Absorbent Body Manufacturing With Dual Pattern Drums
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Solution Overview
Problem
Existing methods for manufacturing absorbent bodies with superabsorbent polymers (SAP) face challenges in controlling the basis weight and distribution of SAP, leading to scattering and inconsistent spraying patterns due to air flow interference.
Innovation Solution
A manufacturing apparatus and method involving a first drum for fiber accumulation and a second drum for SAP distribution, using suction forces to control SAP placement and distribution without air flow interference, allowing for varied basis weight and intermittent spraying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the mixture of fibers and SAP is conveyed via air flow in a duct to accumulate on the fiber stacking drum, then the SAP can be added to the fiber body, but the SAP cannot be arranged in an intermittent manner or have variable basis weight and spraying width
Solution Approach 1:
The invention separates the fiber conveying and SAP spraying operations into distinct stages. Fibers are conveyed through the duct and accumulated on the drum first, then SAP is sprayed separately in a controlled manner. This segmentation allows independent control of fiber deposition and SAP application, enabling variable basis weight and intermittent spraying patterns without the limitations of mixed conveyance.
Solution Approach 2:
The fiber body is accumulated on the fiber stacking drum before SAP spraying occurs. This preliminary accumulation creates a stable substrate that allows subsequent SAP to be sprayed with precise control over basis weight and distribution. The pre-formed fiber layer enables the SAP to be applied in controlled patterns rather than being carried along with the fiber flow.
2Ease of manufacture
If SAP is sprayed while fibers are accumulating on the fiber stacking drum, then SAP can be added to fibers, but SAP scatters to the periphery due to air flow from the duct
Solution Approach 1:
The invention extracts the harmful air flow from the SAP spraying environment. By separating the SAP spraying operation from the fiber conveyance air flow, the patent eliminates the air flow interference that causes SAP scattering. The SAP is sprayed in a controlled environment without the disruptive air currents that would otherwise carry particles to the periphery.
Solution Approach 2:
The fiber stacking drum serves as an intermediary surface between fiber conveyance and SAP application. Fibers are deposited on the drum surface first, creating a stable platform. Then SAP is sprayed onto this intermediate fiber layer rather than being introduced into the air flow path, preventing scattering while maintaining effective SAP application to the fiber body.
3Productivity
If a fiber stacking drum with concave section is used to fiber-stack fibers, then fibers can be accumulated, but a gap is caused between the concave section and duct tip end resulting in air flow that accelerates SAP scattering
Solution Approach 1:
The invention removes the source of harmful air flow by separating the SAP spraying operation from the fiber conveyance system. Instead of spraying SAP into the air flow path near the duct tip and concave section gap, the SAP is sprayed onto the fiber layer already accumulated on the drum. This extraction of SAP from the harmful air flow environment prevents the gap-induced scattering problem.
Solution Approach 2:
The fiber accumulation in the concave section is completed before SAP spraying begins. This preliminary fiber stacking creates a complete fiber layer that covers the concave section area. When SAP is subsequently sprayed, it is applied to the fiber surface rather than being exposed to the air flow gap, preventing scattering while maintaining the productivity benefits of the concave fiber stacking design.
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
Enables precise control over SAP distribution and basis weight, preventing scattering and achieving desired spraying patterns in absorbent bodies.
Implementation Method 1
a first drum (10) to allow the fibers F conveyed through the duct (1) to be accumulated on an outer peripheral face 10F by the suction force from the interior
Implementation Method 2
a spraying device (3) to spray (sprinkle) absorbent particles (granular powder) SA
Implementation Method 3
a second drum (20) to convey an aggregate S obtained by collecting the sprayed particles SA on an outer peripheral face 20F by the suction force from the interior
Data Source
AI summary
A manufacturing apparatus of an absorbent body includes: a duct to convey fibrillated fibers via an air flow; a first drum to allow the fibers conveyed through the duct to be accumulated on an outer peripheral face by the suction force from the interior to convey a fiber body of the accumulated fibers, the first drum being a first pattern drum to define the shape of the fiber body; a spraying device to spray absorbent particles; a second drum to convey an aggregate obtained by collecting the sprayed particles on an outer peripheral face by the suction force from the interior, the second drum being a second pattern drum to control the distribution of the aggregate; and a layering unit to layer the fiber body and the aggregate to each other.