Absorbent Article Factory Lint Control via Air Pressure
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Solution Overview
Problem
In existing factories for manufacturing absorbent articles like disposable diapers or sanitary napkins, lint from nonwoven fabric coils scattered during payout contaminates processing sections on lower stories due to inadequate separation between stories in mezzanine-style buildings.
Innovation Solution
A factory design with a building layout where the upper story is substantially isolated from the lower story by walls and air pressure control, with payout devices for nonwoven fabrics on the upper story and processing sections on the lower story, and air pressure at the boundary between stories higher on the lower side to prevent lint contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a mezzanine-style building is used with intermediate story for material payout, then space utilization is improved, but lint contamination occurs from upper story to lower story
Solution Approach 1:
The building is divided into separate stories with the upper story dedicated to material payout and the lower story to processing. Walls are provided along the entire periphery of each story's floor to segment the space, preventing lint from the upper story from contaminating the lower story while maintaining efficient vertical space utilization.
Solution Approach 2:
An air pressure control system is introduced as an intermediary mechanism between the upper and lower stories. By maintaining higher air pressure at the boundary position on the lower story side compared to the upper story side, the system creates an air pressure barrier that prevents lint from migrating downward through the opening in the upper story floor.
2Length of stationary object
If stories are closely positioned in mezzanine building, then building height is reduced, but lint can easily enter lower story
Solution Approach 1:
A pneumatic control system is implemented to regulate air pressure between the upper and lower stories. Air conditioners on both stories control the air pressure so that the pressure at the boundary position on the lower story side is higher than on the upper story side. This pressure differential creates a protective air flow that prevents lint from entering the lower story through the opening, while allowing the stories to be closely positioned for compact building design.
3Object-affected harmful factors
If walls are provided along entire periphery of each story, then lint contamination is prevented, but ventilation complexity increases
Solution Approach 1:
The air conditioners installed on each story serve multiple functions: they provide cooling/heating, control air pressure differentials to prevent lint migration, and manage ventilation. By making the air conditioning system multi-functional, the design prevents lint contamination through wall separation and pressure control without requiring a separate complex ventilation system, thus reducing overall system complexity.
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
Effectively suppresses lint contamination of processing sections by isolating the payout area from the processing area, ensuring cleaner materials and reducing defects in absorbent articles.
Implementation Method 1
an air pressure at a boundary position between a space on the lower story and the opening being higher than an air pressure at a boundary position between a space on the upper story and the opening
Data Source
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AI summary
It is a factory (10) for manufacturing an absorbent article. The factory (10) includes a building (12) including an upper story and a lower story. The upper story includes: a floor (13u); a wall (14u) provided along an entire periphery of the floor (13u); an illumination device provided on a ceiling; and an air conditioner having an air outlet. The lower story includes: a floor (13d); a wall (14d) provided along an entire periphery of the floor (13d); an illumination device provided on a ceiling; and an air conditioner having an air outlet. In the floor (13u) of the upper story, formed is an opening (13uk) through which the upper story and the lower story communicate. The upper story further includes a paying-out device (30) to which a material coil (1CNW) on which a nonwoven fabric (1NW) is wound is attached and that pays out the nonwoven fabric (1NW). The lower story further includes a processing section (20) that processes the plurality of types of materials (1) including the nonwoven fabric (1NW) that is transported from the upper story through the opening (13uk).