Unitary nonwoven material
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Solution Overview
Problem
Existing nonwoven materials used in pre-moistened cleaning products, such as wipes and mopping cloths, quickly deplete their liquid content and lack effective scrubbing properties, necessitating frequent replacement and additional cleaning tools.
Innovation Solution
A multi-layer nonwoven material comprising bonded natural cellulosic fibers with high capillary action and bonded synthetic fibers, including bicomponent binder fibers, designed to absorb and metered-release liquid, enhancing liquid retention and scrubbing efficacy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional nonwoven materials are used in pre-moistened cleaning products, then the material can initially hold liquid, but the liquid is quickly depleted and the material becomes unusable in a short period
Solution Approach 1:
The nonwoven material is structured with multiple layers having different liquid release rates. The top layer contains shorter fibers that release liquid quickly for immediate cleaning, while the bottom layer contains longer fibers that release liquid slowly for extended duration, resolving the contradiction between initial liquid availability and sustained release
Solution Approach 2:
The patent varies the fiber length parameter within the nonwoven material, using a mixture of short and long fibers to create different capillary action characteristics. This parameter variation enables the material to provide both rapid initial liquid release and sustained prolonged release, addressing the duration contradiction
2Quantity of substance
If single-use pre-moistened materials are used, then liquid retention is achieved, but scrubbing action is insufficient requiring additional products
Solution Approach 1:
The nonwoven material is designed to perform multiple functions simultaneously: it provides liquid retention through capillary action, delivers scrubbing action through its textured fiber structure, and maintains structural integrity during use. This multi-functionality eliminates the need for separate scrubbing tools
Solution Approach 2:
The patent combines different fiber types and lengths in a composite nonwoven structure, creating material with enhanced mechanical properties for scrubbing while maintaining liquid retention capabilities. The composite structure provides both the softness needed for liquid absorption and the texture required for effective scrubbing
3Productivity
If pre-moistened materials deplete liquid quickly, then initial cleaning is effective, but frequent replacement is required increasing product consumption
Solution Approach 1:
The nonwoven material provides continuous liquid release over an extended period through its multi-layer fiber structure. The gradual depletion of liquid from the bottom layer maintains cleaning effectiveness throughout use, eliminating the need for frequent replacements and reducing overall product consumption
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, allowing for extended cleaning coverage and improved scrubbing performance, reducing the need for frequent product replacement.
Implementation Method 1
bonded natural cellulosic fibers characterized by high capillary action
Implementation Method 2
provide a metered release of the liquid
Data Source
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.