Fiber structure manufacturing apparatus, method of manufacturing fiber structure, and fiber structure
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Solution Overview
Problem
Existing fiber structure manufacturing apparatuses face issues with strength defects due to incomplete pressing regions at the seams of the pressing process, caused by limitations in apparatus size and transport accuracy, leading to variations in the pressing process.
Innovation Solution
A fiber structure manufacturing apparatus that alternately repeats transport and pressurization at a pitch shorter than the length of the heated flat plate, creating regions with different pressurization frequencies to ensure uniform heat and pressure treatment, preventing strength defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the flat plate-shaped press length is limited to an allowable length or less to reduce apparatus size, then the apparatus size is reduced, but incomplete pressing regions occur at the seams leading to strength defects
Solution Approach 1:
The patent applies periodic action by alternately repeating the pressing process and web transport multiple times. The fiber web is pressed, transported to a new position, pressed again, and this cycle is repeated so that different regions of the web receive multiple pressing cycles. This ensures that even with a limited-length press, the entire web surface achieves uniform pressing without strength defects.
Solution Approach 2:
The patent implements preliminary action by performing multiple pressing cycles on different regions of the web before final transport and cutting. Each region receives adequate pressing treatment in advance, ensuring uniform bonding strength throughout the fiber structure before the manufacturing process is completed.
2Manufacturing precision
If the press length is extended to cover the entire web width, then pressing uniformity is improved, but the apparatus size and complexity increase
Solution Approach 1:
The patent applies segmentation by dividing the pressing process into multiple sequential stages rather than requiring a single long press. The web is pressed in sections across different positions and times, breaking down the need for an extended press length into manageable segments that can be handled by a compact press mechanism.
Solution Approach 2:
The patent uses periodic action to achieve comprehensive pressing coverage through repeated cycles. Instead of extending the press length, the same press is periodically applied to different regions of the web, ensuring uniform pressing without increasing apparatus dimensions.
3Manufacturing precision
If transport accuracy is increased to prevent incomplete pressing at seams, then pressing uniformity is improved, but device complexity and cost increase
Solution Approach 1:
The patent applies periodic action by repeating the press-transport cycle multiple times. This approach compensates for transport accuracy variations because the periodic repetition ensures that even if some regions receive slightly variable transport, the cumulative effect of multiple pressing cycles achieves uniform overall pressing without requiring high-precision transport control.
Solution Approach 2:
The patent implements preliminary action by performing multiple pressing operations before final web completion. This preliminary repeated pressing ensures adequate bonding strength is achieved throughout the web, providing a margin of tolerance that reduces the need for extremely precise transport 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
The apparatus produces fiber structures with enhanced mechanical strength and reduced shape loss during transport and cutting, ensuring higher quality and dimensional accuracy by uniformly applying heat and pressure across the material.
Implementation Method 1
a heating and pressurizing portion that pressurizes the transported fiber web with a heated flat plate to melt the resin
Implementation Method 2
pressurizes the transported fiber web with a heated flat plate to melt the resin
Data Source
AI summary
A fiber structure manufacturing apparatus including: an accumulation portion that accumulates a material containing a resin and a fiber in air to generate a fiber web; a transport portion that transports the generated fiber web in a transport direction; and a heating and pressurizing portion that pressurizes the transported fiber web with a heated lower flat plate and an upper flat plate to melt the resin, in which a liquid absorbent having a first region where pressurization by the heating and pressurizing portion is performed the predetermined number of times and a second region where the pressurization is performed more than a predetermined number of times is formed by alternately repeating transport at a predetermined pitch shorter than a length of the flat plate in the transport direction by the transport portion and the pressurization.