Airlaying Equipment With Movable Baffles for Sharp Web Edges
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing air-laid webs with short fibers result in longitudinally extending lateral edges that are not sharply defined, leading to waste and inefficiencies in subsequent processing steps.
Innovation Solution
An apparatus and process utilizing movable baffle plates positioned between the collector tool and the fiber supply or suction system to control the lateral edges of the web, allowing for precise width adjustment and sharp edge definition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fluid jets (water or air) are applied to separate and trim the web, then the lateral edges can be separated, but the edges are not sharply defined and require further trimming
Solution Approach 1:
The baffle plates are positioned upstream in the forming box to pre-define the lateral boundaries of the web before it is fully formed. This preliminary action ensures that fibers are deposited only within the desired width, creating sharply defined edges directly during the forming process rather than requiring post-forming trimming operations.
Solution Approach 2:
The invention extracts the edge definition function from the trimming stage and moves it to the forming stage. By using baffle plates to physically block fibers from reaching certain areas during deposition, the solution eliminates the need for complex fluid jet systems and subsequent trimming operations.
2Productivity
If large width apparatuses are used to produce air-laid structures, then production capacity is increased, but lateral edges are not sharply defined and waste is generated
Solution Approach 1:
The baffle plates create localized control within the larger forming box, defining specific regions where fibers should be deposited. This allows the apparatus to maintain large overall dimensions for high productivity while locally controlling fiber deposition to eliminate waste at the edges.
3Manufacturing precision
If movable baffle plates are added to define web edges, then edge sharpness is improved, but device complexity increases
Solution Approach 1:
The baffle plates are made movable to allow dynamic adjustment of the web width during operation. This enables the system to adapt to different product requirements without changing the physical apparatus, maintaining edge sharpness while providing flexibility for various production needs.
4Manufacturing precision
If additional trimming and wrapping steps are added to the process, then consumer appeal is improved, but processing time and complexity increase
Solution Approach 1:
By pre-defining the web edges during the forming process using baffle plates, the invention eliminates the need for subsequent trimming and wrapping operations. This preliminary action saves significant processing time and simplifies the overall manufacturing workflow while maintaining high edge quality.
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
Enables the production of webs with sharply defined lateral edges, reducing waste and improving processing efficiency by eliminating the need for additional cutting or wrapping, and enhancing material distribution.
Implementation Method 1
a suction system for sucking air through the foraminous surface
Implementation Method 2
forming the longitudinally extending lateral edges by directing the stream of air, fibers and particulates, if present, between the pair of baffle plates
Data Source
Figure 1A~1E
Figure 1B
Figure 2A~2D
AI summary
The present invention is an apparatus and a process for forming a fibrous web comprising short fibers and optionally particulate material, whereby the apparatus respectively the process is adapted to provide well defined straight and sharp longitudinally extending lateral edge, preferably further allowing easy adjustment of the web width.