Apparatus and method for manufacturing fibrous web, fibrilla fiber aggregate, or nonwoven fabric, and fibrous web, fibrilla fiber aggregate, or nonwoven fabric manufactured thereby
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Solution Overview
Problem
The existing methods for manufacturing fibrous web and nonwoven fabric are complex and time-consuming, particularly due to the need for processes like pliabilizing and de-knitting, and there is a lack of machines that can efficiently convert woven fabric into these materials with optimized physical properties for hemostatic or antiadhesive applications.
Innovation Solution
A machine comprising a feed roller, a cylinder with a flat bar, a doffer, and a stripper, all with teeth, is used to process woven fabric into fibrous web, which is then calendared to produce fibrillar fiber aggregates or nonwoven fabrics with specific densities for hemostatic or antiadhesive use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the conventional method of manufacturing hemostatic nonwoven fabric is used (including pliabilizing, de-knitting, and cutting steps), then the product quality is maintained, but the manufacturing process becomes long and complicated
Solution Approach 1:
The patent combines multiple separate processing steps (carding, cutting, and web formation) into a single integrated machine system. The carding cylinder with cutting teeth and the doffer with web formation capability work together in one continuous operation, eliminating the need for separate pliabilizing, de-knitting, and cutting processes while maintaining product quality.
Solution Approach 2:
The machine is divided into distinct functional components (feed roller, carding cylinder with flat bar, doffer, stripper) that perform specific tasks in sequence. This segmentation allows each component to be optimized for its specific function while working together in an integrated system, improving overall manufacturing efficiency.
2Loss of time
If woven fabric is fed directly into the machine for simultaneous cutting and combing, then the manufacturing time is reduced, but the physical properties of the formed fibrous web change sensitively requiring optimized combination of components
Solution Approach 1:
The machine incorporates adjustable components including teeth configuration (shape, length, angle, arrangement) and operational parameters that can be dynamically optimized. The carding cylinder and doffer speeds, as well as the teeth geometry, can be adjusted to control the physical properties of the fibrous web while maintaining efficient continuous operation.
Solution Approach 2:
The patent optimizes various parameters including the number, shape, and arrangement of teeth on the carding cylinder and doffer, as well as the operational speeds of different components. These parameter changes allow precise control over the fibrous web properties while maintaining reduced manufacturing time through continuous processing.
3Productivity
If the machine uses teeth on all components (feed roller, flat bar, cylinder, doffer, stripper), then the cutting and combing efficiency is improved, but the device structure becomes more complex
Solution Approach 1:
The teeth configuration is applied across multiple components (feed roller, flat bar, carding cylinder, doffer, stripper) to create a universal cutting and combing mechanism. Each component with teeth performs its specific function while contributing to the overall efficient processing, making the teeth design a multi-functional solution throughout the machine system.
Data Source
AI summary
The present invention relates to an apparatus for manufacturing a fibrous web, a fibrilla fiber aggregate, or a nonwoven fabric by using a woven fabric, a method for manufacturing a fibrous web, a fibrilla fiber aggregate, or a nonwoven fabric by using the apparatus, and a fibrous web, a fibrilla fiber aggregate, or a nonwoven fabric manufactured by the method, especially, a fibrous web, a fibrilla fiber aggregate, or a nonwoven fabric for use in a hemostatic agent or an anti-adhesive agent.