Fiber Bundle Opening Facilitator for Compact High-Speed Production
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Solution Overview
Problem
Existing methods for opening fiber bundles, such as those used in cleaning members, face issues with high-speed production and apparatus miniaturization, as they often result in fiber breakage and require multiple sliding plates, leading to larger equipment sizes.
Innovation Solution
A method involving first and second nip rolls with varying peripheral velocities and an opening facilitator with an edge orthogonal to the machine direction, which applies tensile force and relaxes the fiber bundle to form a belt-shaped bundle, reducing fiber breakage and enabling faster, more compact production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sliding plates are used to open fiber bundles, then the fiber bundle can be opened, but fibers may break particularly in high-speed production
Solution Approach 1:
The patent introduces an opening facilitator as an intermediary component between the sliding plate and the fiber bundle. This facilitator includes a protrusion that pushes the fiber bundle against the sliding plate, mediating the interaction to reduce direct harmful contact and minimize fiber breakage during high-speed production
Solution Approach 2:
The patent changes the geometric parameters of the opening facilitator, specifically designing a protrusion with specific dimensions (width W1, length L1) and positioning it at specific locations. By optimizing these parameters, the facilitator effectively distributes the opening force and reduces fiber breakage while maintaining production speed
2Manufacturing precision
If multiple sliding plates are used to open fiber bundles, then the opening effect is improved, but the apparatus size increases
Solution Approach 1:
The patent merges multiple opening functions into a single integrated opening facilitator component. The facilitator combines the functions of multiple sliding plates and additional opening mechanisms into one compact structure, achieving effective fiber bundle opening while minimizing apparatus size
Solution Approach 2:
The opening facilitator is designed as a multi-functional component that performs multiple opening operations simultaneously. It includes protrusions at different positions and orientations that can handle various fiber bundle configurations, replacing the need for multiple separate sliding plates and reducing overall apparatus footprint
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 method allows for high-speed production of opened fiber bundles in a space-saving manner, minimizing fiber breakage and enabling the creation of compact cleaning member production apparatuses.
Implementation Method 1
conveying a fiber bundle using the first nip rolls and the second nip rolls to apply a tensile force to the fiber bundle
Implementation Method 2
conveying a fiber bundle using the first nip rolls and the second nip rolls
Data Source
AI summary
An object of the present disclosure is to provide a method of producing an opened fiber bundle at high speed and in a space-saving manner. The method is as follows. A method of continuously producing an opened fiber bundle for a cleaning member, comprising the steps of (a1) providing (i) first nip rolls, (ii) second nip rolls, (iii) third nip rolls, and (iv) an opening facilitator; (a2) conveying a fiber bundle using the first nip rolls and the second nip rolls to apply a tensile force to the fiber bundle, the fiber bundle being pushed onto the upstream portion and the edge of the opening facilitator while conveying; and (a3) conveying the fiber bundle using the second nip rolls and the third nip rolls to relax the fiber bundle, thereby forming a belt-shaped fiber bundle.