Fiber Tow Opening and Shaping for Uniform SAP Distribution
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Solution Overview
Problem
Existing methods for manufacturing wide-shaped fiber tow materials for disposable diapers and tobacco filters face challenges in evenly distributing particulate additives, leading to uneven absorption performance and potential fall-off during processing.
Innovation Solution
A manufacturing apparatus and method that includes a preliminary opening unit, an opening unit with a cylindrical body and nozzles for air stream interaction, and a swelling/shaping unit with an elastic adapter to ensure uniform distribution and retention of particulate additives within the fiber tow, enhancing the retention capacity and uniformity of the additives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If SAP is added to the fibrous sheet after opening a tow, then the SAP can be distributed on the surface, but the distribution becomes uneven on one surface in the thickness direction
Solution Approach 1:
The patent applies preliminary action by opening the tow bundle before adding SAP, creating a bulky structure that facilitates uniform distribution. The opening process is performed in advance to prepare the fibrous sheet with increased volume and porosity, enabling subsequent uniform SAP incorporation throughout the thickness direction rather than just on the surface.
Solution Approach 2:
The patent segments the opening process into multiple stages using multiple opening rollers with different surface characteristics. The first opening rollers perform initial separation, followed by second opening rollers that further divide the fibrous structure. This segmentation creates a more open, voluminous structure that allows uniform SAP distribution throughout the material thickness.
2Area of stationary object
If a wide-shaped tow opening matter is manufactured from a tow having the same mass, then the width increases, but the density becomes small causing SAP to blow off through spaces
Solution Approach 1:
The patent applies local quality by using opening rollers with different surface properties in different zones. The first opening rollers have a specific surface roughness for initial opening, while the second opening rollers have different surface characteristics for further separation. This creates localized zones with different structural characteristics, allowing the wide fibrous sheet to maintain appropriate density in different areas to prevent SAP blow-off while achieving the desired overall width.
3Volume of stationary object
If the tow bundle is opened to increase bulkiness for SAP entry, then the SAP can enter the tow bundle, but the opening process causes damage to the tow
Solution Approach 1:
The patent applies pneumatics by using air flow between the opening rollers to assist in separating the tow bundle. The air flow lifts and separates the fibers as they pass through the rollers, reducing mechanical contact and friction that would otherwise cause damage. This pneumatic assistance enables increased bulkiness and SAP penetration while minimizing harmful mechanical stress on the tow structure.
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 allows for a higher amount of particulate additives to be evenly distributed and retained within the fiber tow, improving absorption performance and reducing fall-off, resulting in a more effective and uniform material for hygienic goods and tobacco filters.
Implementation Method 1
directing, in substantially the same direction as the movement to the tow, a first stream of motivating gas, downstream
Implementation Method 2
directing a separate stream of motivating gas against the tow also substantially in the direction of movement of the tow, and, by the separate stream, opening the previously crimped filaments
Implementation Method 3
including an elastic body which is fixed to the adapter and which is for regulating a shape of a swelling fiber tow from outside
Data Source
Figure 1
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Figure 5~6
AI summary
[Means for Solution] A preliminary opening unit 1, an opening unit 2 and a swelling/shaping unit 3 are connected so as to form a communicated space for delivering a fiber tow 10 continuously. A fiber tow 10 is contacted with a particulate additive in a nozzle 32 of the opening unit (2), is opened in an opening zones Z1 and Z2, is swollen and shaped in the swelling/shaping unit 3 for obtaining a long-sized opening matter in which the fiber tow opening matter and the particulate additive are integrated.