Method for producing cleaning member, and system for producing cleaning member
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Solution Overview
Problem
Current methods for producing cleaning members are inefficient in trapping dust and trash, lacking in effective production systems for achieving excellent cleaning performance.
Innovation Solution
A method and system for continuously producing a cleaning member using a multi-layer web comprising an opened fiber bundle and a belt-shaped nonwoven fabric, with a guide member having width-adjusting members to adjust the fiber bundle width, ensuring equal basis weight distribution and efficient stacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional production methods are used, then production process is simple, but cleaning performance is insufficient for trapping dust and trash
Solution Approach 1:
The production system is divided into multiple functional modules including fiber bundle opening devices, width adjustment mechanisms, stacking systems, and sealing devices. Each module performs a specific function in the production process, allowing for optimized cleaning performance while maintaining manageable system complexity through modular design.
Solution Approach 2:
The invention transitions from conventional two-dimensional cleaning member structures to three-dimensional multi-layer web constructions with opened fiber bundles that extend vertically. This dimensional enhancement creates deeper dust trapping cavities and improves cleaning effectiveness by utilizing vertical space for particle capture.
2Manufacturing precision
If fiber bundle width is not adjusted, then production is faster, but basis weight distribution is uneven affecting cleaning performance
Solution Approach 1:
The width adjustment of fiber bundles is performed in advance during the production process, before stacking and final assembly. This preliminary width control ensures uniform basis weight distribution is achieved early in production, preventing downstream quality issues while maintaining continuous production flow and efficiency.
Solution Approach 2:
The invention replaces manual or post-production width adjustment methods with automated mechanical width control mechanisms integrated into the production line. These mechanisms automatically regulate fiber bundle dimensions during manufacturing, ensuring consistent basis weight without requiring additional manual intervention or slowing production speed.
3Reliability
If multi-layer web structure is implemented, then cleaning performance is enhanced, but production complexity increases
Solution Approach 1:
Multiple functional layers including fiber bundles, nonwoven fabrics, and sealing structures are combined into an integrated multi-layer web. This merging of layers creates a unified structure that enhances dust trapping capability while the integrated design reduces the need for separate assembly operations, thereby managing production complexity.
Solution Approach 2:
Belt-shaped nonwoven fabrics are introduced as intermediary carrier layers between the fiber bundles and the final cleaning member structure. These intermediary layers facilitate controlled stacking and positioning of fiber bundles, enabling precise multi-layer construction while simplifying the overall stacking process through the mediating function of the nonwoven fabric carriers.
Data Source
AI summary
A method for continuously producing a cleaning member obtained from a multilayer web that includes at least a fiber bundle with hollow fibers, and non-woven fabric strips includes at least: a step for preparing a guide member provided with a pair of width-adjusting member, and having a predetermined interval; a step for conveying a fiber bundle strip, such as the fiber bundle with hollow fibers, between the pair of width-adjusting members of the guide member, and adjusting the width of the fiber bundle strip so as to match the aforementioned interval; a step for forming the multilayer web by overlaying the strip-like fiber bundle, the width of which has been adjusted, on the non-woven fabric strips; and a step for joining the components of the multilayer web.