Composite Web Meltblowing Intercept Angle Control
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Solution Overview
Problem
Existing methods for producing composite webs with meltblown fibers and particulate material lack the ability to modulate the retention capacity of the particulate material, limiting the versatility of the resulting products.
Innovation Solution
A method involving the controlled interception of thermoplastic and particulate material flows during the meltblowing process, adjusting parameters such as intercept angle, height, and air flow distribution to optimize the retention and distribution of particulate material within the fibers, allowing for the creation of composite webs with varying properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the intercept angle between thermoplastic material flow and particulate material flow is increased, then the distribution of particulate material is improved and process stability is enhanced, but the retention capacity of particulate material in the composite web is reduced
Solution Approach 1:
The patent applies dynamics by making the intercept angle adjustable and variable during the meltblowing process. The angle between the thermoplastic material flow and particulate material flow can be dynamically modified to optimize both distribution and retention characteristics for different product requirements
Solution Approach 2:
The patent utilizes parameter changes by systematically varying the intercept angle as a key process parameter. By changing this angle, the process can be tuned to achieve different balances between particulate material distribution quality and retention quantity in the final composite web
2Quantity of substance
If the intercept angle is reduced, then the constraint factor of particulate material is increased, but the distribution stability and process stability are worsened
Solution Approach 1:
The system enables dynamic adjustment of the intercept angle to achieve the desired constraint factor while maintaining process stability. The angle can be optimized in real-time based on the specific particulate material properties and product requirements
3Quantity of substance
If the intercept height from the collecting suction surface is increased, then all particulate material can be retained and process stability is improved, but excessive quantities of particulate material are lost
Solution Approach 1:
The intercept height is optimized as a critical parameter to achieve the right balance between retaining all necessary particulate material in the composite web and minimizing excessive losses. By carefully controlling this height parameter, the process maximizes retention efficiency while reducing waste
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
This method enables the production of composite webs with adjustable retention capacities, enhancing the production of diverse products like absorbent sanitary items, medical filters, and automotive filters by ensuring stable and balanced distribution of particulate material.
Implementation Method 1
melt blowing a first flow of thermoplastic material comprising the first thermoplastic material towards at least one collecting suction surface moving in a feed direction to obtain the first mass of meltblown fibres
Implementation Method 2
dispensing a flow of particulate material comprising the particulate material towards the collecting suction surface in such a way as to intercept the flow of thermoplastic material
Data Source
AI summary
A method for making a composite web comprises the steps ofmelt blowing a first flow of thermoplastic material including said first thermoplastic material towards at least one collecting suction surface moving in a feed direction;dispensing a flow of particulate material including a particulate material towards the collecting suction surface in such a way as to intercept the first flow of thermoplastic material in an intercept zone; the first flow of thermoplastic material and the flow of particulate material intercept each other in the intercept zone at an intercept angle of between 1 and 90 sexagesimal degrees, preferably between 15 and 40 sexagesimal degrees.