Fiber Mat Production via Segmented Scattering and Turbulent Separation
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Solution Overview
Problem
Current methods for producing material panels, such as chipboard and fiberboard, are limited in creating reproducible layered structures with uniformity and stability, especially when using materials like medium-density fibers or chips, and do not effectively separate finer particles from coarser ones during the production process.
Innovation Solution
A device comprising a metering device, separation roller, guide plate, and vacuum boxes on a forming belt generates turbulent air flows to separate finer material fractions, allowing for the creation of a uniform layered structure by guiding and depositing material onto the forming belt, with adjustable components to optimize turbulence and separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional scattering methods are used to produce fiber mats, then material panels can be produced, but reproducible layered structures with uniformity and stability cannot be achieved
Solution Approach 1:
The device divides the scattering process into multiple distinct scattering spaces (first scattering space with guide plate, second scattering space without guide plate) arranged in sequence. This segmentation allows different material fractions to be separated and deposited in different zones, creating reproducible layered structures with uniform distribution of fine and coarse particles.
Solution Approach 2:
The guide plate is positioned specifically in the first scattering space to create localized turbulence that preferentially directs fine particles onto the forming belt in that specific zone. The second scattering space lacks the guide plate, creating different local flow conditions that allow coarse particles to be deposited subsequently, achieving local quality differentiation in the layered structure.
2Manufacturing precision
If turbulent air flow is generated to separate fine particles, then finer material fractions can be separated, but device complexity increases due to additional components
Solution Approach 1:
The guide plate acts as an intermediary element that generates turbulent air flow when material is scattered against it. This turbulence serves as the mediating mechanism that separates fine particles from coarse particles without requiring complex mechanical separation devices, maintaining relative simplicity while achieving effective particle classification.
3Manufacturing precision
If multiple scattering spaces are arranged in sequence, then layered structures can be produced, but the device length increases
Solution Approach 1:
The device arranges scattering spaces in the transverse direction (width-wise) rather than only in the longitudinal direction. The first and second scattering spaces are positioned side-by-side across the width of the forming belt, allowing layered structure production without proportionally increasing device length, as materials are deposited simultaneously in different transverse zones.
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
The solution enables the production of reproducible, uniform, and stable layered fiber mats or fleeces, allowing for the use of chips or fibers, including recycled materials, with improved separation and deposition of fine particles, enhancing the quality and consistency of material panels.
Implementation Method 1
vacuum boxes on the other side of the forming belt to generate an air flow pointing in the direction of the forming belt in the first scattering space
Implementation Method 2
generate an air flow pointing in the direction of the forming belt
Implementation Method 3
A turbulent air flow is generated in the first scattering space, preferably in the vicinity of the guide plate near the outlet opening of the separation roller, by the (high) peripheral speed of the needle roller
Implementation Method 4
a forming belt that runs endlessly in the transport direction for receiving the material emerging from the outlet opening
Data Source
AI summary
The invention relates to a device for producing a nonwoven fabric from material, preferably over the course of producing a pressed material mat for the production of material panels, and to a method therefor. The device according to the invention comprises: a metering device (22) for the metered output of the material into a chute (5); a separation roller (3) for the material, arranged at the other end of the chute (5) and having a wall (4) arranged in the rotational direction (29) of the separation roller (3) and a outlet opening (26) adjoining same; a first scattering area (27) having a guide plate (7) for limiting and at least partially guiding the material from the separation roller (3) exiting at the outlet opening (26); a forming belt (2), circulating continuously in the transport direction (13) of the exiting material, for receiving the material on a first side of the forming belt (2) in the first scattering area (27); and vacuum chambers (10) on the other side of the forming belt (2) for generating an air flow in the direction of the forming belt (2) in the first scattering area (27).