Cusp Die Multi-Row Hole Pattern for Melt-Blown Fabric
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Solution Overview
Problem
Conventional cusp dies for producing melt-blown non-woven fabric face limitations in hole diameter and density, leading to inefficient barrier performance against water and air, and are prone to polymer buildup and malfunction.
Innovation Solution
A cusp die design featuring multiple rows of holes arranged alternately along the flanks, increasing linear density beyond conventional limits, and a configuration that minimizes empty spaces between fibers, allowing for higher throughput without altering existing melt-blown plant structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of holes per inch is increased to improve barrier performance, then the barrier efficiency against water and air is improved, but the hole diameter becomes smaller than 0.15 mm which is difficult and expensive to drill
Solution Approach 1:
The patent transitions from a single-row hole arrangement to a multi-row alternating pattern, adding a dimensional aspect to the hole distribution. This allows increasing the number of holes per inch without reducing individual hole diameter below manufacturable limits, as holes are distributed across multiple rows rather than concentrated in a single line
Solution Approach 2:
The hole arrangement is segmented into multiple rows (first row and second row) with alternating patterns. This segmentation allows each row to have fewer holes while the combined density across all rows achieves the desired high holes-per-inch ratio, maintaining both manufacturability and barrier efficiency
2Productivity
If the polymer flow rate is increased to improve productivity, then the throughput is improved, but polymer buildup occurs on the blades causing malfunction
Solution Approach 1:
By distributing the polymer flow across multiple rows of holes rather than a single row, the flow rate per individual hole is reduced. This allows the total throughput to be increased while maintaining lower velocity at each hole, preventing polymer buildup on the blades and ensuring operational stability
3Reliability
If conventional single-row hole arrangement is used, then the device complexity is low, but the empty spaces between fibers are excessive reducing barrier performance
Solution Approach 1:
The patent introduces a multi-row alternating hole arrangement that utilizes both horizontal and vertical dimensions for hole distribution. This creates a more uniform fiber distribution with reduced empty spaces compared to single-row arrangements, improving barrier performance while the alternating pattern maintains reasonable manufacturing complexity
Solution Approach 2:
Multiple rows of holes are merged into a single ejection portion, working together to distribute polymer flow more uniformly. This combination of multiple hole rows creates a denser fiber network with fewer gaps, enhancing barrier performance without requiring complex separate systems
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 design enhances the barrier efficiency of the non-woven fabric by reducing empty spaces and increasing the flow rate, producing high-quality fabrics with improved performance without modifying existing plant structures.
Implementation Method 1
a plurality of holes arranged in the ejection portion, placed in fluidic through connection with the extrusion pipe and communicating with the outside
Implementation Method 2
The air blade, on the other hand, is composed of a casing wrapping the cusp of the melt-blown device so as to direct a flow of air, possibly non-turbulent, towards the holes of the cusp
Implementation Method 3
The acceleration of the air inside the blade makes it possible to create a flow that, in contact with the polymer, atomises the polymer, creating sprays comprising very fine particles
Implementation Method 4
conducted under pressure towards the holes arranged on the cusp
Data Source
AI summary
A cusp die for producing melt-blown non-woven fabric is provided, defining a sagittal plane, a main extension direction on the sagittal plane, a first flank and a second flank mutually bounded by the sagittal plane and including an ejection portion extending along the main extension direction and designed to convey, in use, polymeric fluid towards an external air blade, at least one extrusion pipe configured to convey the polymeric fluid towards the ejection portion, a plurality of holes arranged in the ejection portion, placed in fluidic through connection with the extrusion pipe and communicating with the outside, wherein the holes are arranged along at least one first row and a second row that are distinct and arranged respectively at the first flank and the second flank.