Method and system for manufacturing cleaning member
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Solution Overview
Problem
Current methods for producing cleaning members are not efficient in trapping dust and trash, and there is a need for a novel production method and system that can continuously produce high-quality cleaning members with excellent cleaning performance.
Innovation Solution
A method and system that involve connecting the terminal end of one fiber bundle to the starting end of another before opening, allowing for continuous production by forming a connecting part, and then opening and laminating the fiber bundles with a belt-shaped nonwoven fabric, with a detecting unit to ensure the connecting part is securely formed and not opened, allowing for efficient production of high-quality cleaning members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fiber bundles are opened and laminated with belt-shaped nonwoven fabric to produce cleaning members, then cleaning performance is improved, but production efficiency is reduced due to discontinuous processing
Solution Approach 1:
The patent applies continuity of useful action by connecting the terminal end of one fiber bundle to the starting end of the next fiber bundle, creating a continuous fiber bundle structure. This allows the opening and lamination processes to proceed continuously without interruption, thereby improving production efficiency while maintaining the cleaning performance achieved through proper fiber bundle opening and lamination with belt-shaped nonwoven fabric.
Solution Approach 2:
The patent applies preliminary action by pre-connecting the terminal end of one fiber bundle to the starting end of the next fiber bundle before the opening and lamination processes. This preliminary connection ensures continuous fiber bundle supply to the processing line, enabling continuous production while ensuring that each fiber bundle is properly opened and laminated to achieve the required cleaning performance.
2Productivity
If fiber bundles are connected to enable continuous production, then productivity is improved, but manufacturing complexity increases due to additional connecting steps
Solution Approach 1:
The patent applies merging by combining the fiber bundle connection step with the existing opening and lamination processes into an integrated manufacturing system. The connection means is incorporated into the production line such that fiber bundles are connected, opened, and laminated in a coordinated sequence, reducing the number of separate operations and simplifying the overall manufacturing process while enabling continuous production.
Solution Approach 2:
The patent introduces a connection means as an intermediary component that facilitates the joining of fiber bundles. This intermediary device serves as a bridge between discrete fiber bundles, enabling continuous production without requiring complex reconfiguration of the entire manufacturing system. The connection means is designed to work seamlessly with the existing opening and lamination equipment.
3Manufacturing precision
If detecting unit is added to verify connecting part formation, then product quality is improved, but device complexity and production time increase
Solution Approach 1:
The patent applies feedback by incorporating a detecting unit that monitors the formation of connecting parts between fiber bundles. The detecting unit provides real-time information about connection quality, allowing for immediate detection and correction of defects. This feedback mechanism ensures high manufacturing precision for the connecting parts while integrating smoothly into the existing production system.
Solution Approach 2:
The patent replaces complex mechanical inspection methods with a detecting unit that likely uses optical or sensor-based detection. This substitution reduces mechanical complexity while improving the precision of connecting part verification. The detecting unit provides non-contact or minimal-contact inspection, simplifying the overall system while enhancing quality control.
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 approach enables the continuous production of cleaning members with excellent cleaning performance by securely forming a connecting part that is not opened, ensuring efficient production and higher quality cleaning members without stopping the production process.
Implementation Method 1
a detecting unit to detect whether or not the connecting part is opened
Data Source
AI summary
The present invention is a method for manufacturing cleaning members obtained by cutting multi-layer webs formed by: spreading fiber bundles, the lengthwise directions of which are parallel to the direction in which said are conveyed; and layering together at least the spread and non-woven fabric strips. Said method includes a step in which, before spreading, two or more are joined together, forming one or more join sections. Said joins are performed by joining the back end (with respect to the conveyance direction) of one to the front end (with respect to the conveyance direction) of the next fiber bundle.