-based patterning system. Instead of using high mechanical pressure to compress and pattern the web (which adds material and reduces bulk), the invention uses directed water jets that entangle fibers in specific patterns defined by the support member topography, achieving patterning without excessive compression.
3Manufacturing precision
If high pressure compression is applied during calendaring to create patterns, then pattern definition is achieved, but the raised portions become dimensionally unstable and lose structure when handled
Solution Approach 1:
The patent uses hydraulic action (directed water jets) instead of mechanical compression for patterning. The water jets are directed through the support member's depressed areas, causing fiber entanglement that creates raised portions with inherent structural stability. This hydraulic approach allows precise pattern definition while maintaining the dimensional stability of the raised portions, as the fibers are bound through entanglement rather than compression.
4Shape
If a separate patterning process is used, then design requirements are met, but production time and processing efficiency decrease
Solution Approach 1:
The patterning operation is merged with the hydroentanglement processing step itself. The support member performs dual functions: supporting the web during processing and imparting the pattern simultaneously. This eliminates sequential processing steps and allows continuous production at high speed without interruption for separate patterning operations.
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
This solution allows for lower-cost, high-bulk nonwoven products with improved absorbency and aesthetic appeal, achieved through direct integration of patterning during the manufacturing process, reducing fiber loss and enhancing fiber entanglement and product release.
Implementation Method 1
a fiber batt or web is treated with water streams or jets to cause the fibers to entangle with each other and improve the physical properties, such as strength, of the web
Implementation Method 2
the action of water jets under pressure, which act on the fibrous structure like needles
Implementation Method 3
brought onto the surface of a perforated rotary cylindrical drum, to the interior of which a partial vacuum is applied. The basic web is compressed mechanically between the porous support and the rotary drum which both advance substantially at the same speed
Implementation Method 4
a water curtain is directed onto the web and passes successively through the porous support, the compressed basic web and the supporting perforated drum which sucks up the excess water
Implementation Method 5
the sheet contact surface having a pattern including a series of raised land areas and corresponding depressions adapted to impart a texture to the nonwoven product produced thereon
Implementation Method 6
a series of through voids adapted to allow passage of both water and air from the fabric surface into the surface
Data Source
Figure 1~2
Figure 3A
Figure 3B
AI summary
A support member such as a belt or sleeve includes a topographical pattern on its sheet contact side. A plurality of land areas, corresponding depressions, through voids, and/or groove areas are formed on the top surface of the support member to produce the topographical pattern. The land areas, corresponding depressions, through voids, and/or groove areas may be formed by graving, cutting, etching, embossing, mechanical perforation or a combination thereof. The improved belt or sleeve imparts desired physical characteristics, such as bulk, appearance, texture, absorbency, strength, and hand to a nonwoven product produced thereon.