Extrusion Nozzle Columns Integrated with Base Plate
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Solution Overview
Problem
Current nozzle designs for producing spunbonded nonwovens face challenges such as high pressure loss, complex assembly, and limited flexibility to handle a variety of raw materials, leading to reduced throughput and increased production costs, especially with longer nozzles.
Innovation Solution
A nozzle design featuring extrusion columns formed in one piece with a base plate, eliminating the need for support plates and gas flow outlet plates, allowing for low pressure loss and high throughput, and enabling the production of fine fibers with various geometries using a single-piece manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multi-row hollow needle nozzles are used to increase throughput, then productivity increases, but device complexity increases due to complex support plates and gas flow outlet plates
Solution Approach 1:
The patent combines the support plate and gas flow outlet plate into a single integrated component with the nozzle body. The support plate serves dual functions as both structural support and gas flow distribution, eliminating the need for separate gas flow outlet plates and reducing assembly complexity while maintaining high throughput capability
Solution Approach 2:
The support plate is designed to perform multiple functions simultaneously: providing mechanical support for hollow needles, distributing gas flow evenly across the nozzle, and serving as the gas flow outlet. This multi-functional design reduces the number of components and simplifies the overall device structure
2Productivity
If hollow needles are made longer to increase working width and throughput, then productivity increases, but reliability decreases due to vibration and bending from gas flow
Solution Approach 1:
By integrating the support plate and gas flow outlet plate, the patent creates a more rigid structural framework that provides better support for longer hollow needles. The unified structure reduces vibrations and bending caused by gas flow, enabling the use of longer needles to increase working width and throughput without compromising reliability
3Ease of manufacture
If single-row nozzles are used to simplify design, then ease of manufacture increases, but productivity decreases due to high pressure loss and low throughput
Solution Approach 1:
The patent divides the nozzle into multiple rows of extrusion capillaries arranged in a multi-row configuration. This segmentation allows the gas flow and molten material to be distributed across multiple channels, reducing pressure loss in each individual channel while significantly increasing overall throughput compared to a single-row design
4Productivity
If extrusion capillaries are arranged in multiple rows to increase throughput, then productivity increases, but manufacturing precision requirements increase due to reduced distance between capillaries
Solution Approach 1:
By integrating the support plate and gas flow outlet plate into a single component, the patent reduces the overall number of parts that require high-precision manufacturing. The multi-row extrusion capillaries are arranged with optimized spacing that balances throughput requirements with manufacturability, reducing the extreme precision demands that would arise from overly compact capillary spacing
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 design simplifies production and assembly, reduces pressure loss, and increases throughput, enabling the manufacture of longer nozzles with consistent fleece quality from a wide range of raw materials, while minimizing the risk of damage and operational complexity.
Implementation Method 1
a plurality of means for generating gas flow to generate a gas flow at least in the area of the extrusion openings oriented essentially in the direction of extrusion of the filaments
Data Source
Figure 1~2
Figure 3~4
Figure 5a~6
AI summary
The invention relates to a device (1) for extruding filaments (2), having a plurality of extrusion capillaries (3) arranged in at least two rows, one behind the other, having extrusion openings (4) for extruding a spinning solution to form filaments (2) and a plurality of means (7, 8, 10) for generating gas flow in order to produce a gas flow oriented substantially in the direction of the extrusion of the filaments (2), at least in the region of the extrusion openings (4), wherein the extrusion capillaries (3) are arranged in extrusion columns (6), which protrude from a base plate (5) and are integrally formed together with said base plate (5).