3D Nonwoven Web Formation on Rotating Cavity Collectors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manufacturing intricate and complex three-dimensional nonwoven webs is expensive and complex using current techniques, necessitating a more cost-effective and simpler method.
Innovation Solution
Utilizing a rotating collection surface with cavities and land areas to collect continuous filaments, applying fluid pressure to create regions with varying intensive properties, and bonding the intermediate web to form a final three-dimensional web.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional three-dimensional nonwoven making belts are used, then intricate and complex three-dimensional nonwoven webs can be produced, but the manufacturing process becomes expensive and complex
Solution Approach 1:
The collection surface is segmented into multiple regions with different properties (raised areas with lower fluid permeability and cavities with higher fluid permeability), allowing different filament densities and web properties to be formed in different zones without requiring complex manufacturing equipment
Solution Approach 2:
The collection surface is made rotating instead of stationary, enabling dynamic filament collection patterns that create three-dimensional structures. The rotation allows the same simple surface structure to produce varied web configurations through motion rather than through complex mechanical assembly
2Shape
If traditional three-dimensional nonwoven making belts are used, then intricate and complex three-dimensional nonwoven webs can be produced, but manufacturing costs increase
Solution Approach 1:
The patent uses a simple rotating collection surface that can be relatively inexpensive to manufacture compared to traditional three-dimensional nonwoven making belts. The surface features (raised areas and cavities) are formed through straightforward manufacturing processes, reducing overall production costs while achieving the desired three-dimensional web structures
3Device complexity
If a rotating collection surface with cavities and land areas is used, then manufacturing costs and complexity are reduced, but the surface must accommodate varying fluid permeability regions
Solution Approach 1:
Different regions of the collection surface are given different local properties: raised areas with lower fluid permeability for denser filament collection and cavities with higher fluid permeability for more open structures. This local differentiation is achieved through straightforward surface modification techniques rather than complex manufacturing processes
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
Produces high-quality, consumer-desirable three-dimensional nonwoven webs with varying properties like basis weight, volumetric density, caliper, and air permeability, reducing manufacturing costs and complexity.
Implementation Method 1
applying a fluid pressure to the collection surface and collecting the filaments on the collection surface to create an intermediate three-dimensional web
Data Source
AI summary
A method of making a three-dimensional web is provided. The method comprises spinning continuous filaments from a spinneret, moving the spun continuous filaments along a travel path having an end, and rotating a collection surface at or proximate to the end of the travel path. The collection surface comprises cavities and land areas. The land areas are tangentially planar with an outer surface of the collection surface. The cavities are recessed with respect to the outer surface of the collection surface. The method comprises applying a fluid pressure to the collection surface and collecting the filaments on the collection surface to create an intermediate three-dimensional web having first regions formed in the cavities and second regions formed on the land areas. The first and second regions differ in at least one intensive property. The method comprises bonding the intermediate web using a bonding operation to form a final three-dimensional web.