Cross-Folder-Free Aerodynamic Carding for Multi-Layer Nonwoven Fabrics
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Solution Overview
Problem
Existing nonwoven fabric production methods face challenges with high sensitivity to air currents and high speeds, leading to reduced production quality and quantity, especially for lighter fabrics, and require expensive, space-consuming cross-folders that limit productivity and flexibility.
Innovation Solution
A system comprising an aerodynamic carding machine, conveyor belts, and compaction units produces isotropic nonwoven fabrics with high productivity by stretching the fabric by a factor of 1.5 to 4, allowing for flexible production of single- or multi-layer fabrics without a lay-up unit, using airlay carding machines that process a wide range of fiber lengths and types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a cross-folder is used to fold fiber rovings into multi-layer nonwoven, then the MD/CD ratio can be controlled, but the production quality and quantity are limited and investment costs are high
Solution Approach 1:
The patent removes the cross-folder component from the production line entirely. Instead of folding the nonwoven after carding, the system directly produces multi-layer nonwoven with controlled MD/CD ratio through the carding machine's aerodynamic fiber distribution system, extracting the folding function and replacing it with direct aerodynamic layering.
Solution Approach 2:
The carding machine is designed to perform multiple functions: it not only cards the fiber roving but also directly creates the multi-layer structure with controlled MD/CD ratio through its aerodynamic fiber distribution system, eliminating the need for separate folding equipment.
2Manufacturing precision
If a cross-folder is used to fold fiber rovings, then the MD/CD ratio can be controlled, but the space requirements increase due to L-shaped material flow
Solution Approach 1:
The cross-folder is completely removed from the production line. The L-shaped material flow path is eliminated by implementing direct aerodynamic multi-layer production within the carding machine, resulting in a linear material flow that significantly reduces space requirements.
3Quantity of substance
If lighter nonwoven fabric is produced by carding machine, then the fabric weight is reduced, but the folding process becomes more sensitive to air currents and high speeds
Solution Approach 1:
The folding process is completely removed from the production sequence. Lighter nonwoven fabrics are produced directly as multi-layer structures through aerodynamic fiber distribution in the carding machine, eliminating the folding step that causes sensitivity to air currents and speed variations.
4Stability of the object's composition
If aerodynamic carding machine is used to produce fiber fleece, then nearly isotropic fiber fleece can be produced, but the production speed is slow at higher nonwoven weights
Solution Approach 1:
The system produces multi-layer nonwoven fabrics by combining multiple fiber rovings with different orientations and properties through aerodynamic distribution. This composite structure achieves isotropy while allowing higher production speeds and weights compared to single-layer aerodynamic carding.
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 system achieves higher productivity and reduced defect rates, enabling the production of isotropic nonwoven fabrics with varying basis weights and fiber qualities, while minimizing investment costs and space requirements, and allows for flexible production of a wide range of products.
Implementation Method 1
at least one carding machine configured to generate a fiber pile by means of an aerodynamic process
Implementation Method 2
a compaction unit configured to compact the fiber pile into a nonwoven fabric
Implementation Method 3
a downstream stretching device arranged in the material transport direction, which is designed to stretch the nonwoven fabric by a factor of at least 1.5
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
The invention relates to a system and a method, comprising - at least one carding machine (1), which is designed to generate a fibrous web (3) by means of an aerodynamic process, - a first conveying belt (4), which is designed to convey the fibrous web (3) from the carding machine to a compactor, - a compactor, which is designed to compact the fibrous web (3) to a nonwoven (24), - a drafting device (10), which is arranged downstream in the material-conveying direction and is designed to draw the nonwoven (24) by at least the factor of 1.5, - and a consolidator, which is arranged downstream in the material-conveying direction.