Cross-Lapper Insertion Strip Production Without Suction
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Solution Overview
Problem
Existing methods for producing insertion strips for multi-layered fiber webs struggle with complex additional components, waste generation, and system shutdowns, particularly when dealing with fiber webs of high transverse strength or surface weight, making it difficult to transfer them to subsequent functional units like needle machines without suction systems.
Innovation Solution
A method that reduces the laying width of the fiber web to an insertion width using a cross-layer, allowing for the production of an insertion strip without suction systems, enabling manual handling and gradual increase to the predetermined working width, thereby avoiding waste and system shutdowns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If suction systems are used to separate the insertion strip from the fiber web, then the insertion strip can be produced, but the method fails for fiber webs with high transverse strength or high basis weight
Solution Approach 1:
The cross-lapper is configured to initially produce only a narrow insertion strip before full-width production begins. This preliminary action creates a manageable narrow web that can be easily transferred to downstream equipment without requiring complex separation systems or causing system shutdowns.
Solution Approach 2:
The cross-lapper's laying width is made dynamically adjustable, allowing it to transition from producing a narrow insertion strip to producing the full predetermined working width. This dynamic capability enables the system to adapt its output width based on operational requirements without physical modifications or shutdowns.
2Ease of manufacture
If conventional methods (partial extraction, blowing over) are used to produce insertion strips, then the narrow strip can be created, but fiber web waste is generated and system shutdown is required
Solution Approach 1:
The cross-lapper performs the function of producing the insertion strip using its own inherent laying mechanism, without requiring external extraction systems or additional components. The system serves itself by utilizing its normal laying operation to create the narrow initial strip, eliminating the need for separate production methods that generate waste.
3Productivity
If the cross-lapper produces full working width from the start, then maximum productivity is achieved, but transfer to downstream functional units becomes difficult
Solution Approach 1:
The cross-lapper initially produces only a narrow insertion strip as a preliminary action before full-width production begins. This narrow strip serves as a manageable intermediary that facilitates easy transfer to downstream functional units, after which full-width production commences without interruption.
Data Source
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AI summary
The invention relates to a method for forming a nonwoven fabric from several layers of fiber nap using a cross-layer, by means of which several layers of fiber nap are laid on top of each other to set a predetermined working width, wherein, to produce an insertion strip, the laying width of the laid fiber nap is reduced from the predetermined working width to an insertion width by means of the cross-layer. The invention further relates to such a cross-layer and its use.