Fiber Web Forming Lamella Mixing Control
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Solution Overview
Problem
Current methods for forming fiber webs, such as those used in filter media and battery separators, lack efficiency in controlling the mixing of fiber mixtures, leading to inconsistent structural and performance characteristics.
Innovation Solution
The system introduces a series of methods and systems that utilize a lamella to separate the flow zone into upper and lower portions, with adjustable configurations and flow impediments like secondary lamellas, disruptive members, and variable volume members to disrupt laminar flow and promote mixing, allowing for controlled intermixing of fiber mixtures at the fiber web forming zone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional wet laid process is used to form fiber webs, then the process can form fiber webs with basic structural characteristics, but the mixing of fiber mixtures is inconsistent leading to poor structural and performance uniformity
Solution Approach 1:
The flow zone is divided into multiple separate flow channels using lamellas, allowing different fiber mixtures to be transported independently through controlled pathways before reaching the forming zone, thereby improving mixing consistency and structural uniformity
Solution Approach 2:
Variable volume members are introduced into the flow channels to dynamically adjust the flow characteristics and mixing intensity based on process requirements, enabling precise control over fiber mixture blending while maintaining structural uniformity
2Adaptability or versatility
If fiber mixtures are introduced into a common flow zone without separation, then the process is simple, but the degree of mixing cannot be controlled leading to inconsistent fiber web properties
Solution Approach 1:
The flow zone is segmented into multiple independent flow channels using lamellas, enabling separate control of different fiber mixture flows while maintaining overall process integration, thus providing mixing adaptability without excessive complexity
Solution Approach 2:
The lamella structure serves multiple functions including flow separation, mixing control, and structural support within the same component, providing versatile mixing control capabilities while minimizing additional device complexity
3Manufacturing precision
If laminar flow is maintained throughout the flow zone, then the flow is stable and predictable, but mixing between fiber mixtures is insufficient leading to poor homogeneity
Solution Approach 1:
Variable volume members are positioned within flow channels to create controlled turbulence zones that enhance mixing efficiency while maintaining overall flow stability, thereby improving fiber web homogeneity without sacrificing productivity
Solution Approach 2:
Flow impediments serve as intermediary elements that disrupt laminar flow to promote mixing between fiber mixtures, acting as mediators that convert stable but poorly mixing laminar flow into more homogeneous flow patterns while maintaining process 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
This approach enables the formation of fiber webs with gradients in properties across their thickness, enhancing structural and performance characteristics by controlling the degree of mixing and turbulence within the system.
Implementation Method 1
disrupting laminar flow of a fiber mixture in the lower portion or upper portion of the flow zone
Implementation Method 2
promote mixing, allowing for controlled intermixing of fiber mixtures
Data Source
AI summary
Systems and methods for forming fiber webs, including those suitable for use as filter media and battery separators, are provided. In some embodiments, the systems and methods may involve the use of one or more fiber mixtures to form a fiber web. The fiber mixtures may flow in different portions of a system for forming a fiber web that may be separated by a lamella, and may join at a fiber web forming zone to produce a fiber web having multiple layers. The amount of mixing of the fiber mixtures at or near the fiber web forming zone may be controlled to produce fiber webs having different structural and/or performance characteristics. In some embodiments, the systems and methods described herein can be used to form fiber webs having a gradient in a property across a portion of, or the entire, thickness of the fiber web.