Composite Nonwoven Fabric Headbox for Uniform Short-Fiber Distribution
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Solution Overview
Problem
Existing methods for producing composite nonwoven fabrics with long and short fibers are complex, expensive, and require large space, leading to high production costs, especially for applications requiring low-cost production.
Innovation Solution
A method using a headbox with a rotating or static turbulence generator, such as a perforated roll headbox, to apply short fibers to a long fiber layer in a wet laid process, allowing for efficient production of composite nonwoven fabrics with uniform properties across a wide range of speeds and basis weights, reducing production costs and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an inclined wire headbox is used to produce the second layer, then fiber distribution and entanglement are improved, but device complexity, space requirements, and production costs increase
Solution Approach 1:
The patent extracts the essential function of the inclined wire headbox (distributing short fibers uniformly) and implements it through a simpler cross-flow distributor without the complex inclined wire structure. This removes unnecessary complexity while retaining the core functionality of achieving uniform fiber distribution and entanglement in the second layer.
Solution Approach 2:
The patent replaces the expensive and complex inclined wire headbox with a more economical cross-flow distributor system that uses simpler components. This substitution reduces device complexity and production costs while maintaining adequate fiber distribution performance for the application.
2Manufacturing precision
If an inclined wire headbox is used to produce the second layer, then fiber distribution and entanglement are improved, but production space requirements increase
Solution Approach 1:
The patent extracts the essential function of the inclined wire headbox (distributing short fibers uniformly) and implements it through a simpler cross-flow distributor without the complex inclined wire structure. This removes unnecessary complexity while retaining the core functionality of achieving uniform fiber distribution and entanglement in the second layer.
3Ease of manufacture
If multiple devices are arranged in sequence for production, then process specialization is improved, but production time and overall cost increase
Solution Approach 1:
The patent merges the formation of the first layer (long fibers) and second layer (short fibers) into a single simultaneous process using a unified headbox system with cross-flow distributors. This integration eliminates sequential processing steps, reducing production time while maintaining specialized functionality for each fiber type through separate feed systems and distribution patterns.
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 method enables cost-effective production of composite nonwoven fabrics with uniform properties, achieving high production speeds and efficient water management, while minimizing space requirements and operational costs.
Implementation Method 1
headbox comprising a round flow or cross flow distributor with a rotating or static turbulence generator
Data Source
AI summary
A method for producing a composite nonwoven fabric having at least two layers, wherein a first layer is made of long fibers, and a second layer is made of short fibers. The method includes attaching, in a production line, the short fibers of the second layer to the long fibers of the first layer in a wet laid process via a headbox. The headbox has a round flow or cross flow distributor with a rotating or static turbulence generator.