Two-Layer Non-Woven Fabric Composition for Machine Runnability

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Solution Overview

Problem

Existing non-woven wallcover base substrates with high synthetic fiber content face issues of poor machine runnability due to increased air porosity, fiber deposits, and production inefficiencies, compromising dimensional stability and printability.

Innovation Solution

A non-woven fabric with a base layer comprising 80 wt.% synthetic fibers and a top layer with up to 20 wt.% cellulosic fibers, maintaining a total synthetic fiber content of 50 wt.% or more, while ensuring good dimensional stability and printability, is produced by combining two layers with different fiber compositions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the synthetic fiber content is increased to 50 wt.% or higher, then the haptic properties and nonwoven fabric characteristics are improved, but the air porosity significantly increases causing fiber deposits, fiber flying/dusting, and poor machine runnability

Engineering Contradiction:
Improvehaptic propertiesVSAvoidfiber deposits
Core Design Contradiction:
ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The nonwoven fabric is divided into two distinct layers: a base layer with high synthetic fiber content (50-100 wt.%) providing the desired haptic properties, and a top layer with low or no synthetic fibers (0-20 wt.%) that prevents fiber deposits and flying during production. This segmentation allows each layer to fulfill different functional requirements simultaneously.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Different regions of the nonwoven fabric have different fiber compositions tailored to specific functions: the base layer is optimized for haptic characteristics with high synthetic fiber content, while the top layer is optimized for production stability with predominantly natural fibers or binder fibers, creating local quality variations throughout the product.

Inventive Principle:
Principle #3Local quality

2Reliability

If the synthetic fiber content is increased to 50 wt.% or higher, then the nonwoven fabric characteristics are improved, but machine runnability deteriorates due to fiber flying/dusting and weaker bonding

Engineering Contradiction:
Improvenonwoven fabric characteristicsVSAvoidmachine runnability
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The nonwoven fabric is divided into two distinct layers: a base layer with high synthetic fiber content (50-100 wt.%) providing the desired haptic properties, and a top layer with low or no synthetic fibers (0-20 wt.%) that prevents fiber deposits and flying during production. This segmentation allows each layer to fulfill different functional requirements simultaneously.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The top layer acts as an intermediary protective layer that prevents direct contact between the high-synthetic-fiber base layer and the coating process, thereby reducing fiber flying and deposits during production while maintaining the underlying haptic properties.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Reliability

If the synthetic fiber content is increased to 50 wt.% or higher, then the haptic properties are improved, but coating quality deteriorates due to coat strike-through, build-up on counter roll, and streaks in coated surface

Engineering Contradiction:
Improvehaptic propertiesVSAvoidcoating quality
Core Design Contradiction:
ReliabilityVSManufacturing precision

Solution Approach 1:

Different regions of the nonwoven fabric have different fiber compositions tailored to specific functions: the base layer is optimized for haptic characteristics with high synthetic fiber content, while the top layer is optimized for production stability with predominantly natural fibers or binder fibers, creating local quality variations throughout the product.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The top layer acts as an intermediary protective layer that prevents direct contact between the high-synthetic-fiber base layer and the coating process, thereby reducing fiber flying and deposits during production while maintaining the underlying haptic properties.

Inventive Principle:
Principle #24Intermediary (Mediator)

4Reliability

If the synthetic fiber content is increased to 50 wt.% or higher, then the nonwoven fabric characteristics are improved, but production efficiency decreases requiring frequent machine stoppages for cleaning

Engineering Contradiction:
Improvenonwoven fabric characteristicsVSAvoidproduction efficiency
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The nonwoven fabric is divided into two distinct layers: a base layer with high synthetic fiber content (50-100 wt.%) providing the desired haptic properties, and a top layer with low or no synthetic fibers (0-20 wt.%) that prevents fiber deposits and flying during production. This segmentation allows each layer to fulfill different functional requirements simultaneously.

Inventive Principle:
Principle #1Segmentation

Data Source

PatentEP4635729A1Non-woven fabric and method for producing the same
Publication Date: 2025.10.22 GLATFELTER DRESDEN GMBH
  • EP4635729A1 patent drawing
  • EP4635729A1 patent drawing
  • EP4635729A1 patent drawing

AI summary

The present invention relates to a non-woven fabric comprising a base layer comprising 80 wt.-% or more of synthetic fibers, and a top layer comprising cellulosic fibers and 0 to 20 wt.-% of synthetic fibers, wherein a total of the base layer and the top layer comprises 50 wt.-% or more of synthetic fibers. The present invention further relates to a method for producing a non-woven fabric, a non-woven fabric obtainable by said method and uses of the non-woven fabric.