Hot-Air Bonding Drum With Structuring Shell for Nonwoven Patterning
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Solution Overview
Problem
Existing methods for bonding nonwoven fabrics with thermally fusible fibers using hot gases do not effectively combine the processes of bonding and structuring, often resulting in incomplete patterning and lack of control over the textile's appearance and volume.
Innovation Solution
A device and method utilizing a gas-permeable drum with a structuring shell featuring larger openings than the drum's surface, combined with controlled suction and temperature, to bond and pattern nonwoven fabrics by directing hot air through the material web, ensuring thorough bonding and patterning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a gas-permeable drum with a structuring shell is used to bond nonwoven fabrics, then bonding completeness and patterning quality are improved, but device complexity increases
Solution Approach 1:
The structuring shell is nested on the outer circumference of the gas-permeable drum, creating a multi-layered configuration where the drum provides gas permeability and the shell provides patterning. This nested arrangement allows both functions to be integrated in a compact manner, improving patterning quality while managing device complexity through functional integration.
Solution Approach 2:
The gas-permeable drum with the structuring shell serves multiple functions simultaneously: it provides gas permeability for hot air flow, creates patterning through the shell's openings, and enables bonding through controlled suction. This multi-functionality improves manufacturing precision by combining bonding and patterning in one device, while the complexity increase is offset by eliminating the need for separate bonding and patterning devices.
2Manufacturing precision
If controlled suction is applied to draw hot air through the material web, then bonding completeness is improved, but energy consumption increases
Solution Approach 1:
The suction unit continuously draws hot air through the material web during the entire bonding process, ensuring consistent and complete bonding across the entire surface of the nonwoven fabric. This continuous action improves bonding completeness by eliminating gaps or incomplete bonding areas, while the energy consumption is optimized by maintaining steady-state operation rather than intermittent high-power cycles.
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 solution enables comprehensive bonding and structuring of nonwoven fabrics, enhancing their appearance and volume while preventing seam imprints and fraying, allowing for precise control over the textile's texture and pattern.
Implementation Method 1
a suction unit by means of which the drum is placed under suction such that the hot air flows out of the treating chamber through the material web to be bonded
Implementation Method 2
a heater for heating the air that is conducted out of the drum
Implementation Method 3
bonding a nonwoven fabric that has thermally fusible fibers and/or filaments
Data Source
AI summary
In a device for bonding web-shaped textile products by means of hot gases, in particular for bonding a nonwoven fabric that has thermally fusible fibers and/or filaments, comprisinga drum that is rotatably mounted within a treating chamber to which hot air is supplied, said drum comprising a circumferential surface which is designed to be gas-permeable by means of a plurality of openings and which is partly looped by the web to be bondedthe device also comprises a suction unit which is paired with the drum and by means of which the drum is placed under suction such that the hot air flows out of the treating chamber through the material web to be bonded, andthe device comprises a heater for heating the air that is conducted out of the drum,it is provided that a structured lining (8) that embosses the textile product (1, 11) by means of a plurality of openings (9) during the bonding process is wound onto the drum (5) circumferential surface that is designed to be gas-permeable, said openings (9) being larger than the openings in the drum (5) circumferential surface that is designed to be gas-permeable.