Asymmetric Nonwoven Funnel for Fiber Alignment
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Solution Overview
Problem
Existing fleece funnels, such as those disclosed in CH 359073 A, suffer from uncontrolled fiber twisting and chaotic fiber alignment at high speeds, leading to thick points and Z-folded fibers, which negatively impact subsequent processing of the sliver, and are not suitable for compressing nonwoven fabrics into slivers due to their rotationally symmetrical and narrow entry cross-section.
Innovation Solution
A fleece funnel with an elongated entry side, a guide surface between the inlet and outlet sides to direct the fiber fleece, and a gradation that imparts a perpendicular twist, forming a vortex to reduce turbulence and enhance fiber alignment, along with an intermediate surface to increase fiber interconnection and adhesion, resulting in improved sliver quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a rotationally symmetrical funnel with narrow inlet cross-section is used, then the device structure is simple, but the fibers are bundled together in an uncontrolled and chaotic manner at high speeds, leading to thick spots and Z-shaped folds
Solution Approach 1:
The patent applies asymmetry by changing the funnel from a rotationally symmetrical design to an asymmetric design with an elongated inlet cross-section. The inlet has a first inlet side and a second inlet side with different characteristics, allowing fibers to be guided in a controlled manner rather than chaotically. This asymmetric configuration prevents uncontrolled fiber bundling while maintaining structural simplicity.
Solution Approach 2:
The funnel is segmented into distinct functional zones: an inlet region with elongated cross-section for controlled fiber entry, a convergence region with guide surfaces to direct fibers toward the outlet, and an outlet region. This segmentation allows each zone to perform its specific function optimally, preventing chaotic fiber motion while maintaining overall device simplicity.
2Productivity
If the fiber web is guided at high speed through a conventional funnel, then productivity is improved, but turbulence increases causing thick spots and Z-folded fibers
Solution Approach 1:
The patent employs curved guide surfaces within the funnel that smoothly direct fibers from the inlet to the outlet. These curved surfaces replace sharp angles and abrupt transitions, reducing turbulence and preventing fiber distortion at high speeds. The smooth curvature ensures uniform fiber flow while maintaining high productivity.
3Ease of manufacture
If the inlet cross-section is narrow and rotationally symmetrical, then the device is easy to manufacture, but it is unsuitable for compacting nonwoven fabrics into uniform slivers
Solution Approach 1:
The funnel is designed with an asymmetric elongated inlet cross-section that is well-suited for processing nonwoven fabrics. This asymmetric shape guides the fabric in a controlled manner through the convergence zone, ensuring uniform sliver formation. The design remains manufacturable using standard machining processes while dramatically improving sliver 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
The proposed fleece funnel design effectively guides fiber fleeces at high speeds, reducing slubs and Z-folded fibers, enhancing sliver adhesion and quality by creating a controlled vortex that minimizes acceleration forces and directs fibers uniformly into the exit opening.
Implementation Method 1
The incoming fiber web encounters the guide surface and is deflected towards the outlet opening. The guide surface thus compacts the fiber web into a fiber ribbon.
Implementation Method 2
This step imparts a swirl to the portion of the fiber web moving from the guide surface towards the exit opening, acting perpendicular to the direction of movement. This creates a vortex, as viewed from the direction of movement, which originates in the step area and propagates into the exit opening.
Implementation Method 3
The fiber web coming from the direction of the inlet side strikes this intermediate surface at an almost perpendicular angle. Due to this impact, not all individual fibers of the nonwoven are parallel; in particular, some of the individual fibers cross over each other. This increases the bond between the individual fibers thus arranged, which in turn increases the adhesion of the fiber web.
Data Source
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AI summary
The invention relates to a nonwoven hopper for compacting a fiber web, particularly on a drafting machine, carding machine, or combing machine, comprising an elongated inlet side (2) through which the spread-out fiber web enters the hopper (1) and an outlet side (3) through which the fiber web exits the hopper (1) as a fiber ribbon. An outlet opening (4) is arranged at the outlet side (3). At least one guide surface (5a, 5b, 5c, 5d, 5e) for the fiber web is arranged between the inlet side (2) and the outlet side (3) to guide the fiber web flowing into the hopper (1) towards the outlet opening (4). Between the guide surface (5a, 5b, 5c, 5d, 5e) and the exit opening (4) a step (6a, 6b, 6c, 6d, 6e) is arranged and between the step (6a, 6b, 6c, 6d, 6e) and the exit opening (4) at least one intermediate surface (7a, 7b, 7c, 7d) is arranged.