Cleaning Member Web Formation Without Fiber Bundle Shrinkage
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Solution Overview
Problem
Current methods for producing cleaning members are inefficient in trapping dirt, dust, and refuse, and there is a need for a novel method and system that can achieve excellent cleaning performance while allowing for efficient production.
Innovation Solution
A method and system involving the production of a cleaning member from a multilayer web formed by overlaying a fiber bundle and a belt-shaped nonwoven fabric, where the fiber bundle is conveyed with tension to prevent narrowing, and the multilayer web is formed and joined without causing significant shrinkage or crimping, allowing for high-speed productivity and effective cleaning performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fiber bundles are conveyed without tension during production, then the fiber bundles maintain their natural state and are easier to handle, but the fiber bundles narrow and crimp, reducing cleaning performance
Solution Approach 1:
The fiber bundle is conveyed with tension during the production process to prevent narrowing and crimping before the actual cleaning function is utilized. This preliminary application of tension maintains the fiber bundle dimensions throughout manufacturing operations including overlaying with nonwoven fabric and cutting, ensuring the fiber bundles remain straight and effective for cleaning without requiring complex post-processing to correct dimensional distortions.
2Productivity
If high-speed production methods are used, then productivity increases, but the cleaning performance deteriorates due to improper fiber bundle formation
Solution Approach 1:
The fiber bundle is continuously conveyed with tension throughout the entire production process without interruption or relaxation, ensuring consistent dimensional stability. This continuous application of tension during overlaying with nonwoven fabric, joining operations, and cutting enables high-speed production while maintaining fiber bundle straightness and cleaning effectiveness, eliminating the need for slow, intermittent processing steps.
Solution Approach 2:
The physical state of the fiber bundle is maintained under constant tension during production, changing the operational parameters from relaxed to tensioned state. This parameter change ensures the fiber bundles remain straight and properly formed during high-speed manufacturing operations, preventing the narrowing and crimping that would otherwise occur and degrade cleaning performance.
3Device complexity
If fiber bundles are overlaid with nonwoven fabric without tension control, then the manufacturing process is simpler, but the fiber bundles narrow and lose their cleaning effectiveness
Solution Approach 1:
The tensioning mechanism serves multiple functions simultaneously: it prevents fiber bundle narrowing during overlaying, maintains dimensional stability during cutting, and ensures proper fiber bundle formation for cleaning effectiveness. This single multi-functional approach to tension control simplifies the overall process by eliminating the need for separate complexity-inducing mechanisms for each individual function.
Data Source
AI summary
A method of manufacturing a cleaning member includes a fiber bundle conveying step conveying a fiber bundle to a merging section, a nonwoven fabric conveying step conveying the nonwoven fabric strips to the merging section; a multilayer web forming step forming a multilayer web by overlaying the fiber bundle on the nonwoven fiber strips at the merging part; and a joining step joining the fiber bundle and the nonwoven fabric strips to each other in the multilayer web. In the fiber bundle conveying step, the fiber bundle is conveyed at a tension at which there is no width shrinkage in the fiber bundle, and in the multilayer web forming step, the multilayer web is formed by overlaying the fiber bundle on the nonwoven strips while applying a tension that does not cause width shrinkage in the fiber bundle.