A vibration-assisted air-laid system for improving fiber uniformity

Abstract

The utility model relates to a kind of vibration auxiliary air-laid system for improving fiber uniformity, including feeding device, uniform device and discharging device, feeding device is used to send single fiber to uniform device after completing fiber separation, uniform device includes box, several transport plates, camera and several rotating motors, transport plate swings by rotating motor, transport plate is used to shake even and send fiber to discharging device, camera is used to monitor the fiber uniformity on transport plate and control rotating motor drive transport plate shake, discharging device includes discharging conveyor belt, fan and compression roller, discharging conveyor belt is installed at the bottom end of box, fan is installed below discharging conveyor belt, compression roller is installed above discharging conveyor belt.The utility model of a kind of vibration auxiliary air-laid system for improving fiber uniformity can improve the fiber uniformity after fiber carding stage of air-laid machine, can satisfy the even falling in single fiber conveying process, improve web uniformity.

Description

Technical Field

[0001] This application relates to a vibration-assisted airflow web-forming system for improving fiber uniformity, belonging to the field of nonwoven machinery technology. Background Technology

[0002] An airflow web forming machine is an advanced fiber processing device that uses airflow to suspend fibers in mid-air, forming a uniform fiber web on a frame. Airflow web forming machines have wide applications in various industrial fields. They can be used to produce various filter materials, such as air filters, liquid filters, and automotive oil filters. By controlling the type, density, and structure of the fibers, filter materials with different filtration precisions and applicable scenarios can be customized. Airflow web forming machines can also be used to produce various fiber textiles, such as fabrics, clothing, and textile handicrafts. By controlling the type, length, and density of the fibers, textiles of different styles and uses can be manufactured to meet market demands. Furthermore, airflow web forming machines can also be used to produce filter masks, medical dressings, sound insulation materials, decorative materials, and other products, demonstrating broad market prospects and application potential.

[0003] The operation of an air-jet web forming machine includes fiber conveying and fiber combing. First, raw materials for manufacturing the fiber web, typically cellulose, polymers, or metal fibers, need to be prepared. These raw materials undergo pretreatment, such as unwinding, unwinding, and cutting, to facilitate further processing. The prepared fiber material is introduced into the working area of ​​the air-jet web forming machine via a conveying system. Once the fiber material is in the working area, a high-speed airflow is sprayed above the fibers through a nozzle system. This airflow can be compressed air, nitrogen, or other inert gases, and its speed and direction can be adjusted by a control system. As the airflow interacts with the fibers, the fibers are carried and suspended in the air. During this process, the fibers form a web-like structure in the air, gradually depositing and arranging on the web frame. Once the desired mesh structure is formed on the web frame, a curing process is usually performed to ensure the stability and durability of the fiber web. Curing can be accomplished through heat treatment, chemical treatment, or other methods.

[0004] Although air-jet web forming machines play a crucial role in fiber web manufacturing, existing air-jet web forming machines suffer from significant drawbacks. Airflow instability, improper nozzle design, or defects in the fiber delivery system often lead to poor fiber uniformity in web formation. These problems affect the quality and performance of the fiber web, increasing production costs and the defect rate. Solving this problem requires improving the design and control system of air-jet web forming machines to ensure uniform fiber distribution during the web forming process, thereby producing high-quality fiber web products.

[0005] In view of the limitations of the prior art, the present invention proposes a novel vibration-assisted airflow web forming system to improve fiber uniformity and solve the problem of uneven fiber distribution. Utility Model Content

[0006] The purpose of this invention is to provide a vibration-assisted airflow web forming system that can improve the fiber uniformity after the fiber combing stage of an airflow web forming machine, meet the requirement of uniform falling during the single fiber conveying process, and improve the web forming uniformity.

[0007] To achieve the above objectives, the technical solution adopted by this utility model is as follows: a vibration-assisted airflow web forming system for improving fiber uniformity, comprising a feeding device, a uniformizing device, and a discharging device, which are arranged sequentially; the uniformizing device includes a box, several conveying plates, a camera, and several rotary motors, the conveying plates are obliquely installed inside the box, one end of the conveying plate is rotatably connected to the box, and the conveying plate is oscillating through the rotary motors, the camera is installed on the top of the box, the camera is used to monitor the fiber uniformity on the conveying plate and control the rotary motors to drive the conveying plate to vibrate, the discharging device includes a discharging conveyor belt, a fan, and a pressure roller, the discharging conveyor belt is installed at the bottom of the box, the fan is installed below the discharging conveyor belt, and the pressure roller is installed above the discharging conveyor belt.

[0008] By adopting the above technical solution, the single fibers that have been separated into yarns enter the feeding device from the discharge port. The feeding device transports the separated single fibers to the homogenizing device. The homogenizing device makes the incoming fibers more uniform. After homogenization, the fibers fall into the discharge device. The discharge device further fixes the random arrangement of the fibers, removes dust and impurities from the production process, and further flattens the fiber layer after passing through the discharge device to ensure uniform fiber thickness and density.

[0009] The vibration-assisted airflow web forming system for improving fiber uniformity of this utility model is further configured as follows: the feeding device includes a feeding conveyor belt, which is located at the upper end of the box and the conveying direction of the feeding conveyor belt is towards the inside of the box.

[0010] The vibration-assisted airflow web forming system for improving fiber uniformity of this utility model is further configured as follows: a plurality of conveyor plates including conveyor plate one, conveyor plate two and conveyor plate three located in the upper, middle and lower layers of the box body respectively. The end of conveyor plate one connected to the box body is located at the end of the conveying direction of the feeding conveyor belt, the end of conveyor plate two connected to the box body is located at the end of the conveying direction of conveyor plate one, and the end of conveyor plate three connected to the box body is located at the end of the conveying direction of conveyor plate one.

[0011] By adopting the above technical solution, multi-level vibration disturbance and control enable each bundle of single fibers to eventually form different orientations during the same vibration and free fall process after entering the system, thereby achieving the uniformity of fiber web laying.

[0012] The vibration-assisted airflow web-forming system for improving fiber uniformity of this utility model is further configured such that: the transport direction of transport plate one is towards the inside of the box, the transport direction of transport plate two is towards the outside of the box, and the transport direction of transport plate three is towards the outside of the box.

[0013] The vibration-assisted airflow web-forming system for improving fiber uniformity of this utility model is further configured as follows: the conveyor plates are vibrated by a rotary motor, the vibration frequency adjustment range of conveyor plate one is 10–25 Hz, the vibration frequency adjustment range of conveyor plate two is 20–40 Hz, and the adjustment range of conveyor plate three is 5–15 Hz.

[0014] By employing the above technical solution, vibration can uniformly disrupt parallel single fibers into different angles, facilitating subsequent uniform web formation. Vibration also ensures smooth fiber movement after uniform alignment. Specifically, the vibration frequency of conveyor plate one is adjustable from 10–25 Hz, with a recommended operating frequency of 20 Hz, used to disrupt the initially parallel fiber alignment. The vibration frequency of conveyor plate two is adjustable from 20–40 Hz, with a recommended operating frequency of 30 Hz, used to further homogenize fiber distribution and promote initial web formation. Conveyor plate three serves as a buffer layer with a lower vibration frequency, adjustable from 5–15 Hz, with a recommended operating frequency of 10 Hz, to achieve smooth fiber transition and discharge control.

[0015] The vibration-assisted airflow web-forming system for improving fiber uniformity of this utility model is further configured as follows: a camera monitors the fiber uniformity on the transport plate in real time by taking CT scans, and feeds back control signals to the rotary motor to adjust the vibration frequency and angle of the transport plate.

[0016] By adopting the above technical solution, to ensure that the camera can accurately monitor the distribution of all fibers, including the bottom transport plate, all three transport plates in this system are made of transparent acrylic material. This material has excellent optical transmittance, allowing the camera to directly penetrate the visual channel from the top, enabling real-time observation of fiber accumulation and uniformity on the multi-layer transport plates. The transparent plate design effectively avoids the problem of traditional opaque structures obstructing the field of view, thus improving monitoring accuracy.

[0017] The vibration-assisted airflow web forming system for improving fiber uniformity of this utility model is further configured such that: the discharge conveyor belt is located at the end of the three transport directions of the conveying plate, and the movement direction of the discharge conveyor belt is towards the outside of the box.

[0018] The vibration-assisted airflow web-forming system for improving fiber uniformity of this utility model is further configured such that the conveyor belt of the discharge conveyor belt is a web surface.

[0019] By adopting the above technical solution, dust and impurities can pass through the conveyor belt and enter the fan.

[0020] Compared with the prior art, the present invention has the following beneficial effects: 1. The camera in this utility model monitors the fiber uniformity in real time and controls the vibration of the conveyor plate, and adjusts the vibration frequency and angle of the rotary motor through feedback control signals to improve fiber uniformity.

[0021] 2. The three-layer conveying plate in this utility model undergoes preliminary vibration disturbance, secondary uniform vibration, and final vibration balancing, respectively, so that the fiber arrangement is more uniform and the fiber direction is more interlaced.

[0022] 3. The fan in this utility model can provide suction to ensure that the fiber layer is tightly attached to the discharge conveyor belt and remove dust and impurities generated during the fiber homogenization process. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the internal structure of the vibration-assisted airflow web-forming system for improving fiber uniformity according to this utility model; Figure 2 This is a schematic diagram of the structure of the vibration-assisted airflow web-forming system for improving fiber uniformity according to this utility model. Detailed Implementation

[0024] Please refer to the instruction manual appendix. Figure 1 To be continued Figure 2 As shown, this utility model is a vibration-assisted airflow web forming system for improving fiber uniformity. It comprises a feeding device, a uniformizing device, and a discharging device. Single fibers that have already been separated into yarns enter the feeding device from the discharging port. The feeding device transports the separated single fibers to the uniformizing device. The uniformizing device makes the incoming fibers more uniform. After uniformization, the fibers fall into the discharging device. The discharging device further fixes the random arrangement of the fibers, while removing dust and impurities from the production process. Furthermore, the fiber layer is further flattened after passing through the discharging device to ensure uniform fiber thickness and density.

[0025] The feeding device includes a feeding conveyor belt 1, which is horizontally arranged and its transport direction is towards the interior of the homogenizing device. The feeding conveyor belt 1 is used to transport single fibers into the homogenizing device.

[0026] The uniformizing device mainly consists of a box 3, several conveyor plates, a camera 4, and several rotary motors. The feeding conveyor belt 1 is located at the top of the box 3, and several conveyor plates are located below the end of the feeding conveyor belt 1. One end of the conveyor plate is rotatably connected to the box 3. The rotary motor is installed on the box 3, and the output end of the rotary motor is connected to the rotation point of the conveyor plate. The output end of the rotary motor drives the conveyor plate to swing. The conveyor plate is used to shake and transport the fiber to the discharge device. The camera 4 is installed at the top of the box 3. The camera 4 is used to monitor the fiber uniformity on the conveyor plate and control the rotary motor to drive the conveyor plate to shake.

[0027] Several conveyor plates include three layers—conveyor plate 5, conveyor plate 10, and conveyor plate 11—located in the upper, middle, and lower layers within the housing 3. Conveyor plates 5, 10, and 11 are vibrated by rotary motors 2, 22, and 33, respectively. Conveyor plate 5 is connected to the housing 3 at the end of the conveying direction of the feed conveyor belt 1; conveyor plate 20 is connected to the housing 3 at the end of the conveying direction of conveyor plate 5; and conveyor plate 11 is connected to the housing 3 at the end of the conveying direction of conveyor plate 5. The conveying direction of conveyor plate 5 faces inwards from the housing 3, while that of conveyor plate 20 and conveyor plate 11 faces outwards from the housing 3. The vibration of these three layers of conveyor plates makes the fiber arrangement more uniform and the fiber directions more interlaced.

[0028] The conveyor plate 5 is vibrated at high frequency by the rotary motor 2. The working angle of the conveyor plate 5 relative to the horizontal plane is such that during the vibration, the parallel single fibers in the same direction can be evenly disordered into different angles, so as to facilitate the subsequent uniform web formation.

[0029] The second conveyor plate 10 is vibrated by the second rotary motor 12 at a higher frequency and with a more intense vibration than the first conveyor plate 5, which causes the single fibers with different orientations to be evenly distributed and initially linked into a web. In addition, the working angle of the second conveyor plate 10 relative to the horizontal plane is smaller than that of the first conveyor plate 5, resulting in a lower fiber movement speed on the second conveyor plate 10 compared to the first conveyor plate 5. This leads to a higher fiber distribution density on the second conveyor plate 10 and a better web formation effect.

[0030] The conveyor plate 311 mainly serves as a buffer, allowing the single fiber to be smoothly discharged into the discharge device below.

[0031] In a preferred embodiment, the vibration frequency of conveyor plate 5 is adjustable from 10 to 25 Hz, with a recommended operating frequency of 20 Hz, used to disrupt the initially parallel arrangement of fibers. The vibration frequency of conveyor plate 20 is adjustable from 20 to 40 Hz, with a recommended operating frequency of 30 Hz, used to further homogenize fiber distribution and facilitate initial web formation. Conveyor plate 31 serves as a buffer layer with a lower vibration frequency, adjustable from 5 to 15 Hz, with a recommended operating frequency of 10 Hz, to achieve smooth fiber transition and discharge control. Through the aforementioned multi-layered vibration disturbance and control, each bundle of single fibers, after entering the system and undergoing the same vibration and free fall, ultimately forms different orientations, thereby achieving uniformity in fiber web formation.

[0032] Camera 4 is mounted on the top of housing 3, positioned above the conveyor plates. Camera 4 performs real-time monitoring of the fiber uniformity on the conveyor plates using a CT scan method, and simultaneously sends control signals to the rotary motor. To ensure that camera 4 can accurately monitor the distribution of all fibers, including the bottom conveyor plate, all three layers of conveyor plates in this system are made of transparent acrylic material. This material has excellent optical transmittance, allowing the camera to directly penetrate the visual channel from the top, enabling real-time observation of fiber accumulation and uniformity on the multi-layer conveyor plates. The transparent plate design effectively avoids the problem of traditional opaque structures obstructing the field of view, thus improving monitoring accuracy.

[0033] The discharge device includes a discharge conveyor belt 7, a blower 8, and a pressure roller 6. The discharge conveyor belt 7 is installed at the bottom of the box 3. The blower 8 provides suction to make the fiber layer stick tightly to the discharge conveyor belt 7, and also sucks away dust and impurities generated during fiber combing and homogenization. The fiber layer is further flattened by the pressure roller 6 to ensure that the thickness and density of the fiber web are uniform.

[0034] The conveyor belt of the discharge conveyor belt 7 has a fine mesh surface, which allows dust and impurities to pass through the conveyor belt and enter the blower 8.

[0035] The blower 8 is located below the mesh surface of the discharge conveyor belt 7. The fibers are evenly shaken by the conveyor plate 11 and are evenly adsorbed onto the discharge conveyor belt 7 by gravity and the suction of the blower 8. The blower 8 adsorbs fibers on one hand and removes dust and impurities generated during the fiber combing and homogenization process on the other.

[0036] The pressure roller 6 is positioned above the discharge conveyor belt 7. The pressure roller 6 contacts the discharge conveyor belt 7. The fibers are transported by the discharge conveyor belt 7 through the pressure roller 6, which further flattens the fiber layer and transports it to the web forming device.

[0037] The working principle of the vibration-assisted airflow web-forming system for improving fiber uniformity of this invention is as follows: The single fibers, having already been separated, enter the feeding conveyor belt 1 from the discharge port. The feeding conveyor belt 1 transports the single fibers to conveyor plate 5. At this point, the fibers are relatively parallel and neatly arranged. Under the monitoring of camera 4, rotary motors 1-2, 2-12, and 3-13 are controlled to vibrate conveyor plates 1-5, 2-10, and 3-11. The single fiber first enters the conveyor plate 5, which is driven by the rotary motor 2 to vibrate at high frequency. The fiber is subjected to irregular forces on the conveyor plate 5, gradually losing its original parallel alignment and becoming randomly oriented. The overall operating angle of the conveyor plate 5 can be perpendicular to the fiber's direction of movement or at a certain angle. This vibration generates lateral and longitudinal disturbances during fiber transport, disrupting the fiber alignment.

[0038] The single fibers then enter the second conveyor plate 10. The second conveyor plate 10 is driven by a second rotary motor 12 to vibrate at a higher frequency than the first conveyor plate 5, causing the single fibers with different orientations to be evenly distributed and initially linked into a web. The overall operating angle of the second conveyor plate 10 is smaller than that of the first conveyor plate 5, resulting in a lower fiber movement speed on the second conveyor plate 10, thus leading to a higher fiber distribution density and better web formation. The vibration further makes the fiber distribution on the second conveyor plate 10 more uniform and randomized.

[0039] The single fiber enters the conveyor plate 311 for the last time. The conveyor plate 5 is driven by the rotary motor 313 to operate at a low frequency vibration angle. The overall working angle is small, which still helps to fine-tune the fiber arrangement and ensure that each fiber is oriented in different directions as randomly as possible. The conveyor plate 311 mainly plays a buffering role to ensure that the fibers enter the discharge port smoothly after being evenly arranged.

[0040] After being vibrated by the conveyor plate 311, the fibers fall into the discharge conveyor belt 7 below in a free fall state by gravity and the suction of the fan 8.

[0041] The blower 8 evenly attracts the fibers onto the discharge conveyor belt 7. This process further fixes the random arrangement of the fibers while removing dust and impurities from the production process. Finally, the fibers are transported by the discharge conveyor belt 7 through the pressure roller 6, which further flattens the fiber layer, ensuring uniform thickness and density of the fiber web.

[0042] The above-described specific embodiments are merely preferred embodiments of this invention and are not intended to limit this invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this invention should be included within the protection scope of this invention.

Claims

1. A vibration-assisted airflow web-forming system for improving fiber uniformity, characterized in that: It includes a feeding device, a homogenizing device, and a discharging device, which are arranged sequentially. The homogenizing device includes a box, several conveyor plates, a camera, and several rotary motors. The conveyor plates are installed obliquely inside the box, with one end of the conveyor plate rotatably connected to the box. The conveyor plates are oscillating through the rotary motors. The camera is installed on the top of the box and is used to monitor the fiber uniformity on the conveyor plates and control the rotary motors to drive the conveyor plates to shake. The discharging device includes a discharging conveyor belt, a fan, and a pressure roller. The discharging conveyor belt is installed at the bottom of the box, the fan is installed below the discharging conveyor belt, and the pressure roller is installed above the discharging conveyor belt.

2. The vibration-assisted airflow web-forming system for improving fiber uniformity according to claim 1, characterized in that: The feeding device includes a feeding conveyor belt, which is located at the top of the box and the conveying direction of the feeding conveyor belt is towards the inside of the box.

3. The vibration-assisted airflow web-forming system for improving fiber uniformity according to claim 1, characterized in that: Several conveyor plates include conveyor plate one, conveyor plate two and conveyor plate three located in the upper, middle and lower layers of the box body respectively. The end of conveyor plate one connected to the box body is located at the end of the conveying direction of the feeding conveyor belt. The end of conveyor plate two connected to the box body is located at the end of the conveying direction of conveyor plate one. The end of conveyor plate three connected to the box body is located at the end of the conveying direction of conveyor plate one.

4. The vibration-assisted airflow web-forming system for improving fiber uniformity according to claim 3, characterized in that: The transport direction of transport plate one is towards the inside of the container, the transport direction of transport plate two is towards the outside of the container, and the transport direction of transport plate three is towards the outside of the container.

5. A vibration-assisted airflow web-forming system for improving fiber uniformity according to claim 3, characterized in that: The conveyor plates are vibrated by a rotary motor. The vibration frequency adjustment range of conveyor plate one is 10–25 Hz, that of conveyor plate two is 20–40 Hz, and that of conveyor plate three is 5–15 Hz.

6. The vibration-assisted airflow web-forming system for improving fiber uniformity according to claim 1, characterized in that: The camera monitors the fiber uniformity on the transport plate in real time by taking CT scans and sends control signals to the rotary motor to adjust the vibration frequency and angle of the transport plate.

7. The vibration-assisted airflow web-forming system for improving fiber uniformity according to claim 1, characterized in that: The discharge conveyor belt is located at the end of the three transport directions of the conveying plate, and the direction of movement of the discharge conveyor belt is towards the outside of the box.

8. The vibration-assisted airflow web-forming system for improving fiber uniformity according to claim 1, characterized in that: The conveyor belt of the discharge conveyor is made of mesh.

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