Angled Injection Forming Box for Coforming Stability
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Solution Overview
Problem
Existing coforming processes face issues with jet stability, heat transfer, and weight distribution due to the perpendicular injection of filaments and pulp fibers, leading to instability and imperfections in the fibrous structure formation.
Innovation Solution
A forming box design that angles the introduction of materials at less than 90 degrees, minimizing separated flow and maximizing heat transfer by optimizing the geometry and aerodynamics, and incorporating liquid water for rapid heat removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If materials are injected at 90 degrees in a forming box, then commingling of filaments and pulp fibers is achieved, but jet stability deteriorates due to air jet instability
Solution Approach 1:
The patent changes the injection angle parameter from the conventional 90 degrees to an oblique angle (less than 90 degrees). This parameter change resolves the contradiction by reducing air jet instability while maintaining effective material commingling, thereby improving both jet stability and formation quality simultaneously.
2Quantity of substance
If perpendicular injection (90 degrees) is used, then material commingling is achieved, but weight distribution deteriorates due to CD variation effects
Solution Approach 1:
The injection angle parameter is changed from 90 degrees to an oblique angle, which reduces the sensitivity of weight distribution to CD variations in fiber velocity. This resolves the contradiction by stabilizing weight distribution while maintaining proper material quantity commingling.
3Temperature
If open non-enclosed environment is used for coforming, then equipment complexity is reduced, but heat transfer capability deteriorates due to limited air entrainment
Solution Approach 1:
The patent introduces a forming box as an intermediary enclosed environment that enables controlled air flow and enhanced heat transfer. This resolves the contradiction by providing superior heat transfer capability through controlled air entrainment while accepting the necessary structural complexity of an enclosed forming box.
4Stability of the object's composition
If 90 degree injection angle is used, then simple geometry is maintained, but flow separation increases leading to stalled flow zones
Solution Approach 1:
The injection angle is changed from 90 degrees to an oblique angle, which eliminates flow separation and stalled flow zones. This parameter change improves flow stability while maintaining relatively simple injection geometry, resolving the contradiction between flow stability and geometric simplicity.
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
This design enhances jet stability, reduces imperfections, and improves heat transfer and weight distribution, resulting in a more uniform and efficient fibrous structure formation.
Implementation Method 1
minimizing separated flow and maximizing heat transfer by optimizing the geometry and aerodynamics
Implementation Method 2
maximizing heat transfer by optimizing the geometry and aerodynamics
Implementation Method 3
incorporating liquid water for rapid heat removal
Data Source
AI summary
Coforming processes for commingling two or more separate materials, for example solid additives, for example fibers and/or particulates, and filaments, and equipment; namely, forming boxes, useful in such coforming processes and more particularly to coforming processes for commingling filaments with one or more fibers, such as pulp fibers, and forming boxes useful therein are provided.