Adhesive Nozzle Shim Layout for Uniform High-Speed Diaper Bonding
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Solution Overview
Problem
Existing adhesive application systems face issues with non-uniform adhesive distribution and scattering due to varying flow rates, leading to inconsistent bonding strength and production rate limitations when applying adhesive to moving substrates like rubber threads in diaper manufacturing.
Innovation Solution
A nozzle design featuring a pattern shim, adhesive shim, and gas shim with tapered convex portions and slits, along with a head body and face plate, ensures uniform adhesive and gas distribution through precise alignment and angled ejection ports, minimizing scattering and enhancing bonding consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If adhesive is applied at high speed to increase production rate, then productivity improves, but adhesive scattering increases and bonding consistency deteriorates
Solution Approach 1:
The nozzle system dynamically adjusts the ejection timing and pattern of adhesive and gas streams to match the high-speed movement of the substrate. The oscillating pattern created by gas streams impinging on adhesive fibers allows the adhesive to be applied consistently even at high production rates, preventing scattering while maintaining bonding uniformity.
Solution Approach 2:
The adhesive application uses periodic oscillating motion generated by alternating gas streams from multiple discharge ports. This periodic action creates a controlled wave pattern in the adhesive fibers, ensuring consistent application and bonding strength even when the substrate moves at high speed through the apparatus.
2Reliability
If adhesive ejection amount is increased to prevent repelling by fast-moving substrate, then bonding reliability improves, but adhesive scattering increases causing contamination
Solution Approach 1:
The adhesive stream is segmented into multiple fibers by introducing gas streams between them. Multiple gas discharge ports are positioned to jet gas between adjacent adhesive fibers, creating separation and preventing the adhesive from scattering as a single mass. This segmentation allows sufficient adhesive quantity to be applied while maintaining control and preventing contamination.
Solution Approach 2:
Gas streams serve as an intermediary medium between the adhesive ejection system and the substrate. The gas streams impinge on the adhesive fibers to oscillate and separate them, acting as a mediator that controls adhesive behavior without direct contact with the substrate, thus preventing scattering while ensuring reliable bonding.
3Productivity
If multiple adhesive ejection ports are used to cover wide substrate area, then productivity improves, but uniformity of adhesive distribution deteriorates due to varying flow rates
Solution Approach 1:
Each adhesive ejection port is equipped with locally optimized gas discharge ports positioned at specific angles and distances. The gas streams are directed to impinge on adhesive fibers in a manner that compensates for position-dependent variations, ensuring uniform oscillation and distribution characteristics across all ejection ports regardless of their location in the array.
4Manufacturing precision
If gas stream velocity is increased to oscillate adhesive more effectively, then bonding uniformity improves, but adhesive repelling increases causing scattering
Solution Approach 1:
Gas discharge ports are positioned at different locations and angles to create localized oscillation zones for each adhesive fiber. The gas streams are directed to impinge on adhesive at optimal points to generate oscillation without excessive velocity that would cause repelling. Each location has tailored gas stream characteristics to achieve effective oscillation while preventing scattering.
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 nozzle design achieves uniform adhesive distribution and suppresses scattering, maintaining consistent bonding strength and allowing higher production rates without adhesive contamination, thus improving diaper manufacturing efficiency.
Implementation Method 1
Gas streams are jetted to fibers of a viscous fluid material ejected from the nozzle to vibrate the viscous fluid material in the predetermined direction
Implementation Method 2
cause gas streams to impinge on the fibrous liquid substantially from both sides to oscillate the liquid to thereby form an omega-shaped pattern
Data Source
AI summary
To improve distribution of adhesive and gas. A nozzle (1) includes a pattern shim (13) having a plurality of first slits (23) and a plurality of second slits (24), an adhesive shim (12) having a plurality of first holes (33), a gas shim (14), a head body (11) having an adhesive outlet (52) and an adhesive distribution groove (51) communicating with the adhesive outlet, and a face plate (15). Adhesive ejection ports are formed at openings of the plurality of first slits, and gas discharge ports are formed at openings of a plurality of second slits in such a manner that the gas discharge ports are located on both sides of each of the adhesive ejection ports. The plurality of first holes (33) communicate with the adhesive distribution groove (51). The plurality of first holes (33) are formed in such a manner that distances of the first holes (33) from the corresponding discharge ejection ports (6) become shorter as distances of the corresponding first holes from the adhesive outlet (52) become longer.