Fiber Opening Chamber with Vibrating Projections for Nonwoven Web Integrity
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Solution Overview
Problem
Existing methods for producing nonwoven fibrous webs from pre-formed bulk fibers often result in entanglement, agglomeration, or matting, which complicates the air-laying process and can lead to fibers being overopened, causing excessive loss, damage, and reduced web integrity.
Innovation Solution
An apparatus with a fiber opening chamber and forming chamber, utilizing rollers with projections and gas emission nozzles to disperse and transport fibers as discrete, non-agglomerated entities, along with optional particulates for bonding, allows for controlled fiber recirculation and bonding without adhesives, enhancing web integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If pre-formed bulk fibers are used for air-laying, then fiber source availability is improved, but fiber entanglement and agglomeration increase
Solution Approach 1:
The bulk fiber source is segmented into individual fibers through the action of rollers with projections that mechanically separate and open the fiber clumps, transforming the aggregated fiber mass into discrete fibers suitable for air-laying
Solution Approach 2:
Vibrating rollers with projections are used to mechanically open and disperse bulk fibers, preventing entanglement and agglomeration during the air-laying process while maintaining fiber integrity
2Stability of the object's composition
If fibers are overopened to prevent agglomeration, then fiber dispersion is improved, but fiber loss and damage increase
Solution Approach 1:
Vibrating rollers provide controlled mechanical action that opens fibers sufficiently for dispersion while avoiding excessive force that would cause fiber breakage or loss
Solution Approach 2:
The vibration frequency, amplitude, and roller surface properties are optimized to achieve the right balance between fiber opening and fiber integrity preservation
3Stability of the object's composition
If fibers are overopened to improve dispersion, then fiber separation is improved, but web integrity deteriorates
Solution Approach 1:
Controlled vibration opens fibers for good dispersion while preserving sufficient fiber length and strength for web integrity
Solution Approach 2:
Optimization of vibration parameters and roller design maintains the balance between fiber separation and web strength
4Stability of the object's composition
If rollers with projections are used to open fibers, then fiber dispersion is improved, but device complexity increases
Solution Approach 1:
Vibrating rollers with projections provide effective fiber opening through a relatively simple mechanical design
Solution Approach 2:
The roller design allows fibers to be opened and dispersed through their own interaction with the roller surface during normal operation
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 apparatus effectively opens clumped fibers, reduces fiber loss, and enhances the integrity of air-laid nonwoven webs by maintaining fibers in a discrete, non-agglomerated state, enabling better handling and processing capabilities.
Implementation Method 1
at least one gas emission nozzle positioned substantially below the first multiplicity of rollers to direct a gas stream generally towards the open upper end of the opening chamber
Implementation Method 2
a first multiplicity of rollers positioned within the opening chamber wherein each roller has a multiplicity of projections extending outwardly from a circumferential surface
Implementation Method 3
collecting the well-dispersed fibers on a collector surface as the fibers settle through the air under the force of gravity
Data Source
AI summary
Methods and apparatus including a fiber opening chamber having an open upper end and a lower end, at least one fiber inlet for introducing a multiplicity of fibers into the opening chamber, a first multiplicity of rollers positioned within the opening chamber wherein each roller has a multiplicity of projections extending outwardly from a circumferential surface surrounding a center axis of rotation, at least one gas emission nozzle positioned substantially below the first multiplicity of rollers to direct a gas stream generally towards the open upper end of the opening chamber, and a forming chamber having an upper end and a lower end, wherein the upper end of the forming chamber is in flow communication with the open upper end of the opening chamber, and the lower end of the forming chamber is substantially open and positioned above a collector having a collector surface.