Zigzag Bond Pattern for Nonwoven Fastener Web
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Solution Overview
Problem
Conventional nonwoven webs used as receiving components in fastening systems face challenges with pressure fluctuations during processing, leading to reduced strength and quality of fiber-to-fiber bonds, which affects the performance of the fastening system.
Innovation Solution
A nonwoven web with a bonded portion containing zigzag unit patterns disposed in a machine direction at predetermined intervals, providing a bond pattern that reduces pressure fluctuations and maintains sufficient areas of unbonded fibers for effective engagement with engaging components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a nonwoven web is used as a receiving component with fiber-to-fiber bonds formed by heated calendering rolls, then the web structure provides sufficient unbonded fibers for engagement, but pressure fluctuations during processing reduce the strength and quality of fiber-to-fiber bonds
Solution Approach 1:
The patent applies parameter changes by modifying the bonding pattern geometry from conventional designs to a specific configuration where triangles formed by adjacent contact points contain adjacent unit patterns. This geometric parameter change optimizes pressure distribution during calendering, reducing fluctuations while maintaining bond strength and web integrity for reliable fastening performance
Solution Approach 2:
The patent implements feedback by using the bonding pattern design to compensate for pressure variations during processing. The specific arrangement of contact points and unit patterns creates a self-regulating effect where the structure adapts to pressure fluctuations, ensuring consistent bond quality without requiring external pressure control mechanisms
2Ease of manufacture
If fiber-to-fiber bonds are formed by applying constant force through protrusions on calendering rolls, then bonding occurs at pressure application locations, but pressure fluctuations lead to reduced bond quality and strength
Solution Approach 1:
The patent changes the geometric parameters of the bonding pattern, specifically designing triangles formed by adjacent contact points to contain adjacent unit patterns. This parameter modification ensures that the bonding process remains simple while achieving consistent bond quality by optimizing how pressure is distributed across the web during calendering
3Adaptability or versatility
If the nonwoven web contains sufficient unbonded fibers for engagement, then fastening function is enabled, but pressure fluctuations during processing reduce overall web strength
Solution Approach 1:
The patent optimizes the geometric parameters of the bonding pattern where triangles formed by contact points contain adjacent unit patterns. This creates an optimal balance between bonded and unbonded areas, maintaining sufficient unbonded fibers for hook engagement while the optimized bond distribution reinforces the web structure to resist pressure fluctuations and maintain overall strength
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 nonwoven web achieves improved fastening strength, repeat peel strength, and mechanical strength in both machine and cross machine directions, while minimizing pressure fluctuations and enhancing the quality of fiber-to-fiber bonds.
Implementation Method 1
The fiber-to-fiber bonds are typically formed by fusing portions fibers together via, for example, heat, pressure, or sound (e.g., ultrasonic) energy
Implementation Method 2
A constant force is generally applied to one of the calendering rolls such that as the nonwoven web passes between the calendering rolls, the protrusions apply pressure to the nonwoven web
Data Source
AI summary
A nonwoven web is provided. The nonwoven web contains a side-by-side composite fiber having crimps. The composite fiber contains first and second propylene polymers. The nonwoven web contains a bonded portion that contains a bonding pattern containing zigzag unit patterns. The zigzag unit patterns are continuous and substantially parallel with a first direction and are disposed in a second direction at predetermined intervals. A triangle formed by adjacent three contact points of a first diagonal line and a second diagonal line of the unit pattern contains a part of the unit pattern that is adjacent to the triangle in the second direction.